description
stringlengths
2.98k
3.35M
abstract
stringlengths
94
10.6k
cpc
int64
0
8
BACKGROUND OF THE INVENTION Beneficial uses of microorganisms are well known in the art and have been documented at great length. Many patents have issued which claim new microbial processes pertaining to the production of antibiotics, enzymes, ethanol, and a multitude of other useful products. Microorganisms are also used to clean up toxic wastes and oil spills, mill pests, recover minerals, and provide nutrients to plants. It has been known for many years that some organisms produce compounds which are toxic to other organisms. The production of the antimicrobial compound penicillin by penicillium mold is one such example. Microorganisms are particularly attractive candidates for use in making and delivering organic compounds because they can be extremely efficient and safe. The modern tools of genetic engineering have greatly enhanced the ability to exploit the efficiency and relative safety of microbes. Even in the absence of genetic manipulation, however, microbes can perform highly specific tasks which make them indispensable in certain applications. Thus, there is a constant ongoing search in many areas of research for new microbes with specific advantageous properties. The subject invention concerns the discovery of one such microbe. The tree species Melaleuca quinquenervia (Cam.) Blake (Melaleuca) is an exotic pest species which is native to Australia and was introduced into Florida in the early 1900's as an ornamental tree and possibly as a commercial source of wood. Several of Melaleuca's innate characteristics have facilitated its spread throughout South Florida. Melaleuca grows more densely in Florida than in Australia and "crowds out" native plants. Prolific seed production, fire adaptation and release from natural competition, insect feeding and disease further abet its competitive ability. The Melaleuca may become a large tree exceeding 50 feet in height. The tree may have a single trunk or have multiple stems arising from the base of the tree. The bark covering the trunk is white to cream-colored and is very thick and soft, and easily peels in multiple layers from the tree. The tree is easily recognized when flowering, being covered with clusters of white flowers born on the ends of the twigs. Melaleuca flowers throughout the year in Florida, with heavier blooms reported during the wet season with lighter blooms occurring throughout the winter. Individual trees have been reported to bloom as many as five times a year and an individual branch may have three or more blooms each year. Seed capsules which are formed on the flower spike, are from 0.1 to 0.2 inches long and are short and cylindrical. Each capsule, which contains over 200 seeds, may remain attached to the branch for an extended period of time. A large, mature melaleuca tree has a high reproductive potential as the branches contain millions of seeds stored in the capsules. By flowering three to five times yearly, large numbers of seedlings are produced. These seedlings can, in turn, produce seeds within two to three years, and a mature tree can store over 20 million seeds. Encroachment into ecosystems formerly devoid of Melaleuca is irreversible, permanently replacing natural plant communities and the animals that live in them. Melaleuca was planted from seeds obtained from Australia in the early 1900's at two coastal locations. The present distribution of melaleuca is predominantly centered around the areas of original introduction. Its spread was enhanced through its use as wind breaks and fence rows, and its popularity as a fast growing ornamental. Canals have most likely facilitated the spread of the buoyant seeds in to the interior of conservation areas where relatively undisturbed inland wetlands have been invaded. Sites conducive to Melaleuca development are usually poorly-drained areas which have high water table levels or are flooded periodically each year. These sites comprise much of the ecologically-sensitive wetland areas of South Florida, including the Everglades National Park, the Big Cypress Preserve, and the Loxahatchee National Wildlife Refuge. Melaleuca is highly resistant to stress, including herbicides and fire. Not only is this species physically resistant to fire, but the seed capsules are stimulated to open by the extreme heat and drying produced by fire. The trees grow rapidly, even when completely submerged in flood waters for periods of six months or longer, and they resume vigorous growth after the water recedes. Melaleuca has been identified as a potential threat to South Florida's water supply. Future spread of melaleuca throughout the Everglades has the potential to impact regional surface water supplies by replacing open grassy paries with forest. A task force assigned to study the melaleuca problem has concluded: "It is the consensus opinion of the [task force] that the uncontrolled expansion of melaleuca constitutes one of the most serious ecological threats to the biological integrity of South Florida's natural systems." Control of this encroachment is a formidable task, even when chemical herbicides are applied either to individual trees or to groups of trees by aerial spraying. Eradication frequently requires two or three applications of herbicides which increases herbicidal contamination of wetlands. Thus, chemical weed control programs are seriously inadequate for the control of Melaleuca. Also, the use of chemical pesticides in agriculture is currently a major concern in the U.S. For example, pesticides are being blamed for an epidemic of cancer in children and young adults in the San Joaquin Valley (Weisskopf, M. [1988] The Washington Post Weekly Edition 5(47):10-11, Washington, D.C.). New technologies in detection methods are enabling researchers to find pesticides in the environment that were previously thought to be totally degraded. Perhaps the major public concern of the 1980's is protection of groundwater. The Environmental Protection Agency (EPA) estimates that 100,000 of the nation's 1.3 million wells are contaminated with pesticides (Fleming, M. H. [1987] Amer. J. Alterative Agriculture 2:124-130). This has alarmed the general public since 50% of all Americans depend on groundwater wells for their fresh water supplies. Because herbicides are so widely used in agriculture, and because they are often applied directly to the soil, the potential for movement into groundwater by leaching is perhaps greater than any other pesticide. Other inadequacies of chemical controls include lack of residual control, injury to non-target organisms, undesirable residues in harvested products, and carryover in subsequent crops. Among the chemical herbicides now being used in efforts to control Melaleuca are Arsenal (isopropylamine salt of 2-[4,5-dihydro-4-methyl-4-91-methylethyl)-5-oxo-1H-imidazol-2-yl]-3-pyridinecarboxylic acid), Bonvel 720 (diethylamine salt of 2,4-dichlorophenoxy-acetic acid+dimethylamine salt of 3,6-dichloro-0-anisic acid), Garlon 3A (triethylamine salt of 3,5,6,-tricloro-2-pyridinyloxyacetic acid), Rodeo (isopropylamineamine salt of N-(phosphonomethyl)glycine), Spike (N-[5-(1,1-dimethylethyl)-1,3,4,-thiadiazol-Z-yl]-N,N'dimethylurea), and Velpar (3-cyclohexyl-6-dimethylamino) 1-methyl-1,3,5-triazine-2,4(1H,3H)-dione). Certainly, the use of chemical herbicides must be avoided or reduced to the extent possible in the environmentally sensitive wetlands of South Florida. Therefore, the use of bioherbicides is becoming an increasingly important alternative to chemical herbicides. This importance is exemplified by several patents which have been issued for bioherbicides and their use. Some of these patents, by way of illustration, are as follows: U.S. Pat. No. 3,849,104 (control of northern jointvetch with Colletotrichum gloeosporioides Penz. aeschynomene); U.S. Pat. No. 3,999,973 (control of prickly sida [teaweed] and other weeds with Colletotrichum malvarum); U.S. Pat. No. 4,162,912 (control of milkweed vine with Araujia mosaic virus); U.S. Pat. No. 4,626,271 (Cyanobacterin Herbicide); and U.S. Pat. No. 4,915,726 (Biological Control of Dodder). Melaleuca quinquenervia has not been reported to have any natural enemies in Florida capable of inducing mortality. Fungi of the genus Botryosphaeria, including B. ribis, have been shown to grow on other species of plants (Ramos, L. J., S. P. Lara, R. T. McMillan, Jr., K. R. Narayanan [1991] Plant Dis. 75:315-318; Venkatasubbaiah, P., T. B. Sutton, W. S. Chilton [1991] Phytopath. 81:243-247; Webb, R. S. [1983] Plant Dis. 67:108-109). However, the fungus is not shown to cause sufficient damage to induce mortality in any of the specifies shown to be infected with the fungus. Mellein and 4-hydroxymellein are isocoumarin compounds which have previously been described (Moore, J. H., N. D. Davis, and U. L. Diener [1972] "Mellein and 4-hydroxymellein production by Aspergillus ochraceus wilhem,' Microbiology 23(6):1067-1072; Cole, R. J., J. H. Moore, N. D. Davis J. W. Kirksey, and U. L. Diener [1971] "4-hydroxymellein: A new metabolite of Aspergillus ochraceus J. Agr. Food Chem., 19(5):909). Phytotoxic properties have not previously been reported for these compounds. Nor has there been any report that these compounds are produced by Botryosphaeria ribis. BRIEF SUMMARY OF THE INVENTION The subject injection pertains to a novel means for producing the phytotoxins mellein and 4-hydroxymellein as well as a highly efficient means for delivering these compounds to a target pest plant. The isocoumarin compounds mellein and 4-hydroxymellein are produced by the fungus Botryosphaeria ribis. In addition to the discovery that the isocoumarin compounds are produced by B. ribis the subject invention pertains to the means of delivering these phytotoxins to a target pest plant. Specifically, the fungus can be applied directly to a target plant, and preferably, to a wound on the plant. Growth of the fungus results in the direct administration of the phytotoxins to the target plant. In a preferred embodiment, the subject invention concerns the discovery of a novel method for control of the exotic pest tree Melaleuca quinquenervia. Specifically, the subject invention pertains to a highly effective means for delivering a phytotoxin to melaleuca trees. This method has been shown to have surprising ability to provide specific control of Melaleuca trees. In this preferred embodiment of the invention, the phytotoxin of the subject invention is delivered to the Melaleuca tree by applying an effective amount of the fungus Botryosphaeria ribis directly to the tree. This fungus produces sufficient quantities of a phytotoxic compound to inhibit the growth or actually induce mortality of Melaleuca trees. The growth of the fungus can also mechanically disrupt nutrient transport in the vascular system of the tree. Advantageously, the fungus may be applied to a wound in the target tree to facilitate the introduction of phytotoxin into the vascular system of the tree. These wounds may either be natural wounds or mechanically made wounds. Alternative means of introducing the fungus include, but are not limited to, transmission vectors such as parasitic or symbiotic insects. The phytotoxic composition delivered by the methods of the subject invention comprises mellein, 4-hydroxymellein, or a combination of the two. The methods of the subject invention cause stem cankering, foliar wilt, and death of the target Melaleuca tree. These symptoms and the ultimate control of Melaleuca can be enhanced by the mechanical disruption of the tree's vascular fluid flow caused by the growth of the fungus. DETAILED DESCRIPTION OF THE INVENTION According to the subject invention, the isocoumarin phytotoxins mellein and 4-hydroxymellein are produced by the fungus Botryosphaeria ribis. This fungus can be grown directly on target plants so as to effectively deliver these phytotoxins to the plant. The phytotoxins produced according to the subject invention having the following structures: ##STR1## Botryosphaeria ribis is unusual in its production of the trans-isomer of 4-hydroxymellein. The subject invention provides an effective species-specific means for controlling pest trees of the species Melaleuca quinquenervia. Specifically, a phytotoxin, or mixture of phytotoxins is delivered to the vascular tissue of these trees. In a preferred embodiment of the subject invention, the spores or hyphae of the fungus Botryosphaeria ribis can be applied directly to the Melaleuca trees. This fungus produces phytotoxins which control the Melaleuca. These phytotoxins enter the vascular tissue of the Melaleuca and cause foliar wilt and mortality. This effect can be enhanced by mechanical disruption of the plant's vascular system caused by the growth of the B. ribis. One of the reasons frequently mentioned for the success of M. quinquenervia as an invasive pest plant species was the apparent lack of mortality-inducing natural enemies. Melaleuca quinquenervia has not been reported previously in the literature to be colonized by microorganisms which lead to tree death. The use of this fungus to administer the species-specific phytotoxin which incites stem cankering and, ultimately, mortality of infected M. quinquenervia trees is a highly advantageous means of reducing host populations. Among advantages are (1) avoidance of pesticidal contamination of waterways and wetlands, where M. quinquenervia grows most frequently; and (2) contribution to inoculum buildup and natural spread of the fungus from dead and moribund trees. The phytotoxic composition of the subject invention can be delivered to the pest tree by allowing B. ribis to grow directly on the tree. Advantageously, the phytotoxic composition is most effectively introduced into the tree by applying the fungus to a wound on the tree. Alternative means of introducing the fungus are by transmission vectors, which can include parasitic or symbiotic insects. A subculture of the Botryosphaeria ribis has been deposited in the permanent collection of the American Type Culture Collection (ATCC), 12301 Parklawn Drive, Rockville, Md. 20852 U.S.A. The culture was assigned the following accession number by the repository: ______________________________________Culture Accession number Deposit date______________________________________Botryosphaeria ribis ATCC 74057 May 6, 1991______________________________________ The subject culture has been deposited under conditions that assure that access to the culture will be available during the pendency of this patent application to one determined by the Commissioner of Patents and Trademarks to be entitled thereto under 37 CFR 1.14 and 35 USC 122. The deposit is available as required by foreign patent laws in countries wherein counterparts of the subject application, or its progeny, are filed. However, it should be understood that the availability of the deposit does not constitute a license to practice the subject invention in derogation of patent rights granted by governmental action. Further, the subject culture deposit will be stored and made available to the public in accord with the provisions of the Budapest Treaty for the Deposit of Microorganisms, i.e., it will be stored with all the care necessary to keep them viable and uncontaminated for a period of at least five years after the most recent request for the furnishing of a sample of the deposit, and in any case, for a period of at least 30 (thirty) years after the date of deposit or for the enforceable life of any patent which may issue disclosing the culture. The depositor acknowledges the duty to replace the deposit should the depository be unable to furnish a sample when requested, due to the condition of the deposit. All restriction on the availability to the public of the subject culture deposit will be irrevocably removed upon the granting of a patent disclosing it. Botryosphaeria ribis can be grown on solid or in liquid media. Solid media that can be used include water agar, potato dextrose agar, V-8 agar, and string bean agar (strained extract of macerated string beans solidified in agar). Spores are produced on solid V-8 medium exposed to fluorescent light. Specifically, solid media can be, for example, (1) water agar, (2) potato dextrose agar (Difco), (3)lima bean agar (Difco), (4) corn meal agar (Difco, (5) potato-carrot agar (Tuite 19), and (6) Desmodium agar (blend 10 g Desmodium plant parts or plant extracts in 1000 ml water and solidify with 20 g agar). For large scale production in fermentation tanks, liquid media is used, for example: ______________________________________Formula I - Modified Richard's Solution - V-8*______________________________________Sucrose 50.00 gmPotassium nitrate 10.00 gmPotassium phosphate, monobasic 5.00 gmMagnesium sulfate.7H.sub.2 O 2.50 gmFerric chloride 0.02 gmV-8 juice 15.00 mlDistilled water to make 1000.00 ml______________________________________ *Trademark, The Campbell Soup Company for mixed vegetable juices. Formula II--Modified Richard's Solution--Distillers Solubles--Same as Formula I but substitute 15 gm Distillers solubles for V-8 juice. Formula III--Modified Richard's Solution--Brewers yeast--Same as Formula I above but substitute 15 gm brewers yeast for V-8 juice. Formula IV--Modified Richard'Solution--Torula Yeast--Same as Formula I above but substitute 16 gm torula yeast for V-8 juice. Formula V--Oatmeal solution--4%+2% sugar--40 gm oatmeal, 20 sucrose, 1000 ml distilled water. The preparation of spores is commenced in preseed liter flasks containing about 300 ml of liquid medium which have been inoculated with spores. The medium is incubated for 1-3 days with agitation at a temperature of about 26° C. to about 30° C. The preseed is then transferred aseptically to 20 liter seed tanks with additional sterile medium as described above. The tanks are provided with sterile air and agitation. The cycle is continued at a temperature of about 26° C. to about 30° C. for 1 to 3 days. Larger fermentors (250 liter) are aseptically inoculated with the seed tanks (entire contents), described above. Additional sterile medium, as used above, is added the pH adjusted to about 6.0. The fermentor is supplied with sterile air and agitation, and is maintained at a temperature of about 26° C. to about 30° C. for from 1 to 3 days. The fermentor is then harvested by filtering the contents to remove insoluble solids and mycelia growth. The filtered beer is then centrifuged, the supernatant is discarded, and the remaining spore concentrate is collected, placed in plastic bags, and stored in ice. The concentrate so stored maintains an 80% germination for up to 21 days. The spore concentrate is mixed with an agriculturally acceptable diluent or carrier for application to the Melaleuca tree or a situs. By the term "situs" is meant those areas infested with the undesired tree or potential infestation sites. The preferred carrier is water, and the spore concentrate is dispersed to make a concentration of from about 2×10 4 to 2×10 7 spores/ml. The formulation can be sprayed on the undesired tree or situs by conventional spraying equipment. The effectiveness of the novel B. ribis may also be enhanced by mixing it with chemical herbicides such as 2,4-D, atrazine, linuron, paraquat, alachlor, metolachlor, glyphosate, dichlobenil, EPTC, and arsenicals. Table 1 provides a list of other groups of herbicides which could be used in conjunction with the novel fungus of the subject invention. TABLE 1______________________________________Herbicide group Example______________________________________Carbamate dichlobenilThiocarbamate EPTCSubstituted urea linuronTriazine atrazineAsymmetrical triazine metribuzinSubstituted uracil terbacilChloroacetamide metolachlorAcid amide pronamideBipyridinium paraquatSulfonyl urea chlorsulfuronImidazoinone imazaquinDinitroaniline trifluralinDiphenyl ethers oxyfluorfenDifenoxycarboxylic acid fluazifopBenzoic acid amibenPhenoxy 2,4-DUnclassed glyphosate______________________________________ Though spores are the preferred form the fungi, the fungi can also be used in their vegetative form. For example, fragmented mycelia can be formulated and applied to purple nutsedge in much the same manner as described above for the spore form. Use of the fungus Botryosphaeria ribis Grossenbacher & Duggar to introduce phytotoxins offers a safe, economical, effective, residual, and non-polluting method of reducing the population of M. quinquenervia. Following are examples which illustrate procedures, including the best mode, for practicing the invention. These examples should not be construed as limiting. All percentages are by weight and all solvent mixture proportions are by volume unless otherwise noted. EXAMPLE 1 Introduction of Phytotoxin Via Mechanical Wound The introduction of a phytotoxic composition to the vascular system of Melaleuca (or other target plant) can be effectively achieved by placement of hyphae and/or spores of the fungus B. ribis into a wound in the bark of the Melaleuca. The wound may be, for example, a small mechanical wound, i.e., hole <5 mm diameter, in the stems of young Melaleuca or a large wound on an older Melaleuca. This locus of fungal inoculum rapidly spreads under the bark and colonizes xylem and phloem tissue. With inoculated seedlings, cankers develop circumferentially as well as distally toward the foliage-bearing areas of stems or branches. Canker formation interferes with water flow which can enhance the effect of the phytotoxin and eventually results in wilting, defoliation, and tree death. Within five to ten days after inoculation, seedlings are either moribund or dead. Although sprouts occasionally develop below the point of inoculation, the fungus enters the new vascular tissue and incites cankers similar to those produced on main stems by the original inoculation. Moreover, death of the tree does not retard expansion of the fungus, whose spores can transfer to nearby trees. When creating a mechanical wound for introduction of the fungus of the subject invention, any method can be used which penetrates the outer bark and exposes vascular tissue. It is the vascular tissue which is most susceptible to the action of the phytotoxin as well as mechanical disruption caused by the growth of the fungus. Thus a wound could be made using a knife, shears, machete, ax, or other appropriate tool, depending upon the size of the tree. Also, a composition comprising the fungus and/or phytotoxins of the subject invention may be injected into the tree using injection techniques which are well known to those skilled in this art. The fungus or phytotoxic composition may also be introduced into a naturally occurring wound on the Melaleuca tree. EXAMPLE 2 Alternative Methods of Inoculation In addition to introduction of a phytotoxic composition by means of applying fungi into a wound mechanically created in the pest plant species, insect vectors can be used to inoculate the plant with fungus. In this embodiment, an insect which naturally inhabits Melaleuca (or other target plant), and preferably a species of insect which prefers this plant species, can be exposed to hyphae and/or spores of the fungus which then become attached to the body of the insect. These insects which carry the fungal spores are then released into the area in need of Melaleuca control. The insects which carry the fungus introduce the fungus to the tree. Most preferably, these insects, either as parasites or symbiotic species, bore into the tree or otherwise introduce the fungus below the protective layer of bark. The fungus, once introduced, establishes a colony on the plant species whereby the production of a phytotoxic composition by the fungus disrupts plant growth and leads to mortality of the tree. EXAMPLE 3 Isolation and Identification of the Phytotoxins, Mellein and 4-Hydroxymellein Mellein and 4-hydroxymellein can be isolated from culture filtrate of B. ribis using a variety of extraction procedures which are well known to those skilled in this art. For example, B. ribis cultures can be filtered through weighed 33 cm Whatman no. 2 filter papers that are dried at 70° C. for 12 hours. Mycelial mats can be washed with demineralized water, and weights determined after drying for 12 hours at 70° C. and cooling in a desiccator for one hour. Filtrates can be adjusted to their original volume with demineralized water and their pH values measured with a Corning model 12 pH meter. Filtrates can be adjusted to pH 4 and mellein and 4-hydroxymellein extracted from 25 ml of each filtrate with two 25 ml portions of chloroform in a 500 ml separatory funnel. Solid substrate can be extracted by blending with 200 ml of chloroform for 1 minute in a Waring blender. The slurry can then be filtered and the residue washed with another 100 ml of chloroform. The chloroform can be evaporated to dryness on a boiling water bath, and the residue of each flask is redissolved in 0.5 ml of chloroform. Analogous extraction procedures using ethyl acetate can also be utilized. Identity of the extracted phytotoxin can be confirmed by TLC co-chromatography with authentic mellein and 4 -hydroxymellein or by spectral analysis. A person skilled in the art could obtain mellein and 4-hydroxymellein by growing large quantities of B. ribis and isolating the phytotoxins therefrom. The phytotoxic composition obtained in this manner could then be applied directly to melaleuca or other plants. The phytotoxins could be applied, for example, as a spray or wash administered directly to the outside of the plant or to a wound on the plant. Also, the phytotoxins could be injected into the vascular system of the plant using techniques which are well known to those skilled in the art. To apply the phytotoxin by any of these means, the phytotoxins could first be combined with appropriate agricultural carriers or other phytotoxins which are well known to those skilled in this art. EXAMPLE 4 Herbicidal Activity of Mellein and 4-Hydroxymellein Extracts of B. ribis which contain mellein and 4-hydroxymellein have been shown to be active against melaleuca and sorghum. The results are presented in Table 2. TABLE 2______________________________________Effect of B. ribis cell-free culture filtrate (cf) on root growth Root Growth (mm) cf cf Distilled WaterSeedling (as such) (5 fold conc.) Control______________________________________Melaleuca 24 hr 0.0 0.0 3.0 48 hr 1.0 0.0 4.0 72 hr 1.5 0.0 6.5 96 hr 1.7 0.0 7.8Sorghum 24 hr 4.5 0.0 22.0 48 hr 7.5 0.0 42.0 72 hr 8.4 0.0 48.0 96 hr 8.6 0.0 63.0______________________________________ The culture filtrate from B. ribis has also shown phytotoxicity on weed leaves. Specifically, the filtrate has shown phytotoxicity against sicklepod, prickly sida, and johnsongrass. It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims.
The subject invention relates to a novel means of producing mellein and 4-hydroxymellein. The subject invention further concerns a novel means for introducing phytotoxin, disrupting nutrient flow, and inducing selective mortality for population control of a pest plant species.
2
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims priority under the Paris Convention to Chinese application number CN 201310393733.1, filed on Sep. 2, 2013, the disclosure of which is here with incorporated by reference in its entirety. FIELD OF TECHNOLOGY [0002] The following relates to a field of Semiconductor manufacturing, more specifically, it relates to a process of manufacturing the gate oxide layer. BACKGROUND [0003] Negative Bias Temperature Instability (abbreviation: NBTI) is a series of electrical parameter degradation triggered by the negative gate voltage, which is applied to PMOSFET at high temperature generally, in the stress condition at the constant temperature of 125° C. of the gate oxide electric field, of the source electrode, of the drain electrode and of substrate earth. [0004] NBTI effects comprise the generation and the passivation of positive charge, i.e., the generation of the interface trapped charge, the positive charge fixed on the oxide layer and the diffusing process of diffusing material. Hydrogen and water vapor are two main material results in NBTI. NBTI effect substantively impairs the devices and the circuits, such as increasing the gate current of the device, the negative drift of threshold voltage, decreasing of the subthreshold slope, transconductance, decreasing of the leakage and so on. NBTI effect also results in the cause the mismatch of the transistors in analog circuits and the timing drift decrease of the noise margin and the product failure in digital circuit. [0005] With the development of the process of semiconductor devices, the requirement of the device performance becomes higher and higher. The size of device becomes smaller and smaller. However, with the reduce of the device size, the working voltage is not reduced proportionally. It increases electric field of gate oxide layer, where NBTI is triggered easily. Particularly, the gate oxide layer is adopted the traditional wet-oxygen oxide Si+H 2 O→SiO 2 ). The interface of the gate oxide layer includes a huge number of Si—H bonds which are easily to generate H atoms in hole under the thermal excitation and to leave dangling bond on the interface. Due to the instability of H atoms, i.e., two H atoms is easily to react into H2, released in the form of hydrogen molecules. H2 diffuse far to the surface of gate, which causes the negative drift of threshold voltage, forms NBTI effect, decreases the performance of the device and even impairs the device. [0006] Chinese Patent (Publication Number: CN 1264164A) disclosed a method for forming the gate oxide of a Metal-Oxide-Semiconductor (MOS). It adopts a process of dry, wet and dry oxide of semiconductor. This method results in reducing the interface state density at the semiconductor-oxide interface. However, it did not disclose the solution to eliminate NBTI effects. [0007] Chinese patent (Publication Number: CN 1722408 A) discloses a method of forming the gate oxide film forms. It forms dielectric film on the substrate. The sacrifice or the gate oxide film is formed to be used as oxide film. The resist layer is used as mask, as a result, the ion implanting layer is formed with one or more implanting process by argon or fluorine ions through the oxide film. Moreover, when the oxide film is used as the sacrifice oxide film after the resist layer and the oxide layer forms is removed, the gate oxide film is formed in the device port. When the oxide film is used as the gate oxide film, the oxide film is etched once to reduce the thickness. It thickens the oxide film after removing the resist layer, due to the forming the ion implanting layer to form the thick gate oxide film. The patent did not disclose the solution for NBTI. SUMMARY [0008] Due to the defects of the traditional art, the present invention discloses a method of a process of manufacturing the gate oxide layer, which adopts the furnace tube to form the said gate oxide layer, comprising; [0009] a process of dry oxidation and a process of wet oxidation are applied to a semiconductor substrate in sequence to form a gate oxide layer; [0010] the gate oxide layer is annealed by nitrogen in a high temperature; [0011] wherein oxygen gas is applied to the said dry oxidation, deuterium is applied to the said wet oxidation. [0012] According to the above method, it comprises that after the said wet oxidation, the said dry oxidation is applied to the said semiconductor substrate to form the said gate oxide layer. [0013] According to the above method, wherein the temperature of the said dry oxidation is 700° C. to 900° C., and the flow of oxygen gas supplied is larger than or equals to 1 slm. [0014] According to the above method , wherein the temperature of the said wet oxidation is 700° C. to 900° C., the time is 25 min-35 min. [0015] According to the above method, wherein the ratio of gas flow of deuterium and oxygen is 1:2-2:1 when the said wet oxidation is in process. [0016] According to the above method, wherein value of the high temperature is larger than or equals to 900° C. [0017] According to the above method, wherein the gate oxide layer is annealed by nitrogen of which flow is larger than or equals to 5 slm. [0018] According to the above method, wherein the time when the gate oxide layer is annealed is 10 minutes to 15 minutes. [0019] According to the above method, wherein further comprising: [0020] after the loading process is applied to the said substrate, the increasing rate of the temperature ranges from 7° C. per minute to 13° C. per minute, the temperature of the reactor chamber will be raised to the said temperature required by the dry oxidation process, meanwhile, the flow of oxygen to be larger than or equals to 0.3 slm. [0021] According to the above method, wherein comprises as follows: [0022] Before the said annealing process is applied to the said substrate, the increasing rate of the temperature is 7° C./min-13° C./min, the temperature of the reactor chamber will rise to the said temperature required by the annealing process; [0023] before the unloading process is applied to the said substrate, the decreasing rate of the temperature is 1° C./min-5° C./min, the temperature of the reactor chamber will drop to the said temperature required by the unloading process; [0024] The advantageous effects of the above technical solution are as follows: In conclusion, the present invention, a process of forming the gate oxide layer, which adopts wet oxidation by deuterium to form the gate oxide layer. The nitriding treatment is applied to form the gate oxide layer by the annealing process of high temperature. The stable Si-D bonds is formed on surface of the gate oxide layer to reduce silicon dangling bonds, which reduces the defect of the gate oxide interface and lowers the interface defect density of the gate oxide layer and the charge density effectively to avoid NBTI. Consequently, the reliability and yield of product is improved. BRIEF DESCRIPTION [0025] FIGS. 1-5 are the structure diagrams of the process of forming the gate oxide layer. DETAILED DESCRIPTION [0026] The present invention will be further illustrated in combination with the following figures and embodiments, but it should not be deemed as limitation of the present invention. [0027] FIGS. 1-5 are the structure diagrams of the process of forming the gate oxide layer. As shown in FIGS. 1-5 , a process which forms the gate oxide film adopts furnace tube to form the said gate oxide layer. Firstly, as shown in FIG. 1 , a loading process (LOAD) is applied to a Substrate 1 in the temperature of 600° C. through the process of stabilization (STAB). The temperature rises where the increasing rate of temperature is 7° C./min-13° C./min, such as 7° C./min, 10° C./min or 13° C./min and so on. The temperature of the reactor chamber will ramp up to the temperature of 700° C. to 900° C., such as 700° C., 800° C., or 900° C. and so on, stabilizing the team (TEAM STAB), which satisfies the temperature requirement in the follow-up dry oxidation. Meanwhile, the appropriate oxygen gas is supplied to the reactor chamber. The flow of the oxygen gas is larger than or equals to 0.3 slm, such as 0.3 slm, 0.5 slm or 0.8 slm and so on. [0028] Secondly, the dry oxidation (DRY OXIDE) is applied to the Semiconductor Substrate 1 , then a First Gate Oxide Layer 21 is formed on the upper surface of the semiconductor substrate, which covers the upper surface of a first remaining Semiconductor Substrate 11 . And then the structure is formed as shown in FIG. 2 ; wherein, the dry oxidation lasts 15 min to 25 min, such as 15 min, 20 min or 25 min and so on at the temperature of 700° C. to 900° C., such as 700° C., 850° C. or 900° C. and so on. Meanwhile, the flow of the oxygen gas which is introduced into the reactor chamber is larger than or equals to 1 slm, such as 1 slm, 3 slm or 5 slm and so on. [0029] Next, the wet oxidation (WET+DCE) is applied to the first remaining Semiconductor Substrate 11 so that a Second Gate Oxide Layer 22 is formed at the upper surface of the first remaining semiconductor Substrate 11 , and Second Gate Oxide Layer 22 covers the upper surface of a second remaining gate oxide layer 12 . The First Gate Oxide Layer 21 covers the upper surface of the Second Gate Oxide Layer 22 . The structure is formed as shown in FIG. 3 . The stable Si-D bonds (Si+D 2 O →SiO 2 ) is formed in the gate oxide layer, which can reduce the silicon dangling bonds. Consequently, the goal for reducing defect is achieved; wherein, the wet oxidation last 25 min to 35 min, such as 25 min, 30 min or 35 min and so on at the temperature of 700° C. to 900° C., such as 700° C., 800° C. or 900° C. and so on. Meanwhile, deuterium gas is supplied to the reactor chamber, the ratio of gas flow of deuterium gas and oxygen gas is 1:2-2:1, such as 1:2, 1:1 or 2:1 and so on. [0030] Then, the dry oxidation (DRY OXIDE) is applied to the second remaining Semiconductor Substrate 12 , so that Third Gate Oxide Layer 23 is formed at the upper surface of the second remaining Semiconductor Substrate 12 . Third gate oxide layer 23 covers the upper surface of the Third Gate Oxide Layer 13 . The Second Gate Oxide Layer 22 covers the upper surface of Third Gate Oxide Layer 23 . The structure is formed as shown in FIG. 4 . As shown in FIGS. 4 and 5 , First Gate Oxide Layer 21 , Second Gate Oxide Layer 22 and Third Gate Oxide Layer 23 make up of Gate Oxide Layer 2 ; wherein, the dry oxidation last 3 min to 7 min (such as 3 min, 5 min or 7 min and so on at the temperature of 700° C. to 900° C., such as 700° C., 800 ° C. or 900° C. and so on. Meanwhile, the flow of the supplied oxygen gas in reactor chamber is larger than or equals to 1 slm, such as 1 slm, 3 slm or 5 slm and so on. [0031] The temperature rises, and the increasing rate of temperature is still 7° C./min-13° C./min, such as 7° C./min, 10° C./min or 13° C./min and so on. The temperature of the reactor chamber will ramp up the temperature which is larger than or equals to 900° C., such as 900° C., 1000° C. or 1100° C. and so on, which satisfies the temperature requirement of the follow-up annealing process. [0032] At last, when the temperature is larger than or equals to 900 ° C. (such as 900 ° C., 1000 ° C. or 1100 ° C. etc), the annealing process which is applied to the gate oxide layer 2 lasts 10 min to 25 min (such as 10 min, 15 min or 25 min etc) with nitrogen gas whose flow is great than or equals to 5 slm (such as 5 slm, 7 slm 9 slm etc), and the gate oxide layer 2 is treated by the nitriding treatment so as to reduce the interface detect density and the charge density of the gate oxide layer 2 ; [0033] Then the temperature drops, and the decreasing rate of the temperature is still 1° C./min-5° C./min (such as 1° C./min, 3° C./min or 5° C./min etc), the temperature of the reactor chamber will ramp down about 600° C. to finish follow-up unloading process. [0034] Although a typical embodiment of a particular structure of the specific implementation way has been given with the above description and the figures, it is appreciated that other changes based on the spirit of this invention may also be made. Though the preferred embodiments are proposed above, these contents will never be the limitation of this invention. [0035] The Claims attached may incorporate changes and modifications which cover the intention and the range of this invention. Any and all equivalent contents and ranges in the range of the Claims should be regarded belonging to the intention and the range of this invention.
A process of manufacturing the gate oxide layer, which uses the wet oxidation by deuterium to form gate oxide layer, wherein the nitriding treatment is applied to formed gate oxide layer by high temperature annealing process, the stable Si-D bonds is formed on surface of the gate oxide layer to reduce silicon dangling bonds, which reduce the defect of the gate oxide interface and lower the interface defect density of the gate oxide layer and the charge density effectively to avoid NBTI, is provided.
7
BACKGROUND OF THE INVENTION 1. Field of the Invention The invention concerns an apparatus for adjustably affixing a support bracket or the like to a part of a machine frame, and in particular concerns an apparatus for adjustably affixing a support bracket bearing a warp deflecting roller to a lateral part of the frame of a weaving machine, the apparatus including an adjustment screw for adjusting the position of the support bracket and means for clamping the support bracket in its set position to the lateral part of the frame of the weaving machine. 2. Description of Related Art It is known with respect to weaving machines to mount machine components, in particular a support bracket holding the support mechanism of a warp deflecting system, in a height-adjustable manner to the frame of the weaving machine by means of adjusting screws. The support bracket is secured to the machine frame by additional fasteners after positioning so as to hold it in place during weaving. It is further known to use screw means which must be tightened very hard for the additional fastening. These screw means include several screws, which makes it difficult to operate the screw means. Moreover, the screws are frequently located in positions on the machine frame which preclude easy access. SUMMARY OF THE INVENTION The objective of the invention is to provide an apparatus for adjustably affixing a support bracket or the like to a part of the machine frame, and which can be operated more easily than previous such apparatuses. This objective is achieved in a preferred embodiment of the invention by providing a guide with an undercut groove and a guide-fitting between the support bracket and the part of the machine frame to which the bracket is affixed, and by mounting at least one clamp actuated by a setting component between the support bracket and the machine frame, the clamp making it possible to press the guide fitting against a surface of the groove. The apparatus of the preferred embodiment is easily and quickly operated because the adjustment screw and the setting component can be mounted at easily accessible places on the frame. BRIEF DESCRIPTION OF THE DRAWINGS Further features and advantages of the invention are elucidated in the following description of the illustrative embodiments shown in the drawing. FIG. 1 is a vertical section of an apparatus of a preferred embodiment of the invention, FIG. 2 is a section along line 11--11 of FIG. 1, FIGS. 3 through 6 show a detailed segment F1 of the apparatus of FIG. 1 in different positions during affixing and detaching, and FIG. 7 is a section similar to that of FIG. 1 of a modification of the apparatus of FIGS. 1-3. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an apparatus 1 with a support mechanism for supporting a deflecting roller 3. Deflecting roller 3 supports and deflects a plurality of warps 14 supplied from a warp beam. By means of its shaft 12, the deflecting roller 3 rests on two rockers 5 which in turn rest by a pivot shaft 4 on support brackets 2. Each free arm of the two rockers 5 is biased by a compression spring 7 supported by a rest 8 on one of the support brackets 2 so as to be pivotable about a spindle 9. The compression spring 7 is connected to arm 5 by a tip 10 which fits within a notch 11 of the arm 6 of the rocker 5. The compression spring can be pivoted in such manner about the pivot shaft 9 that the tip 10 also can also be caused to fit within other notches 13, and thus provide an adjustable bias force. Each of the two support brackets 2 can be affixed in height-adjustable manner at the end-faces of lateral parts 16 of the frame of the weaving machine. A vertical and undercut groove having edges 34 is present in the region of the end-face of the lateral part 16, the groove guiding a guide fitting 19 of the support bracket 2. Guide fitting 19 is in the shape of a hammer head. The hammer head-shaped fitting 19 rests by guide surfaces 32 facing the support bracket 2 on the matching surfaces 33 of the edges 34 of the undercut groove, and includes a thread engaged by an adjustment screw 17 within the groove, the head of the screw 17 resting on a plate 18 which forms an upper boundary of the groove and is affixed to the lateral part 16. By rotating respective adjustment screws 17, the height position of each of support brackets 2 and hence that of the deflecting roller 3 may be adjusted. The weight of the support brackets 2 and of the deflecting roller 3 is borne by the adjustment screws 17. Two wedging clamp elements 20, 21 are provided in order to fix the support brackets 2 in the adjusted height position. The two clamp elements 20, 21 each possesses a surface 27 parallel to the end face 15 of the lateral part 16, and an oblique wedge surface 28. The oppositely oblique wedge surfaces 28 of the two clamp elements 20, 21 face corresponding oppositely oblique surfaces 29 of the support bracket 2. The two clamp elements 20, 21 are connected by a screw 22 which acts as a setting component. The screw 22 is threaded into a thread of the clamp element 20. The head of the screw 22, which passes through a borehole in the other clamp element 21, is located on the side away from the clamp element 20. The screw 22 passes through the support bracket 2 inside a clearance 35 which houses a drive 23 for the clamp element 21. The drive 23 consists of a shell 24 resting on a support component 25 consisting of two check nuts 26 screwed onto the screw 22. The support arm 2 is provided with stops 30, 31 limiting the excursion of the clamp elements 20, 21. As shown in FIG. 1, the adjustment screw 17 and the setting screw 22 for the clamps 20, 21 are parallel, with both their heads being accessible from above to corresponding tools, as a result of which operation is convenient and access is easy. The position of the apparatus shown in FIG. 1 is one in which the support bracket 2 is affixed to the lateral part 16 of the machine frame, screw 22 having been tighted to hold the two clamp elements 20, 21 in the clamping position. In this position, the clamp elements 20, 21 ensure that the surfaces 32 of the guide fitting 19 of the support bracket are reliably pressed against the matching surfaces 33. If now the position of the support bracket 2 must be changed in height, then the setting components, namely the screws 22, must first be loosened. This loosening results in the position of the clamps shown in FIG. 3, wherein the driver 23 has traveled so far that the free edge of the shell 24 rests now against the clamp element 21. If the screw 22 is rotated further in the loosening direction, the clamp element 21 will be moved by the screw to the position shown in FIG. 4. As soon as the clamp 21 makes contact with the stop 31, further rotation of the screw 22 will loosen the clamp. Similarly, if the clamp 20 is loosened first, then clamp 20 will come to rest against the stop 30 (FIG. 6). Further rotation of the screw 22 results in loosening the opposite clamp element 21, and hence, in both cases, a position is reached in which the wedge surfaces 28 of the two clamp elements 20, 21 are detached from the opposite surfaces 29 of the support bracket 2 (FIG. 5). When in this position, the support brackets can be changed in their height by rotating the adjustment screws 17. Thereupon the height position is fixed in place by tightening the screw 22 acting as a setting means for the clamps 20, 21. FIG. 7 shows another embodiment of the invention, with a simplified design for a driver of the clamp element 21 in that the driver 23 of this embodiment consists of a cross-pin 36 inserted into a cross-borehole of the screw 22. In another variation of the apparatus of the invention, the screw 22 may be provided with two oppositely running thread segments associated with the respective clamp elements 20, 21. Furthermore, as a modification of the above embodiments, other clamps may also be used, in particular clamps which are not moved into the detached or clamped positions by being shifted axially relative to each other, but instead by rotation. For example, an eccentric roller may be mounted parallel to the adjustment screw 17 in the guide fitting 19, the roller also being actuated by a setting component parallel to the adjustment screw 17. Each of the above variations and modifications maintains the advantage of the present invention is that the adjustment screw 17 and the setting element (screw 22) are accessible from almost the same location and hence simple and convenient operation is made possible. Numerous other such modifications of the invention will undoubtedly occur to those skilled in the art, and thus those skilled in the art will appreciate that the invention should not be limited by the above description or illustrations, but rather it is intended that the invention be limited solely by the appended claims.
An apparatus for adjustably affixing a support bracket to a part of a machine frame includes an adjustment screw to adjust the height of the support bracket on the frame and a pair of oppositely movable clamp elements having oblique surfaces for wedging the support bracket in place following adjustment. Wedging is accomplished by turning a setting screw to move the clamp elements in mutually opposite directions. The setting screw is parallel to the adjustment screw, allowing equal access to both the adjustment and setting screws.
3
BACKGROUND OF THE INVENTION The present invention relates to a new and improved apparatus for the continuous wet treatment of strand-like or rope-like textile material, wherein treatment liquid flows through a pipe system in countercurrent with respect to the direction of movement of the continuously conveyed textile material, and the textile material is squeezed at least once within the pipe system. With heretofore known methods of this type and equipment for the performance of such methods, for instance as disclosed in Swiss Pat. No. 385,152 or Austrian Pat. No. 202,959, the increased exchange or interaction, which is strived for by the counterflow principle, between the treatment liquid adhering to the textile material and the remaining liquid located in the pipe system, decreases with increasing velocity or speed of movement of the textile material and constant velocity of the treatment liquid. This is so because with increasing velocity there is entrained, by the textile material, a corresponding greater amount of treatment liquid in the same direction of flow. This undesired effect, as has likewise already been proposed, could be at least partially counteracted by providing relatively larger cross-sectional areas of the pipe or conduit system. Yet, this solution requires an appreciably greater quantity of treatment bath. This, in turn, is contrary to the more recent attempts which are being made, in consideration of the increasingly more stringent requirements regarding protection of the environment, to maintain the liquid consumption as small as possible and to optimumly utilize the treatment agent or liquid. Also, it is already known to the art, as for instance documented by the previously mentioned patents, to improve the action of a treatment liquid at a textile material by squeezing such textile material once or a number of times during the course of its treatment. The squeezing action is accomplished, for instance, by passing the textile material between squeezing or pinch rolls or guiding such in a zig-zag configuration over deflection rolls which then simultaneously produce a squeezing action at the textile material. Particularly when using narrow pipe or conduit systems, as such is desired for the purpose of saving on treatment liquid, there is however formed, forwardly of the squeezing location or locations, a slug of treatment liquid, since the squeezed-off treatment liquid tends to collect or dam-up and partially or completely occupies the cross-section of the pipe conduit or the like. Consequently, there is not only impaired a treatment in countercurrent flow within such dam-up or collecting region, rather such damming-up of the treatment liquid also hinders the throughflow of the treatment liquid from one end to the other end of the pipe system. SUMMARY OF THE INVENTION Therefore, with the foregoing in mind it is a primary object of the present invention to provide an improved apparatus for the continuous wet treatment of strand-like textile materials in a manner not associated with the aforementioned drawbacks and limitations of the prior art proposals. Another and more specific object of the present invention aims at an apparatus of the character described, wherein through the use of simple means it is possible, even in a relatively narrow pipe system, to essentially continuously maintain the countercurrent flow principle and at the same time, in comparison to prior art apparatuses working with the countercurrent flow principle, affords an improved utilization of the treatment bath. Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the inventive method for the continuous wet treatment of strand-like textile material contemplates that part of the treatment liquid which collects or dams-up in front of the squeezing location, is removed from the pipe system and is again reintroduced into the pipe system at a location situated behind the dam-up region, considered with respect to the flow direction of the treatment liquid. As mentioned, the invention is not only concerned with the aforementioned method aspects, but also pertains to apparatus for the performance thereof, such apparatus comprising a pipe system in which there is arranged at least one squeezing element. At the region of the squeezing element there is arranged the upper end of an auxiliary line or conduit, the lower end of which opens into the pipe system intended for the treatment of the textile material. The inventive method and the apparatus for the performance thereof can be advantageously employed during bleaching, desizing, washing-out, treatment in a caustic-soda bath, impregnation, dying and similar methods. By virtue of the fact that the dammed-up treatment liquid or a part thereof, is removed forwardly of the squeezing location, advantageously by means of an auxiliary line or conduit, from the dam-up region and again introduced into the pipe system at a location situated rearwardly of the flow direction, it is firstly possible to reduce the tendency for the damming-up phenomenon to arise, and specifically, to shorten the time of damming-up of the treatment liquid in the pipe system. As a consequence thereof, the textile material is brought into contact, over a longer path, directly with treatment liquid which flows opposite to its direction of movement. At the same time, however, the part of the treatment bath removed by the auxiliary line as excess and ineffectual treatment bath at the dam-up region and again later introduced into the pipe system, is at least partially again entrained by the textile material, and thus, can flow back again in countercurrent flow either in the pipe system or again into the auxiliary line. Consequently, a not inappreciable part of the entire treatment bath thus flows so-to-speak in a pilgrim step from one end of the pipe system to the other. Hence, this part of the treatment bath is effective at the textile material for a longer period of time than if, for instance, in order to avoid the previously mentioned disadvantageous damming-up of the treatment bath, there were used very large pipe cross sections, or also the textile material were moved at extremely low velocities. In addition to the foregoing, a further advantage of the invention resides in the fact that the treatment bath experiences an increase in velocity between the location at which it is removed from the pipe system and the location where it is again reintroduced into the pipe system. Consequently, there is not only avoided the formation of a slug at the opening or mouth location, rather there is augmented the countercurrent flow in the pipe system. Hence, by virtue of the measures contemplated by the invention, there is appreciably increased the efficiency in contrast to known methods, in relation to the quantity of employed treatment liquid. It is particularly advantageous to again infeed the treatment liquid which has been removed at the dam-up region of the squeezing elements, to the pipe system at a location where the liquid flow does not completely fill the cross-sectional area of the pipe system. This can be for instance accomplished according to an embodiment of the inventive apparatus, wherein the pipe system comprises a number of interconnected pipes or conduits which are arranged above one another in a zig-zag configuration. Further, the connection locations between such pipes and serving for housing deflection rolls, simultanteously functioning as squeezing elements, are widened into chambers or compartments. Importantly, the invention contemplates in this regard, by way of example, that at the region of the deflection roll or the deflection rolls, in other words at the chamber where such deflection roll or rolls are arranged, there is arranged the outlet opening, and such auxiliary line leads to a connection location between two pipes and which connection location is located therebelow, and opens into the there situated chamber or compartment. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: FIG. 1 is a longitudinal sectional view through a first exemplary embodiment of inventive apparatus: FIG. 2 is a variant construction of apparatus from that shown in FIG. 1; FIG. 3 shows a still further embodiment of inventive apparatus; and FIG. 4 is a schematic sectional view of the arrangement of FIG. 3, taken substantially along the line IV-IV thereof. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Describing now the drawings, and referring specifically to the arrangement of FIG. 1, it will be seen that the essentially strand-like or rope-like textile material 2 is guided, in the direction indicated by the arrow 2a, from the bottom towards the top through a relatively narrow, essentially vertically arranged pipe or tube 1 or equivalent structure. The treatment liquid 4 is introduced, at the liquid inlet location 5, with or without being pressurized, into the pipe 1 and then flows in countercurrent with respect to the direction of movement 2a of the textile material 2 downwardly through the pipe 1. Within the pipe length the textile material 2 is squeezed by means of two squeezing or pressure rolls 3 or equivalent structure, which can be driven or non-driven. The squeezed-out treatment liquid tends to dam-up or collect below the squeeze rolls 3 in the chamber or compartment 6, since owing to the quantity of treatment liquid entrained by the strand or textile material 2, and which quantity of entrained treatment liquid is indicated by reference character 9, such cannot flow rapidly enough, at this pipe location, through the pipe 1. Merging in flow communication with the chamber of compartment 6 is an auxiliary line or conduit 7 which, in the embodiment under discussion, is constructed as a pipe or tubular jacket surrounding the pipe 1. The auxiliary line or conduit 7 flow communicates at its upper end by means of the outlet openings 10 with the chamber 6 and at its lower end by means of inlet openings 8 with the pipe 1. A part of the dammed-up treatment liquid thus enters the pipe jacket or shell 7 and flows, externally of the not paticularly referenced wall of the pipe 1, towards the inlet location of inlet openings 8 where it again flows back into the pipe 1. The dam-up zone a is thus bypassed by the squeezed-off and newly infed treatment liquid, so that the counter flow principle is again established in the zone or region b located below the inlet openings 8, with the same quantity of treatment liquid. FIG. 2 illustrates a further exemplary embodiment of apparatus constructed according to the invention, which here is provided with a number of squeezing devices. Also with this embodiment the pipe system comprises an essentially vertically extending pipe 1 having one or more infeed openings 4 for the treatment liquid. Within this pipe 1, the cross-section of which can have a random shape and can be accommodated to the textile material 2 to be treated, there are arranged a number of pairs of squeeze or pressing rolls 3. The auxiliary lines comprise pipe lines or conduits 7, the upper ends of which, in each case, are located directly below the related squeeze rolls 3 and the lower ends of which open between two successive pairs of squeeze rolls 3 into the pipe 1. The auxiliary lines 7 are arranged in offset relationship, as shown, so that the liquid is guided from each squeezing location to the next lower pipe section. In this way there is brought about the beneficial result that the treatment liquid which flows-off through an auxiliary line, does not flow-off through the next following auxiliary line and thus does not come into contact with or only in insufficient contact with the textile material 2. On the other hand, by virtue of the described arrangement of the auxiliary lines 7 there is insured for a uniform flow of the infed treatment liquid throughout the entire pipe system. This also is the case if the system is operated with different speeds of movement of the textile material and with the textile material having varying running weight per meter. Now in FIGS. 3 and 4 there is shown a further exemplary embodiment of apparatus designed according to the invention. Here, the pipe system consists of a multiplicity of pipes or conduits 1a, 1b, 1c, 1d and so forth which are arranged in a zig-zag configuration in relation to one another and interconnected in flow communication with one another. The connection of the individual pipes 1a, 1b, 1c, 1d and so forth is accomplished by means of chambers or compartments 11, 12, 13, 14, 15, 16, 17, and in each such compartment there is arranged a respective deflection roll 3 for the textile material 2. At the region of such deflection rolls 3, which are effective as squeezing rolls for the textile material 2 which is guided thereover, there are arranged the auxiliary lines or conduits 7a, 7b, 7c and 7d, and specificially, each auxiliary line flow communicates each two respective chambers or compartments which are situated above one another. Hence, it will be seen that the line or conduit 7a flow communicates the chamber 11 and 13, the line 7b the chambers 12 and 14, the line 7c the chambers 15 and 17, and finally, the line 7d the chambers 14 and 16. During operation of this equipment, the textile material 2, which is pulled upwardly with a tensile load in the direction of the arrow 2a, is automatically squeezed during its deflection about each of the deflection rolls 3, so that part of the treatment liquid is removed from the strand-like textile material 2. The squeezed quantity of treatment liquid causes a damming-up of the treatment liquid over the level of the corresponding outlet opening of the related auxiliary line 7a, 7b, 7c, 7d, as the case may be, so the treatment liquid can flow through the auxiliary lines 7a, 7b, 7c, 7d into the respective chambers or compartments 11, 12, 13, 14, 15, 16, 17 located therebelow. The arrangement of the auxiliary lines or conduits 7a, 7b, 7c and 7d can be different. Although, in the previously explained manner, the auxiliary lines 7a and 7c connect a deflection chamber with the next lower situated deflection chamber and each deflection chamber possesses either only one outlet opening or one inlet opening (chambers 11, 13, 15, 17), it is also possible to have one or more of the chambers (such as the chamber 14) possess both an inlet opening for the line 7b as well an outlet opening for the line 7d. Advantageously, within the chamber 14 the outlet opening of the line 7d is located at a higher elevational position than the inlet opening of the line 7b. When using the lines or conduits 7b and 7d, which interconnect each chamber with the chamber situated therebelow, there alternately comes into play the one auxiliary line 7b or the other auxiliary line 7d, in that, for instance, upon increasing the travel speed of the textile material during the through-passage there is likewise increased the quantity of entrained treatment liquid, so that in this case the auxiliary line 7d is effective until the liquid level has dropped below the liquid outlet location of the auxiliary line or conduit 7d. On the other hand, the treatment liquid flows through the auxiliary line 7b, without the auxiliary line 7d becoming effective, for instance then when during the continuous passage of the textile material the latter suddenly travels through the installation at a smaller running weight per meter, and therefore, the treatment liquid initially entrained by the heavier textile material suddenly flows more rapidly through the pipe sections, whereby there is only temporarily caused a damming-up of treatment liquid in the chamber 12, not however in the chamber 14. From the showing of FIG. 4 it will be apparent how the strand-like textile material 2 is automatically pressed flat by means of the deflection rolls 3, so that part of the treatment liquid is pressed out of the strand-like textile material. Also, it can be advantageous to increase the flow velocity of the withdrawn treatment liquid, especially when working with essentially horizontal pipes. In this case it is advantageous if the auxiliary lines or conduits 7 do not lead from one deflection chamber into the next lower deflection chamber, rather extend from one chamber into the second or third following lower chamber. By means of the described method there is realized, particularly during washing-out processes, an outstanding utilization of the infed washing bath. This is so because the washing bath, owing to the alternate periodic flow in the same direction as the movement of the textile material and the periodic counterflow, is utilized a number of times during the entire passage of the textile material through the equipment, and the same liquid has a longer residence time in the equipment due to the periodic flow in the same direction as the movement of the textile material, and thus, remains for a longer period of time in contact with the textile material. While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly, 9n
An apparatus for the continuous wet treatment of strand-like textile material wherein a treatment liquid flows countercurrent with respect to the direction of movement of the continuously conveyed textile material, and the textile material is squeezed at least once in a pipe or conduit system. A part of the treatment liquid which dams-up or collects in front of the squeezing location, is removed from the pipe system and reintroduced again into the pipe system at a location behind the dam-up region, considered with respect to the direction of flow of the treatment liquid.
3
FIELD OF THE INVENTION [0001] The present invention relates generally to stacked semiconductor device assemblies and packages, as well as to associated assembly and packaging methods. More particularly, the invention pertains to multi-chip assemblies and packages with good thermal properties and dense chip packaging. BACKGROUND [0002] The dimensions of many different types of state of the art electronic devices are ever decreasing. To reduce the dimensions of electronic devices, the structures by which the microprocessors, memory devices, other semiconductor devices, and other electronic components of these devices are packaged and assembled with carriers, such as circuit boards, must become more compact. In general, the goal is to economically produce a chip-scale package (CSP) of the smallest size possible, and with conductive structures, such as leads, pins, or conductive bumps, which do not significantly contribute to the overall size in the X, Y, or Z dimensions, all while maintaining a very high performance level. [0003] Conventionally, semiconductor device packages have been multilayered structures having one, two or more chips stacked above each other. The major problems of such systems are of thermal nature since it was not possible to dissipate the heat efficiently in these systems. Further problems are also signal falsification and wiring problems. One example of the state of the art is given in FIG. 1 . In this example four chips are stacked above each other to form a package, so that this arrangement will also be referred to as a one-four-stack arrangement. The disadvantage of this package is very poor heat dissipation, long signal routes, possible inter-crossing of the connections, routing problems and cross talk. A further disadvantage of the package as shown in FIG. 1 is the elevation of the entire package. [0004] Furthermore, WO 96/13855 discloses an arrangement in which two chips are provided on the opposite sides of a lead plate. [0005] For these and other reasons there is a need for the present invention. [0006] Following terms will be used in following: [0007] The semiconductor integrated circuit chip will be in following referred to as a “chip”; [0008] In the packaging process a chip may also be referred to as a “die”; [0009] The term stacked means an arrangement where two objects are placed above each other; [0010] “stacked in parallel” means that the chips are stacked essentially exactly above each other, wherein a top surface of one chip is facing a bottom surface of the chip arranged above it; [0011] “stacked anti parallel” means that the chips are stacked essentially exactly above each other, wherein a top surface of one chip is facing a top surface of the chip arranged above it or wherein a bottom surface of one chip is facing a bottom surface of the chip arranged above it; [0012] “a bottom surface of a chip” is a surface which is closer to the printed circuit board; the bottom surface is also the surface of the chip which is provided with pads connected to the printed circuit board. “a top surface of a chip” is a surface opposite to the bottom surface. SUMMARY [0013] The present invention provides a multi-chip package and method of making a multi-chip package. In one embodiment, the multi-chip package includes at least four of spaced semiconductor integrated circuit chips mounted on a printed circuit board, consisting of the first pair of the semiconductor integrated circuit chips and the second pair of the semiconductor integrated circuit chips. The chips of the first pair of the semiconductor integrated circuit chips are arranged substantially parallel and the chips of the semiconductor integrated circuit chips of the second pair are arranged substantially stacked over the chips of the first pair of the semiconductor integrated circuit chips. BRIEF DESCRIPTION OF THE DRAWINGS [0014] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present invention and together with the description serve to explain the principles of the invention. Other embodiments of the present invention and many of the intended advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts. [0015] FIG. 1 illustrates a cross view example of a multi-chip package assembly according to the prior art. [0016] FIG. 2 illustrates a cross view example of a multi-chip package assembly according of the present invention. [0017] FIGS. 3-5 illustrate various examples of a multi-chip package of the present invention when attached to a printed circuit board and some processes in their manufacturing. DETAILED DESCRIPTION [0018] In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. [0019] The present invention provides higher density organization of a plurality of semiconductor integrated circuit chips wherein the semiconductor integrated circuit chips are arranged such that good thermal properties and short signal times can be achieved. [0020] The present invention also provides an assembly which effectively dissipates heat generated during normal operation. Efficient thermal management increases the operational life of the module, and improves reliability by eliminating the effects of elevated temperature on the electrical characteristics of the integrated circuit and packaging. When packages are not stacked, heat from the embedded integrated circuits, generated through normal operation, is primarily dissipated by convection from the package's external surfaces to the surrounding air. When modules are formed by stacking packages, the buried packages have reduced surface area exposed to the air so that the heat dissipation is reduced. [0021] According to the present invention, a multi-chip package and interconnect assembly is provided which allows short interconnection between chips as well as good heat conduction from the chips to the package exterior. The transit time of signals between chips is typically about 30-40% than less that of using individual packages. Furthermore, heat generated during the operation of the chip can be efficiently dissipated. According to one embodiment of the present invention there are provided two stacks of chips, wherein each stack consists of two chips and not of four as in the prior art. Even though the surface of the arrangement is somewhat increased, due to the possibility to arrange a heat sink in between the chips and to connect the chips in a much shorter manner, the arrangement of the present invention is superior to the one of the prior art. The two-two-stack-arrangement of the invention enables a better signal properties than the one-four-stack of the prior art. The routing between the chips can further be optimized by providing a simpler pin allocation so that it is possible to completely avoid the wiring intercrossing. [0022] In one embodiment, the present invention provides a package having at least four chips wherein the four chips are divided into the first pair of chips and the second pair of chips, wherein the first pair of chips are arranged essentially in parallel in the XY plane and second two pair of chips are stacked in parallel or anti-parallel with regard to the first pair of chips. It is to be noted that the reference to the XYZ-planes is only for the purpose of describing the special arrangement of the chips is not intended to be limiting for the arrangement of the present invention. For the purposes of simplicity XY plane will be regarded as the plane of the portion of the printed circuit board onto which two chips are provided. [0023] In one embodiment, between the first pair of chips and/or the second pair of chips at least one heat sink is provided which is thermally connected to at least the first and/or the second pair of chips. [0024] In another embodiment a single heat sink is provided, which is arranged between the first and the second pair of chips, wherein the heat sink is thermally connected to both the first and the second pair of chips. [0025] In a preferred embodiment of the invention a first and a second heat sink are provided, wherein the first heat sink is thermally connected to the first and the second heat sink is thermally connected to the second pair of chips. [0026] In a preferred embodiment of the invention the packaging of the chip are preformed in a ball grid arrays design, which are used to connect the package to a printed circuit board (PCB). [0027] Turning now to the figures and, more particularly, FIG. 2 illustrates a cross view example of a first embodiment with multi-chip package assembly 100 according to the present invention. [0028] As it can be seen from FIG. 2 , chip 1 and chip 4 form the first pair of chips, and chip 2 and chip 3 form the second pair of chips. The same applies throughout the description of the Figures. [0029] According to FIG. 2 , the second pair of chips is stacked above the first pair of chips in an anti-parallel above each other. In the anti-parallel manner means in this case the top surface 11 of chip 1 for example is viewing the top surface 12 of chip 2 . The same applies to the top surface 13 of chip 3 and the top surface 14 of chip 4 . [0030] Chips 1 , 2 , 3 and 4 are interconnected by means of wiring means 20 , which connect pads 40 of chips 1 , 2 , 3 and 4 . Between chips 2 and 3 as well as between chips 1 and 4 heat sinks 30 and 31 are provided. [0031] FIGS. 3 a and 3 b illustrate one preferred embodiment of the present invention. In this embodiment chips 1 , 2 , 3 and 4 are arranged in such a way that all four chips are in a thermal contact with heat sink 30 . A method of manufacturing the arrangement of FIG. 3 b is schematically illustrated in FIG. 3 a. [0032] As it can be see from FIG. 3 a, chips 2 , 3 , 4 and 1 are mounted in this order on printed circuit board (PCB) 5 . Section 6 of printed circuit board 5 on which chips 2 and 3 are mounted is connected to section 7 of printed circuit board 8 , on which chips 4 and 1 are mounted by means of flexible printed circuit board 9 . Between chips 2 and 3 , and 4 and 1 routing means or bonds 21 are provide in order to electrically connect chips 2 , 3 , 4 and 1 . By folding flexible printed circuit board 9 at 180° in such a way that the top surface of chips 2 / 3 face the top surface of chips 1 / 4 it is possible to arrange chips 2 / 3 , which form the first pair of chips in an anti-parallel manner with the chips 1 and 4 so that top surface 11 of chip 1 faces top surface 12 of chip 2 . The same applies to top surfaces 13 of chip 3 and top surface 14 of chip 4 respectively. [0033] Thereafter, heat sink 30 can be introduced in such a manner that a thermal connection between chips 1 , 2 , 3 and 4 with heat sink 30 can be established. By way of example it is also illustrated how printed circuit board 4 is arranged with balls 50 . [0034] FIG. 4 b illustrates another preferred embodiment of the present invention. In this embodiment chips 1 , 4 , 3 , and 2 are arranged anti-parallel to each other and are facing outwards and so that it is possible to obtain an arrangement without having to provide a heat sink since the heat exchange between the chips and the ambient environment is possible. [0035] A method of preparation of this embodiment is schematically illustrated in FIG. 4 a. As it can be see from FIG. 4 a, chips 1 , 4 , 3 , and 2 are mounted in this order on printed circuit board (PCB) 50 . Section 60 of printed circuit board 50 on which chips 2 and 3 are mounted is connected to section 70 of printed certain board 50 , on which chips 4 and 1 are mounted by means of flexible printed circuit board 90 . Between chips 2 / 3 , and 4 / 1 routing means or bonds 21 are provide in order to electrically connect chips 1 , 4 , 3 , and 2 . [0036] By folding flexible printed circuit board 90 at 180° in such a way that the bottom surfaces of chips 1 / 2 , and 3 / 4 face each other it is possible to arrange chips 1 and 2 , and 3 and 4 in an anti-parallel manner so that top surface 41 of chip 1 faces top surface 42 of chip 2 . The same applies to top surfaces 13 of chip 3 and top surface 44 of chip 4 respectively. In this manner an subassembly 60 can be manufactured which can then be connected with a PCB with usual means. [0037] Even though it is not absolutely necessary in this embodiment a heat sink (not illustrated) can also be introduced in such a manner that a thermal connection between chips 1 / 2 and/or 3 / 4 with the heat sink can be established. [0038] FIG. 5 b illustrates another preferred embodiment of the present invention. In this embodiment chips 4 / 1 and 3 / 2 are arranged in a parallel manner. A method of preparation of this embodiment is schematically shown in FIG. 5 a. [0039] As it can be seen from FIG. 5 a, chips 3 and 2 as well as chips 4 and 1 respectively are mounted separately on a printed circuit board. By means of ball grid arrays it is then possible to connect the printed board section on which chips 3 / 2 and 4 / 1 respectively are mounted. [0040] While the invention has been described in terms of several (example) preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims. [0041] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.
A multi-chip package and method is disclosed. In one embodiment, the multi-chip package includes at least four of spaced semiconductor integrated circuit chips mounted on a printed circuit board, consisting of the first pair of the semiconductor integrated circuit chips and the second pair of the semiconductor integrated circuit chips. The chips of the first pair of the semiconductor integrated circuit chips are arranged substantially parallel and the chips of the semiconductor integrated circuit chips of the second pair are arranged substantially stacked over the chips of the first pair of the semiconductor integrated circuit chips.
7
CROSS-REFERENCE TO RELATED APPLICATION This Application is a Section 371 National Stage Application of International Application No. PCT/ GB2009/001649, filed 1 Jul. 2009 and published as WO 2010/001120 on Jan. 7, 2010, in English, the contents of which are hereby incorporated by reference in their entirety. TECHNICAL FIELD The present invention relates to ironing boards and ironing tables, and more specifically to improvements to the robustness, and ease and speed of use. BACKGROUND ART FIG. 1 shows a conventional ironing board 1 comprising an ironing surface 10 supported by a pair of legs 20 , 22 . The legs 20 , 22 extend from the underside of the ironing surface to a pivot 30 and further to feet 40 . At the pivot 30 the legs meet in a crossed scissor-like configuration. There are four feet 40 formed at the ends of the pair of legs 20 , 22 . Adjacent to one end of the ironing surface 10 is an iron rest 50 on which the iron can be placed, and that is not damaged by the heat of the iron. Commonly, one of the legs is rotatably coupled to the underside of the ironing surface, and the other leg is slidably coupled to the underside of the ironing board. This arrangement allows the ironing board to be collapsed by the user for storage. The collapse of the ironing board is achieved by the movement of the legs which allows the ironing board 1 to be stored in a narrow flat space. To provide a robust surface for ironing, the legs 20 , 22 must be held firmly in position when the ironing board is in the upright position for use shown in FIG. 1 . FIG. 2 shows two arrangements used on conventional ironing boards to allow the legs to collapse down flat. FIG. 2 a shows the underside of a conventional ironing board 1 and how the pair of legs are coupled to the underside. Leg 22 is arranged to rotate about a fixed pivot attached to the underside of the bar. The other leg 20 has a cross beam 65 at the top end of the leg. The cross beam is arranged between a pair of slide surfaces 70 . By sliding the cross beam 65 in the direction of the arrow 75 , the height of the ironing surface can be adjusted. By sliding the cross beam further in the direction of the arrow 75 , the legs will close flat against the underside of the ironing surface. In FIG. 2 a , the position of the cross beam 65 can be fixed by the lever arm 80 . The lever arm is pivoted at its center. Towards the one end of the lever arm 80 are a series of hooks 82 (two shown in FIG. 2 a ) which the cross beam fits into. The hooks 82 prevent the cross beam 65 and legs 20 , 22 from sliding and the ironing board collapsing. The hook restraining the cross beam can be released by moving the handle at the other end of the lever arm towards the ironing surface. Conveniently, the handle is biased away from the ironing surface, and the required releasing motion is a squeezing of the handle toward the ironing surface. This causes the lever arm to pivot and the cross beam is released from the hook to allow the ironing board to be collapsed flat. The prior art device of FIG. 2 a has a problem in that the legs are only constrained when the hooks 82 engage with the cross beam 65 , that is, when the ironing board is in an ironing position with the legs open. Multiple hooks can be used to provide the ironing surface at different heights to allow the user to select the most comfortable. However, the legs are not restrained in the closed position. Thus, a user when picking up the ironing board with the legs in the closed position, from for example, a cupboard, has to grasp the legs to prevent them flying open and hitting the user or surroundings as the ironing board is moved. FIG. 2 b shows a common alternative to the above prior art mechanism. In this case, the lever arm with hooks is replaced by a long rod 90 extending from cross beam 65 . Intersecting with the long rod 90 is bar 94 . The bar 94 is arranged to pivot about axis A through the center of the bar. At one end of the bar 94 is a tab 96 with a circular hole 98 through it, as shown in FIG. 2 c . The other end of the bar 94 has a handle for turning the rod 94 about axis A. The handle may be biased away from the ironing surface such that the hole 98 in the tab 96 grips the rod 90 . When the handle is squeezed toward the ironing surface the tab is rotated bringing the tab 96 perpendicular to the rod 90 effectively increasing the cross-section of the hole as viewed along the rod 90 . With the tab perpendicular to the rod, the hole no longer grips the rod 90 and the rod can slide freely through the hole 98 . This movement of the rod allows the legs to be moved between a closed or collapsed position, and an upright or open ironing position. The prior art device of FIGS. 2 b and 2 c partly overcomes the problem of holding the legs in the closed position when the ironing board is carried. However, the legs are not held very securely in the closed position because the braking mechanism is only designed to act in one direction to hold the legs in the open ironing position. Furthermore, the device also suffers from a different problem. The mechanism holding the ironing board legs in the open position consists of a hole in a tab of metal gripping against a rod. This does not provide a robust and solid position to the ironing surface, and can sometimes slip thereby lowering the height of the board. The stability and robustness of the position of the ironing surface is of particular importance when the ironing board is used with a steam generator iron rather than a conventional iron. Such steam generator irons include a large and cumbersome base unit that is filled with 1 to 2 liters of water. Thus, the stability and robustness of the ironing board is particularly important when used with a steam generator. Another problem with conventional ironing boards such as that of FIG. 1 , is that the tip 55 is designed to be useful for ironing a variety of different garments, but this results in the surface not being particularly suited to any go/went. For example, the narrowing of the width of the ironing surface is designed to be useful in ironing trousers because the top of the trouser can be placed over the tip to allow the waist and seat of the trousers to be ironed. However, the tip is also shaped to allow the shoulder yoke of a shirt to be ironed. Because the tip of the ironing board is narrowed, the area of the shoulder yoke that can be ironed at one time without movement of the shirt is small. Hence, ironing shirts requires the shirt to be repositioned many times during ironing. A number of attempts have been made to improve the shape of ironing boards, such as in U.S. Pat. Nos. 5,016,367, 6,151,817, WO 2007/018791, and U.S. Pat. No. 6,286,237, but each of these attempts is limited by ease of use and the shapes of ironing surface that can be provided. A further problem associated with conventional ironing boards is that the ironing surface cools rapidly. The surface is normally metal covered with fabric, or a fabric coated with foil. The foil is used to reflect the heat, However, with conventional ironing boards thick layers must be ironed on both sides to remove creases, and multiple layers cannot be ironed at once to remove all creases successfully. Another problem with conventional ironing boards is that after use for several years the fabric top that forms the ironing surface 10 begins to migrate. A user will tend to iron garments using ironing strokes of the same direction. As a result, after several years of ironing, the fabric top will begin to slide towards one side. It is difficult to reposition the top because the fabric adopts the shape given by the edge of the ironing board. Repositioning results in the ironing surface not being flat. Some ironing boards allow the fabric top to be replaced, but this is usually a difficult task and the same problems will only recur again a few years later. SUMMARY OF THE INVENTION The present invention provides an ironing board system, comprising: an ironing board having a flat elongate surface for ironing, the surface having a perimeter which at an end comprises three adjacent same shaped arcs or curved portions; and at least one attachment or wing having a first edge complementary to each of said arcs, the system adapted such that the wing detachably couples to the ironing board at any of the three arcs to extend the surface for ironing in different ways. The coupling of the wing results in the ironing surface being extended to form one of a plurality of shapes. By ironing board we also mean ironing tables and the like. The system has advantages in that the shape of the end of the ironing board can be changed to suit the garment being ironed. For example, by coupling one wing to the central arc, the ironing surface is extended to provide a tapered tip suitable for ironing the seat of trousers. By coupling two wings to the outer arcs, the tip of the ironing board is matched to the shoulder yoke of a shirt. In addition because the arcs are the same, a single wing can be fitted interchangeably at any of the arcs. The wing or attachment may have a shape such that when coupled to the ironing board at any one of the three arcs, a second edge of the wing meets another of the arcs in a continuous curve or line. That is, a second edge of the wing aligns into an arc of the ironing board such that the edge lines up with end trajectory of the arc to continue that trajectory. Thus, the direction of the end of the arc aligns with the direction of the second edge of the wing. The wing or attachment may have a shape such that when coupled to the ironing board at any one of the three arcs, a second edge of the wing meets another of the arcs at a tangent. The flat surface of the ironing board is tapered by the outer two of the three arcs, and when the wing is coupled to the ironing surface at the central one of the three arcs the taper may be extended. The taper may also considered to be a wedge shape. This tapered of wedge shape is suited to ironing inside narrow items such as the seat of trousers. When the wings are fitted to the outer two of the three arcs, the center arc and edges of the wings may form a shoulder yoke shape. The arcs of the perimeter are preferably convex. The first edge of the wing is non-concave. The wing may be considered to be of generally triangular shape having three sides or edges, one of them being curved complementary to the arcs of the ironing board. The perimeter of the ironing surface may comprise two sides separated by two ends, wherein of the three equally shaped arcs the outer two arcs meet the sides, and the central one of the three arcs meets the outer arcs at corners. There is also provided an ironing board or ironing table comprising: an elongate flat ironing surface having a perimeter or circumference comprised of two sides separated by two ends, wherein at one end (the end furthest from an iron rest if provided) the perimeter or circumference is formed of three curved or linear portions, the first curved or linear portion meeting the first side, the third curved or linear portion meeting the second side, and the second curved or linear portion meeting the first and third curved or linear portions at corners. The shape of the ironing surface is optimised for ironing shirts. If curved portions are included, the curvature is matched to the curvature across the shoulder yoke of shirts. The three curved or linear portions may have substantially the same shape. The radius of curvature of a curved portion may increase towards the extremities of the curved portion. The edge having curved portions is convex. The ironing board may further comprise receiver means for receiving an attachment for extending the ironing surface. Receiver means may be provided at each of the three portions to receive an attachment at the three portions. By providing three positions at which an attachment may locate, the shape of the tip of the ironing board can be changed to suit the garment being ironed. Furthermore, since all receiver means are the same, a single attachment may be used at all three locations. The present invention also provides an ironing board/table attachment for extending the ironing surface of an ironing board, the attachment having an ironing surface, the circumference of the ironing surface comprised of first and second straight edges and a third edge, the three edges meet at corners to define a substantially triangular ironing surface, wherein the attachment comprises mounting means arranged to releasably couple the attachment to an ironing board. The third edge may be curved or linear to fit the curved or linear portions of the ironing board described above. If the second portion of the tip is curved, the curvature combined with the extended ironing area provided by the attachments or wings is advantageously matched to the shape of the shoulder yoke of shirts, thereby making ironing of shirts easier because they do not require as much repositioning. The mounting means may be a retractable tongue. An ironing board system comprising an ironing board or ironing table described above, and the attachment described above. The attachment may comprise a retractable tongue, and the ironing board may comprise a slot for receiving the tongue, the slot positioned so as to align the ironing surface of the attachment coplanar with the ironing surface of the ironing board. The retractable tongue is used to provide support to the attachment when fitted to the ironing board. The present invention also provides an ironing board system, comprising: an ironing board having an elongate flat ironing surface; an attachment arranged to detachably couple to the ironing board to extend the ironing surface, wherein the ironing board comprises a plurality of receivers for receiving the attachment at a plurality of positions. The ironing board may have three receivers for receiving the attachment at three positions. The attachment may be coupled to any one of the receivers to provide different shaped ironing surfaces. A plurality of attachments may be provided may also be provided. When an attachment is coupled to the ironing board at a first position, the extended ironing surface tapers toward a point, but the actual point may be rounded. This tapered shape finds advantage in making it easier to iron the seat of trousers. The ironing board system may further comprise a second attachment, wherein when the two attachments are coupled to the ironing board at second and third positions, the extended ironing surface widens to form a hammerhead shape. This shape may also be considered to consist of a pair of wings. The shape provides the advantage of fitting the shoulder yoke of shirt to allow the shirt to be ironed without having to reposition the shirt many times. The perimeter of the ironing surface may have one or more curved portions, and when coupled to the ironing board the one or two attachments meet one or more curved portions tangentially or collinearly. The present invention further provides an ironing board, comprising: an ironing surface; and an iron rest having a connector coupled to the ironing surface and an iron support arranged to receive an iron, wherein the iron support is arranged for rotation with respect to the connector and about an axis through said iron support. The iron support may also be known as a turntable. The iron support may be a platform, ring or rim that can be rotated. The advantage of the turntable of the present invention is that it allows the iron to be put at rest from a variety of directions, while also being more compact that prior art devices. The iron rest may be provided adjacent to an edge of the ironing surface. The present invention also provides an ironing board having an ironing surface, and comprising: a frame or base arranged to support an ironing surface; legs coupled to the frame and arranged to support the frame at a height suitable for ironing; wherein the ironing surface is a layer or sheet covering at least one side of a rigid panel, the rigid panel detachably coupled to the frame. Because the rigid panel is removable, the layer or sheet forming the ironing surface can be changed easily. The rigid panel is preferably flat. When the rigid panel is mounted to the frame, the layer or sheet is gripped between the rigid panel and the frame preventing movement of the layer or sheet. This arrangement results in the sheet or layer of the ironing surface being clamped between two surfaces preventing movement. The sheet or layer may be fabric, fabric covered foil, or foil. The panel may be detachably coupled to the frame by an engageable member. The engageable member may be a foot protruding from the panel and has a ridge for engagement with a notch in the frame. The present invention also provides an ironing board, comprising: an ironing surface supported by a frame or case; legs to support the frame and arranged to move between a closed position for storing the ironing board and an open position for use of the ironing board, at least one of the legs being slidable with respect to the ironing surface; and a brake assembly arranged to releasably restrain, with respect to the ironing surface, the position of the slidable leg, the brake assembly comprising: a slide rod or connecting rod coupled to the slidable leg, the slide rod extending from the leg to a bearing surface; a cam mounted on a shaft, the shaft having a handle arranged to rotate the cam about the shaft, wherein the shaft is biased towards a first position in which the cam bears against the slide rod pushing the slide rod against the bearing surface thereby restraining the position of the leg. The handle may be squeezed toward the ironing surface by the user to move it to a second position. In the second position the cam has rotated and no longer causes the connecting rod to bear against the guide thereby allowing the connecting rod to slide. Thus, when the handle is pressed the connecting rod and legs can move. The connecting rod may be enclosed, fully or partially, within a guide, and the bearing surface may be part of the guide. The present invention additionally provides an ironing board comprising an ironing surface and legs to support the ironing surface, at least one of the legs being arranged to slide with respect to the ironing surface between a storage position and an open position, the ironing board further comprising a pair of brakes to restrain the position of the at least leg. The pair of brakes may be operated independently, such that the ironing board cannot be collapsed or folded away without operating both brakes. This provides a safety advantage because it prevents a child from operating the brakes inadvertently closing the board. independently operable. The first brake assembly may have a cam and slide rod arranged to prevent movement of the slide rod in a first direction, and the second brake assembly may have a cam and connecting rod arranged to prevent movement of the connecting rod in a second direction opposite to the first direction. A pair of brakes arranged to operate in opposite directions prevents the legs falling open or closed. Additionally, the first brake may also provide a smaller braking force in a second direction, and the second brake may provide a smaller braking force in the first direction. The ironing board may comprise an ironing surface and legs for supporting the ironing surface, at least one of the legs being movable with respect to the ironing surface between a storage position and an open position, wherein the ironing board further comprises a pair of brakes, the first brake arranged to releasably restrain at least one of the legs in the storage position, and a second brake arranged to releasably restrain at least one of the legs in the open position. Because the pair of brakes are required to be operated together to close or open the ironing board, this provides a safety feature preventing a child from closing the legs while the ironing board is in use, perhaps with a hot iron. There is also provided an ironing board comprising a surface for ironing supported by a rigid panel, the ironing surface formed of a flexible sheet, wherein between the flexible sheet and the rigid panel is a resilient non-permeable interlayer to cushion the ironing surface and prevent steam penetration from the ironing surface to the rigid panel. The steam does not penetrate through to the rigid panel, but is reflected by the interlayer through the flexible sheet. The rigid panel may comprise holes, such as a mesh, or be a solid panel. The flexible sheet may be fabric. The interlayer may be closed cell foam. The closed cell foam may have a thermal conductivity of less than 0.2 W/m·K. The foam may have a hardness of 5 to 40 on the OO Durometer scale. The foam may be extruded silicon sponge, such as is used for seals and gaskets. Alternatively, the interlayer may be a resilient material laminated with plastic. The resilient material may be open cell foam, felt, or other matted or non-woven material. The ironing boards described above may have an ironing surface comprising a flexible sheet covering a rigid panel, disposed between the sheet and rigid panel may be a heat retaining material. The heat retaining material may have a thermal conductivity less than 5 W/m/K, less than 0.5 W/m·K, or less than 0.2 W/m·K. The heat retaining material may be a silicon foam or silicone foam. Such heat retaining material does not cool quickly and thereby provides an increased decreasing duration. The foam is preferably resilient. The foam is also preferably closed cell foam to prevent water or steam penetrating through the foam such that the steam is reflected back from the foam. Alternatively, the foam may be of any kind but is laminated with a membrane through which the steam cannot pass. Preferably the membrane is on the side of the foam closest to the ironing surface such that water is not absorbed in the foam. Preferably, the foam has a hardness of 5 to 40 on the OO Durometer scale, or even between 5 and 20 on the same scale. The sheet of the ironing surface may be a felt or felt-like material. The rear side of the felt may be laminated with a polymer or plastic material to retain heat. A foam material may also be used as the heat retaining material and does not necessarily need to be limited to the felt or fabric. The ironing board attachment described above may also include a heat retaining material as described above. There is also provided an ironing board comprising: an elongate flat ironing surface having a perimeter comprised of two sides separated by two ends, wherein at one end the perimeter is formed of three portions, the first portion meeting the first side, the third portion meeting the second side, and the second portion meeting the first and third portions at corners. The three portion may be curved portions. The three curved portions may have substantially the same shapes. The radius of curvature of each curved portion may increase towards the extremities of the curved portion. A first side may be tangential to the first curved portion, and the second side may be tangential to the third curved portion. The angle between a first end of one of the curved portions and a second end of one of the curved portions may be 140° to 150°. The normal to the center of the first portion may preferably be at angle of 140° to 155° to the normal to the center of the third portion, or more preferably 145° to 150°. The shape of the ironing surface is preferably symmetric about an axis centrally along the length of the surface. The two sides of the ironing surface are preferably parallel. Optionally, the ironing board further comprises receiver means for receiving an attachment for extending the ironing surface, a receiver means provided at each of the three portions to receive an attachment at the three portions. There is also provided an ironing board attachment or wing for extending the ironing surface of an ironing board, the attachment having an ironing surface, the perimeter of the ironing surface comprised of first and second straight edges and a third edge, the three edges meeting to define a substantially triangular ironing surface, wherein the attachment comprises mounting means arranged to releasably couple the attachment to an ironing board. Preferably, the third edge is a curved edge. The mounting means may be arranged to align the ironing surface of the attachment coplanar with the ironing surface of an ironing board. The mounting means may be a retractable tongue. The first and second straight edges may be at an angle of 60° to 75° to each other, or more preferably at an angle of 65° to 70° to each other. There is also provided an ironing board system comprising the ironing board described above and the attachment or wing described. The attachment or wing maybe adapted to releasably couple to the ironing board at a plurality of positions. The attachment is adapted to couple to the ironing board at a first position, the edge formed by the second portion of the ironing board meets the first or second straight edge of the attachment tangentially or collinearly. In addition, the attachment is adapted to couple to the ironing board at a second position, the edge formed by the first portion of the ironing board meets the first or second straight edge of the attachment tangentially or collinearly. The attachment may comprise a retractable tongue, and the ironing board comprises a slot for receiving the tongue, the slot positioned so as to align the ironing surface of the attachment coplanar with the ironing surface of the ironing board. There is also provided an ironing board system, comprising: an ironing board having an elongate flat ironing surface; and an attachment arranged to detachably couple to the ironing board to extend the ironing surface, wherein the ironing board further comprises a plurality of receivers for receiving the attachment at a plurality of positions. The ironing board may have three receivers for receiving the attachment at three positions. The attachment may couple to the ironing board at a first position such that the extended ironing surface is tapered. The ironing board system may further comprise a second attachment, wherein when the two attachments are coupled to the ironing board at second and third positions, the extended ironing surface widens to form a hammerhead shape. The perimeter of the ironing surface may have one or more curved portions, and when coupled to the ironing board the one or two attachments meet one or more curved portions tangentially. The present invention also provides an ironing surface comprising a sheet covering a rigid panel, wherein between the sheet and rigid panel is a heat retaining material having a thermal conductivity less than 5 W/m/K. The heat retaining material may be a foam material. The foam material may be silicon foam. The heat retaining material may be a polymer laminated on the sheet. The sheet may be fabric. The sheet may be felt or a felt-like material. BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the present invention, along with aspects of the prior art, will now be described with reference to the accompanying drawings, of which: FIG. 1 illustrates an ironing board of the prior art; FIG. 2 a shows the mechanism for locking the legs of an ironing board in open and retracted positions according to a first prior art example; FIGS. 2 b and 2 c are detailed views of the mechanism for locking the legs of an ironing board in open and retracted position according to a second prior art example; FIG. 3 is an isometric perspective view of an ironing board according to an embodiment of the present invention; FIG. 4 is a detailed plan view of the tip of the ironing board according to an embodiment of the present invention; FIG. 5 is a detailed plan view of the tip of the ironing board according to an embodiment, showing the location of a shirt during ironing; FIG. 6 is a detailed plan view of a wing for attachment to the ironing board; FIG. 7 a shows the tip of an ironing board with a pair of wings fitted; FIG. 7 b shows the placement of an adult's shirt on an ironing board with wings fitted; FIG. 7 c shows the placement of an child's shirt on an ironing board with wings fitted; FIGS. 8 a , 8 b , 8 c show the tip of the ironing board in three configurations, respectively no wing fitted, one wing fitted, and two wings fitted; FIG. 9 is an isometric perspective view of the underside of the ironing board and wing according to an embodiment of the present invention; FIG. 10 a shows in isometric perspective the turntable iron rest of an embodiment of the present invention; FIGS. 10 b , 10 c show the turntable iron rest in two different orientations; FIG. 10 d shows the turntable iron rest in cross-section with an iron resting thereon; FIG. 11 shows a removable panel that forms the rigid part of an ironing surface; FIG. 12 shows in detail the coupling mechanism for locking the removable panel to the case or frame of the ironing board; FIG. 13 shows in cross-section the removable panel clamping the ironing surface sheet to the frame; FIG. 14 , shows the ironing board from the underside, with legs open; FIG. 15 shows the braking mechanism for restraining the legs in a fixed position; FIGS. 16 a - 16 c show a guide and slide rod of the braking mechanism; and FIGS. 17 a - 17 b show the different versions of the braking mechanism used on the two sides of the ironing board. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments provide an ironing board or ironing table having an improved tip shape which is also optimised for attachment of removable wings, turntable iron rest, improved materials for the surface of the ironing board, an improved braking mechanism to hold the legs of the ironing board in position, and a removable top to allow the cover to be changed easily and also to hold the cover in position more rigidly. Each of these improvements is described below. Each of these improvements may be included by itself in an ironing board or with any number of the other improvements. FIG. 3 shows an ironing board 100 having an ironing surface 110 and three linear legs 120 , 122 a , 122 b . These may be circular or square tubes, solid, or preferably of rectangular cross-section. Two of the legs 122 a , 122 b are fixed parallel to each other. The third leg 120 passes between the two legs 122 a , 122 b . At the end of each of the legs are feet 140 , 142 . The feet extend laterally from the legs to provide widely spaced points were the feet touch the floor. Spacing the feet more widely than the legs increases the stability of the ironing board. The feet may extend perpendicularly to the legs or may be curved as shown in FIG. 3 . At the ends of the feet where contact is made with the floor, pads may be provided. Legs 122 a , 122 b are parallel and the positions where the legs meet foot 142 are slightly spaced apart. The legs 120 , 122 a , 122 b meet at a pivot 130 comprised of a circular shaft passing perpendicularly through the legs. Spacing the legs apart on the pivot rod 130 are spacers 132 . The pivot rod 130 is held in position by nuts or other fastening means on the end of the rod. The legs can pivot with respect to each other about the pivot, though legs 122 a , 122 b are fixed together at the foot and cannot move with respect to each other. At the top of the legs is provided ironing surface 110 . The ironing surface may be supported on a frame. The legs may be connected to the underside of the frame by the prior art means described above, or by further means described below. One of the legs will be pivotally coupled to the underside of the ironing surface or frame, whereas the other leg is able to both pivot and slide. In the current embodiment, legs 122 a , 122 b are pivotally coupled, whereas leg 120 can both slide and pivot. In some embodiments, the arrangement may be reversed. The pivotable and slidable arrangement for the legs means that the ironing board can be conveniently folded away. That is, the legs 120 that slide and are locked in the position shown in FIG. 3 for ironing, can be released. The top of the leg 120 can be slid in the direction of arrow 115 . As this happens the legs close in a scissor-like manner, the pivot 130 moving closer to the underside of the ironing surface 110 until the legs lie parallel with ironing surface and frame. The surface of the ironing board is of an elongate or rectangular shape, and may be formed of a metal base covered by fabric, optionally, the metal base may be supported by the frame as described above. Although the embodiment described above has three legs, it is also possible that embodiments may incorporate two legs, or more than three legs. Ironing Surface Shape and Wings In the currently described embodiment, the ironing surface is based on, but is different to, a normal ironing board shape, that is of an elongate or rectangular shape. The elongate shape has two long sides 131 that are linear along the majority of their length, a short side 132 , and a tip 130 . Adjacent to the short side 132 may be an iron rest 150 for resting the iron when hot or temporarily not in use. In the current embodiment, the tip 130 has a shape comprised of three similar curved portions 133 a , 133 b , 133 c . These three curved portions are preferably identical. Each curved portion has the same length and same curvature. The curvature is at its greatest at the center of the curved portion and decreases further away from the center, becoming linear at the extremes of the curved portion. Each curved portion 133 a , 133 b , 133 c is symmetric, and the three curved portions themselves are arranged symmetrically about the long axis of the ironing surface. Curved portions 133 a , 133 c arranged at the sides of the tip of the board meet the long sides 131 of the board. The decreasing curvature of the curved portion means that portions 133 a , 133 c blend to the linear long sides 131 . Centre curved portion 133 b meets the side curved portions 133 a , 133 c at corners. FIG. 4 shows the tip of the ironing board in detail. This arrangement has been optimised to fit the shoulder yoke of shirts and blouses. The shoulder yoke is the piece of material that forms the shoulders of the shirt. The curvature of the tip of the ironing board is optimised to fit most, if not all, shirts and blouses. The angle between normals to the two side curved portions 133 a and 133 c is preferably between 140° and 155°. In FIG. 4 , 147° is shown as this is a particularly preferred embodiment. Thus, the angle between each of the three curved portions is between 70° and 78°, and is preferably around 73-74°. FIG. 5 shows how shirts (sometimes known as dress shirts) of any size are placed on the ironing surface 110 . Dashed line 134 a FIG. 5 shows how a child's shirt may be placed on the ironing board, while dashed line 134 b shows an adult's shirt. Both shirts require the same curved portion to fit the shoulder yoke of the shirt, but the child's shirt uses a smaller part of the curved portion 133 b than the adult's. Approximately, and depending on actual size, an adult's shirt will roughly line up so that the middle of the shirt is aligned with the center line of the ironing board, or extend beyond the center line of the ironing board as shown by line 134 b in FIG. 5 . In this way a whole front side (left or right) may be ironed at once without having to reposition the shirt. Conventional ironing boards, such as in FIG. 1 , have a pointed tip. This means only part of the top front, or shoulder yoke, of the shirt is supported at any one time, To iron all of one side of the front of the shirt, the shirt will have to be repositioned many times to realign the tip of the ironing board within the shoulder yoke of the shirt. The ironing board of the current embodiment has a curved tip 130 optimised to fit most, if not all, shirts to allow a front side of the shirt to be ironed at once without requiring repositioning of the shirt. This means ironing of shirts is completed more quickly and easily. The ironing board of the current embodiment is also particularly useful for ironing T-shirts, tunics, nightshirts, jumpers etc, or any other garment that fits across the shoulders and may have a shoulder yoke. In an alternative embodiment three equal sized linear portions may replace curved portions 133 a , 133 b , 133 c to achieve a similar effect. The embodiment of FIGS. 3 to 5 may also be provided with attachable wings to further improve the ironing of shirts etc. FIG. 6 shows the approximate shape of a wing 170 . The wing is of a generally triangular shape but is arranged to fit against one of the curved portions 133 a , 133 b , 133 c . Therefore, the wing has a concavely curved edge 171 . The curve of this edge matches that of the curved portion 133 a , 133 b , 133 c of the ironing board of FIGS. 3 to 5 . Thus, the curved edge is symmetric and the curvature is greatest at the center of the curve and decreases towards the extremes of the curve such that at the very extremes the edge is approaching linear. Because the curved portions 133 a , 133 b , 133 c preferably all have the same curved form, the wing 170 will fit against any of these portions. The wing also has a pair of substantially linear edges 172 to make up the generally triangular shape of the wing 170 . The apex where the two linear edges 172 meet may be rounded as shown in FIG. 6 . FIG. 7 a shows a pair of wings arranged against side curved portions 133 a , 133 c of the tip 130 . The linear edges 172 of the wing meet and extend the curved edge portion 133 b . Thus, the linear edge 172 of one wing, along the curved portion 133 b , to the linear edge of the second wing, makes a continuous smooth line which is optimised to match the shoulder yoke of many shirts and similar garments. In the embodiment shown in FIGS. 6 and 7 a , the angle subtended by the linear edges 172 of the wing is between 60° and 75°, and preferably between 65° and 70°, such as 68° as shown in FIG. 6 . As shown in FIG. 4 , the angle between the two curved portions 133 a , 133 c is between 140 and 155°, and preferably 147°. The symmetry line of the wings 173 are also at this angle to each other, as shown in FIG. 7 a . Based on the above, angle calculations reveal that the angle between the linear edge 172 of one wing, and the linear edge 172 of the other wing is approximately 145°. This is similar to the angle of 147° shown on FIG. 7 a . In some embodiments these angles may equal. FIG. 7 b shows how a shirt fits to the ironing board. For example, a shirt with buttons and placket down the center of the front of the shirt will align approximately centrally or beyond the center line of the ironing board. The wings partially fill out the ends of the sleeves. The edge, denoted by reference numerals 172 , 133 b , 172 fits in to the shoulder yoke of the shirt. To align the shirt on the ironing board, the shirt should be pulled from one side so that the wing fits into the top of the sleeve. The shirt should also be pulled downwards slightly to fit the curved edge 172 - 133 b - 172 into the shoulder yoke. One half of the front side may be ironed without requiring repositioning of the shirt. Conventional ironing boards would require the shirt to be repositioned many times to be able to completely iron the shoulder yoke and top of the sleeve. For the current embodiment, the placket of the shirt is shown aligned centrally on the ironing board ( FIG. 7 ). However, the actual position of the placket or center line of the front of the shirt will be depend on the size of the shirt. The position of a child's shirt may differ to that of an adult's as shown in FIG. 7 c . For a child's shirt the shoulder yoke may be less curved and fit better to the linear portion which is part of the wing. Hence, the shirt may be placed over the tip and wings at angle to the longitudinal direction of the board, as shown in FIG. 7 c. As described above, the tip 130 of the ironing board may comprise three identical curved portions 133 a , 133 b , 133 c . FIG. 7 a shows wings attached to two of the curved portions 133 a , 133 c . A wing may also be attached to the curved portion 133 b . FIG. 8 shows the tip of the ironing board with no wings attached ( FIG. 8 a ), a pair of wings attached ( FIG. 8 b ), and a single wing attached ( FIG. 8 c ). The single wing attached to the middle curved portion 133 b provides the ironing board tip with a pointed shape, particularly useful for ironing the seat and tops of the legs of trousers (or pants). The shape of the wings and curved portions are optimised for this purpose. As shown in FIG. 8 c , the linear edges 172 of the wing blend to meet the curved portion of the tip to provide an edge that forms a smooth continuous line. In an alternative embodiment where the ironing board is provided with three equal linear portions rather than curved portions 133 a , 133 b , 133 c , the wings may be provided with an additional linear edge rather than the concavely curved edge. The additional linear edge will meet the ironing board tip when fitted to the tip. If the ironing board is provided with three wings then wings may be fitted to all three curved portions of the tip. In total, the tip and wings may be combined to provide an ironing board with eight different shaped tips. Briefly, they are i) no wings, ii-iv) one wing mounted on the left, in the center, or on the right, v) two wings with one mounted on each aide, vi-vii) two wings with one mounted in the center, and one on the left or right side, and viii) three wings, one mounted in each position. FIG. 9 shows a wing 170 in detail, along with the tip 130 of the ironing board. The wing has an underside 175 and an ironing surface (not shown). When attached to the tip 130 , the ironing surface of the wing meets and is coplanar with the ironing surface 110 of the ironing board to provide a single continuous surface. The wings extend the area of the ironing surface. The wing 170 is attached to the tip by tongues. There is provided a slidable tongue 177 , and two fixed tongues 176 . The slidable tongue 177 is provided in a slot 178 in the underside of the wing. The slidable tongue 177 is an elongate slidable tab having a rounded knob or button 179 for actuating the tongue 177 . The button is located in the slot 178 and the shape of the slot limits the movement of the tongue 177 . The button may take other shapes or forms. Movement of the button from one end of the slot 178 to the other causes the tongue to move from a retracted position to an extended position. Fixed tongues 176 are semicircular discs that protrude from the curved edge of the wing. When retracted, the slidable tongue still protrudes a small amount from the curved edge 171 . The amount the slidable tongue 177 protrudes is substantially the same as the amount the fixed tongues protrude. The end of the slidable tongue is semicircular, to match the shape of the fixed tongue. Other shapes of slidable and fixed tongues are possible. To attach the wing to the tip of the ironing board, the wing should be positioned to locate the tongues in recesses (not shown) in the edge of the tip 110 . The central recess is deeper to accommodate the slidable tongue. The fixed tongues aid with alignment, and the slidable tongue provides most of the support to the wing when fitted to the tip. The tongues may be provided with lugs or ridges (not shown) that fit into keeper notches when the tongues are fully pushed into the recesses in the ironing board tip. The lugs and keeper notches retain the wing securely in the fitted position and prevent it from coming loose. The wing may be removed from the tip by a gentle pulling action to release the lugs from keeper notches. In some embodiments not all of the tongues are provided with lugs. The wings may be fitted to the tip in other ways. For example, the wings may be hinged to the underside of the ironing board, or the wings may slide out of the tip and be retractably stored in the tip. In the embodiment shown in FIG. 9 , after use the wing may be conveniently stored in the cavity 180 in the underside of the board. The cavity in FIG. 9 is shown at the tip end of the ironing board. A second cavity may be included at the other end of the ironing board, or elsewhere on the underside of the board. The cavity 180 is of a generally triangular shape to match the shape of the wing. That is, the cavity 180 has an outline matching the shape of the wing by having two linear edges and a concavely curved edge. The wing is stored in the cavity by first locating the tongues in recesses in the curved edge of the cavity, and then by pushing the wing against the underside of the board. The cavity is deeper at one end than the other such that the wing protrudes outside the cavity. This allows the user to grasp the wing at one end to remove it from the cavity. As shown in FIG. 9 , the cavity is deeper at the curved end. The ironing surface of the wings is provided with a material similar to that used for the ironing surface of the board. Iron Rest As shown in FIG. 3 , adjacent to the short side 132 of the ironing board 110 , and at the opposite end of the ironing board tip 130 , there may be located an iron rest 150 . FIG. 10 shows in detail an iron rest according to an embodiment. The iron rest comprises a rotatable turntable 151 and a fixed part 152 . The fixed part supports the turntable and is connected to the ironing surface or the underside thereof. In some embodiments the ironing surface may be formed of a top surface for ironing which is supported by a frame. In such an embodiment, the fixed part 152 of the turntable is connected to the frame. The fixed part 152 is of a shape similar to half an ellipse (cut along the short axis), but may take many other shapes such as rectangular, square etc. The turntable is circular in shape with a rim 151 a around the edge. The fixed part 152 has a circular cut-out in which the turntable 151 rests. The rim 151 a of the turntable rests on the top of the fixed part, but may also have a portion that extends into the circular hole in the fixed part. The rim 151 a provides alignment of the turntable with the hole in the fixed part 152 . Forming chords across the circular rim are pair of flaps 151 b . These flaps have a horizontal part and an inclined part. The inclined part is normally to be used for resting the iron on such that the heel of the iron rests against and below one of the flaps, with the sole plate of the iron touching the other flap, as shown in FIG. 10 d . Since the turntable can rotate, the flaps can be oriented at any angle to the ironing board. FIGS. 10 b and 10 c show the turntable at two positions spaced by 90°, though any position in between may also be achieved. Alternatively to placing the iron on the iron rest as shown in FIG. 10 d , the iron can be placed on the rest end on with the iron pointing vertically upward. The flaps are covered with heat resistant material and hence are not damaged by the heat of the sole plate of the iron. Advantageously, the turntable 151 can be oriented at any angle. This can help the user in putting the iron on the rest. For example, with the iron rest oriented as in FIG. 10 b or 10 c it may be awkward to put the iron on the rest. When the user is standing at a midpoint along the side of the ironing board, and reaches to put the iron down on rest 150 , the iron will be at an angle to the directions of the turntable shown in FIGS. 10 b and 10 c . Thus, the turntable should be rotated by 20-40° to be in alignment with the direction of the user's arm. Furthermore, the turntable can be rotated to be suitable for use wherever around the ironing board the person stands. For example, some people may not stand at the midpoint of one side but closer to one end. Hence the turntable may be reoriented to suit the user. The turntable may also be reoriented to suit left or right handed users whom may stand on different sides of the ironing board. In some embodiments the turntable may be mounted on bearings or rollers. In the current embodiment, the rim 151 a retains the turntable by providing surfaces above and below the fixed part which prevent the turntable from being displaced, but allowing it to rotate. The surfaces are bearing surfaces which slide against the fixed part to allow the turntable to rotate. To achieve this arrangement, the rim may be formed of two circular components which fit together to provide a channel to retain the turntable in the circular hole in the fixed part 152 . One of the components sits on the top surface of the fixed part, while the other sits below. Alternatively, a one piece turntable 151 may be provided that has a retainer ridge which locates in a channel in the fixed part 152 . The channel extends all of the way around the side of the circular hole in the fixed part 152 . Hence, as well as retaining the turntable, it also provides a channel in which the ridge slides as the turntable is rotated. Ironing Surface The ironing surface 110 of FIG. 3 may be comprised of several components. There may be a base or frame part to which the legs are coupled to. The top surface that is used for ironing may be formed of fabric wrapped around a panel 220 . Such a panel is shown in FIG. 11 . The panel 220 forms the full size of the ironing surface including curved portions at the ironing board tip. The panel 220 has many holes bored through. These holes are to allow steam from the wet or damp garment being ironed to pass out of the garment. The holes also help to reduce weight and material cost. Many holes are provided over each unit of area of the panel, and across the whole of the panel. The panel 220 is connected to the base or frame of the top by a push and click motion. That is, the panel is provided with feet 225 . Preferably, four feet are provided, two on each of the long sides of the ironing surface spaced towards the ends of each side. The feet comprise an ankle that extends downwards away from the panel. Towards the end of the ankle, the feet extend parallel to the longitudinal direction of the panel. All feet point in the same direction. On the horizontal part of the foot is provided a latch or catch 228 which may consist of a small triangular protrusion facing toward the panel 220 . FIG. 12 shows the panel fitted to the frame or base of the ironing surface. The frame 230 is provided with an aperture through which the foot 225 can be passed. When the panel is pushed against the frame or base, and slid in the direction of arrow 235 the catch on the foot engages with a notch 240 in the underside of the base. The notch and latch engage to hold the panel on to the base. All feet are arranged to engage with similar notches on the base at the same time. In FIGS. 11 and 12 the panel or top surface is shown without a fabric covering. FIG. 13 shows in cross-section the panel 220 covered with fabric 232 and fitted to the frame 230 . The panel of the embodiment is covered with fabric 232 prior to fitting to the frame 230 . The fabric 232 is sized to cover the whole panel and is provided with a drawstring 234 around the edge of the fabric. To fit the fabric, it is draped over the top surface, pulled tight across the surface and wrapped a small amount around the edge and underneath the panel. At this point the drawstring 234 can be pulled tight to pull the fabric 232 tightly against the top surface of the panel. The panel can now be clipped into the frame as described above. Because the panel 220 and frame 230 meet towards the edge of the panel, the fabric 232 is gripped tightly between the panel and the frame when the panel is clipped in position by the cooperating notch and catch pairs. Other engaging means to hold the panel to the case may alternatively be used. The gripping arrangement prevents the fabric moving under continued usage of the ironing board. On conventional ironing boards, the fabric is merely tied by a drawstring under the ironing surface. After years of repeated use and continued ironing in the same direction, the fabric begins to migrate in the direction of ironing. After a long time the fabric has moved so much that part of the underlying metal surface of the ironing board may become exposed. The gripping arrangement of the current top prevents the migration of the fabric surface on the top of the board. Additionally, to avoid puckering or creasing of the fabric top at the corners of the ironing board, the fabric is tailored to fit the board. In particular, the fabric may be stitched or glued to form a pocket around the ironing board tip and along the long sides of the board. Instead of the drawstring described above, the fabric may be held in position by one or more straps across the board. Where the straps meet they may buckle together, tie together, or be adhered to each by the use of Velcro®. The ability to remove the panel from the top and easily replace the cover also has advantages in matching the ironing board to the household decor. The fabric may be easily changed to match and coordinate with the colours of the room in which it is used. The fabric used for the ironing surface of the ironing board may be a non-woven cloth produced by matting, condensing and pressing fibers. The fabric provides a smooth non-slip surface over which garments can be placed for ironing. When a garment is in contact with the fabric over a large area, the fabric holds the garment in place. That is the garment will not slide easily as the iron is passed over it. However, when the garment is lifted from the fabric surface, the smoothness of the fabric means that it can be repositioned easily. This ability to both grip the garment but also to allow the garment to be easily moved makes ironing easier and quicker. Underneath the fabric outer surface which the garment is placed on for ironing may be an insulating layer. The panel underneath may be metal which conducts the heat away rapidly. However, by adding a heat retaining or insulating layer between the fabric and panel heat can be retained close to the garment. The longer heat is retained close to the garment, the longer the de-creasing effect will be. Thus, having run the iron over the surface of the garment, by retaining heat in the surface of the ironing board, the ironing action will not need to be repeated as many times. In a preferred embodiment, the heat retaining material may be a silicon or silicone foam. The silicon or silicone foam is a poor conductor of heat, and the air trapped in the foam will also trap heat. By reducing the number of times the iron needs to be repeatedly passed over a garment, the speed of the ironing task will be increased. Also, because the board retains some heat the iron may not need to be heated as much, and hence may remove creases sufficiently at a lower heat setting. Thus, the reduced iron temperature combined with the increased speed of ironing will reduce the amount of energy required to iron a garment. Other types of foam may also be used but they must be able to withstand the high temperatures (up to 200° C.) resulting by close contact with the sole plate of an iron and from contact with steam. The foam should also be a closed cell foam such that the steam cannot penetrate through the material. Conventional ironing board covers use open celled foam to allow the steam to pass through (CH 672152). By providing a foam that is not permeable to steam or water, it cannot penetrate through the foam to the metal frame or panel beneath. The use of a steam generator type iron, or an iron that generates large amounts of steam, may result in the water causing the frame or panel to rust, rot, or become coated in lime scale or other deposits. Thus, the use of closed cell foam causes the steam to be reflected or bounced back from the surface of the ironing board, passing back through the garment, such that it evaporates in the air and does not collect on the surface of the ironing board. As well as preventing rusting etc mentioned above, the steam reflected from the surface results in more efficient steam ironing because the steam passes through the garment twice. Additionally, the reflected steam means water does not collect or pool on the ironing surface. Alternatively, an open cell foam can be used provided it is coated with a thin non permeable membrane. The foam should also be deformable or resilient such that the ironing surface is soft to the touch. When the iron is passed over the ironing surface the foam cushions the path of the iron. The foam is preferably of a light to medium density offering a hardness measured on the OO Durometer scale and preferably in the range 5-40 on that scale. As an alternative measurement of hardness, the compression deflection should be in the range 0.02 to 0.10 MPa. Thermal conductivities of 0.06 to 0.12 W/m·K are expected, and preferably around 0.0695 W/m·K which is the value for the silicone foam. Uncompressed densities are in the range 230 to 280 Kg·m −3 (14 to 18 lbs per cubic ft), and preferably around 255 Kg·m −3 (16 lbs per cubic ft). Other specifications for the silicone foam used are given in the table below: Elongation at break 225% Tensile Strength 65 Newtons Compression Recovery 24 hrs @23° C. = 100% after 1 hr (25% deflection) 24 hrs @100° C. = 95% after 1 hr 72 hrs @150° C. = 85% after 48 hrs Temperature Range −40 to +190° C. Toxicity NES 713 ISS 3 14 MM Smoke Index NES 711 46 Burn Rate BS4735 0.03 mm per second The values in this table are measured values from samples tested and some variations from the exact values given above is expected. Closed cell silicone foam forms a barrier to the steam or water such that it is reflected from the ironing surface. Such foam can also withstand the high temperatures resulting from the ironing process as well as being deformable to cushion the path of the iron. In an alternative embodiment, the foam can be replaced by other resilient material laminated with a layer through which water or steam cannot penetrate through. For example, a layer of felt can be used to provide the cushioning effect. This is laminated with thin plastic which is preferably flexible. This laminated layer is provided between the rigid panel and fabric sheet. Preferably, the laminated side of the layer faces the rigid panel, but alternatively the laminated side may face the fabric sheet. The latter arrangement prevents water from collecting in the felt and making it damp or wet. As an alternative to felt other types of soft or resilient material may be used. The plastic laminate should be less than half a millimeter thick, and preferably in the range from 10's to 100's μm thick. The felt-plastic is less expensive than silicon foam, and retains the ability to reflect back steam. Mentioned above are wings 170 , the surface of these wings may also be covered with the same fabric. The wings may also include a heat retaining or insulating material underneath the fabric, such a silicon foam. Other types of heat retaining material may also be used, such as silicon rubber. Braking Mechanism FIG. 14 shows a view of the underside of an ironing board of FIG. 3 . This view is a plan view of the ironing board when it is in the upright position. The legs are shown in their open position ready for use of the ironing board. This view shows some of the features of the mechanism used for restraining the legs in the open or closed position. That is, the open position for ironing, and the closed position for storage of the ironing board. Legs 120 , 122 a , 122 b are shown in FIG. 14 . As described above, the legs 122 a , 122 b are coupled by a pivot 270 to the board. Leg 120 meets legs 122 a , 122 b at pivot rod 130 . The top of leg 120 slides in channel 290 . Within case 300 on the underside of the ironing surface there is provided a leg restraint mechanism, or braking mechanism, for holding the leg 120 in the desired position. The mechanism is actuated by handles 280 located in the case 300 . FIG. 15 shows the braking mechanism in more detail with some of the case 300 removed. FIG. 15 also views the mechanism from the opposite direction to FIG. 14 , that is FIG. 15 is viewed from the top side of the case 300 towards legs 120 , 122 a , 122 b . Hence, the channel 290 shown in FIG. 14 , is shown as a rectangular moulding 290 in FIG. 15 . In the sides of the channel 290 are provided slots 292 through which a bar is located. This bar 296 also passes through the end of leg 120 . At each side of the channel 290 is provided a hollow guide 294 which has a rectangular cross-section. A slot is also provided in the guide. The slot corresponds with the slot 292 in channel 290 . The slot extends along most of the length of the guide such that along this length the guide has a C-shaped cross-section. Bar 296 extends into the corresponding slot in the guide. A spacer may be mounted on the bar between the channel 290 and guide 294 . Inside the guide 294 , a connecting rod or slide rod 298 couples from the bar 296 to the handle 280 , as shown in detail in FIG. 16 . The connecting rod 298 is mounted to the bar 296 such that the bar may rotate freely without causing rotation of the connecting rod. However, if the leg 120 is moved, the bar will slide also sliding the connecting rod 298 . The connecting rod extends toward the handle 280 , but proximal to the bar 296 the connecting rod has two bends. The bends realign the direction of the connecting rod such that its direction does not project through the axis of the bar but is spaced from it. The purpose of the bends is to position the connecting rod 298 close to the inside surface of the guide 294 for as much of its length as possible. The handle 280 is connected to an axle 282 passing through the guide 294 . The handle acts as a lever to turn the axle. On the axle is mounted a cam 284 . The cam has an approximately oval shape and is arranged to press against the side of the connecting rod 298 . The handle is biased such that when no pressure is applied by the user, the cam pushes against the connecting rod, the opposite side of which is in turn pushed against the inside wall of the guide 294 , as shown in FIG. 16 b . The bias may be supplied by a lever spring, coiled spring or concentrically coiled spring mounted on the axis. Friction between the inside wall of the guide and the connecting rod, and between the cam and the connecting rod, provides a force to stop the connecting from moving. With the connecting rod restrained at a given position, the legs are also restrained at a given position. To release the connecting rod 298 to allow the legs to move, the handle is depressed to turn the cam. As the cam turns, the profile of the cam is such that after turning, the part of the cam now closest to the connecting rod has a smaller radius. Thus, the cam no longer pushes the connecting rod against the inside wall of the guide and there is a small gap between the guide and the connecting rod. This is shown in FIG. 16 c . After the handle 280 is released by the user, the bias will turn the cam back to the position shown in FIG. 16 b to hold the connecting rod in position. As shown in FIG. 14 , the ironing board may be provided with two handles and thus two mechanisms for restraining the leg 120 at given position. The brake mechanism provided on one side of the ironing board is arranged to operate in the opposite direction to the brake mechanism on the other side. The braking mechanism shown in FIGS. 16 a - 16 c is used on a first side of the channel, and a modified mechanism is used on the other side of the channel. The mechanism for the other side also comprises a connecting rod but the bends are formed in the opposite direction to those on the mechanism of FIGS. 16 a - 16 c . In FIGS. 16 a - 16 c the connecting rod passes along the top inner surface of the guide and over the cam. In the mechanism for the other side of the board, the connecting rod passes along the bottom inner side of the guide and underneath the cam, as shown in FIG. 17 b . Thus, for either mechanism, by pushing the cam handle downward, although the cams are rotated in opposite direction, the same braking forces are applied. In FIGS. 16 a - 16 c , the position of the bar 296 indicates that the legs are retracted closed. When the legs are opened to the position for ironing, the bar will move to the left as shown by the arrow 297 . Whether the legs are open for ironing or retracted for storage, the bias on the cams will turn them to push the cam against the connecting rod and against the inside wall of the guide. Thus in any restrained position, each connecting rod will be held in position by two pairs of frictionally opposed surfaces, i.e. cam to connecting rod, and connecting rod to guide wall. Furthermore, because of the shape of the cam shown in FIG. 16 b , this cam will be more efficient at preventing movement in the direction of the arrow 297 . The alternative arrangement used for the other guide will be more efficient at preventing movement in a direction opposite to the arrow 297 . This is shown in more detail in FIG. 17 . In FIG. 17 a , if a force is applied to the connecting rod to push it to the left, the shape of the cam means that it will push the connecting rod harder against the wall of the guide thereby gripping it tighter. In FIG. 17 b , the opposite is true, if the connecting rod is pushed to the right the cam will push the connecting rod harder against the bottom wall of the guide holding it tighter. Thus, each braking mechanism provides a directional braking action. The two braking mechanisms together provide bi-directional braking mechanism The braking mechanism described above allows the ironing board to be set to a continuous range of heights for ironing, and not a small number of discrete heights as some prior art devices. In addition, the two braking mechanisms together restrain the iron board at the correct height for the user in a more robust manner than some braking mechanisms. This is especially useful when a heavy steam generator is placed on the ironing board. In addition, the need to push two handles simultaneously to release the brakes provides a safety feature making it difficult for a young child to release both brakes, thereby making the incidence of accidents involving hot irons rarer. An ironing board having the advantage described above may also be provided by using a pair of brake assemblies of the prior art. In an alternative arrangement, the handles and cams may be configured differently. In the embodiment described above, the handles are squeezed toward the board surface to release the brakes. In the alternative arrangement, the handles are instead pushed towards the edge of the board. The cams are thus arranged to bear on a side surface of the connecting rod rather than the top or bottom surface. Other configurations may also be possible. The person skilled in the art will readily appreciate that various modifications and alterations may be made to the above described embodiment of ironing board or ironing table without departing from the scope of the appended claims.
Ironing board systems comprising an ironing board having an elongate surface for ironing wherein at an end of its perimeter, said surface for ironing has three adjacent equally spaced arc. The ironing board system includes said ironing board and a wing shaped attachment with an edge having an arc complementary to the arcs of the ironing board. The wing shaped attachment is adapted to detachably couple to said ironing board at any of the three adjacent arcs to extend the ironing surface. The ironing board may comprise a rotatable iron rest, and a braking mechanism for restraining the ironing board in open and closed positions.
3
BACKGROUND OF THE INVENTION The present invention relates to wall systems in general, and more particularly to a wall system which has pronounced sound absorbing, heat insulating and fire retarding properties. Still more particularly, the present invention relates to a wall system which may be used either as a permanent, a temporary or a slidable partitioning wall. Various wall systems are well known in the building industry and they have found widespread application. One of the main requirements for such systems is that they have good sound absorbing, heat insulating and fire retarding properties, whether such wall systems are used as permanent parts of the building structure, as dismountable partitions or as slidable partitioning walls. However, these requirements are not fully met even if the wall system is a solid masonry wall made of sound-absorbing and thermally insulating fireproof material; these requirements are even more difficult to meet in relatively thin partitioning wall systems. This results from the fact that the walls are at least partially permeable to sound and/or heat due to the immediate or mediate connection between the two opposite major surfaces of the wall facing the compartments being separated from one another by the wall or, in case of an outside wall, one of the surfaces facing the exterior of the building. Attempts have already been made to reduce the permeability of wall systems to pentration of sound and heat therethrough by providing a hollow insulating space inside the wall system which effectively separates one wall portion facing one of the compartments from another wall portion facing the other compartment or the exterior of the building. As a result of this arrangement, the heat and sound transmission through the wall system has been significantly reduced since the heat and sound conduction occurs predominantly through connecting portions or elements of the wall which bridge the hollow space and connect the two major wall portions to one another. Since these connecting portions or elements have a relatively small cross-sectional area, the heat and sound conduction therethrough is insignificant when compared to that of a solid wall but not negligible. In fact, the amount of heat and the intensity of sound penetrating through such hollow wall are still substantial. While the temperature drop between two neighboring compartments may be small so that the heat insulating properties of the wall system may not be of real significance in some wall systems, particularly in partitioning wall systems erected inside a building, the problem of sound penetration is to be avoided in such wall systems whether they are used as exterior or as partitioning walls, and particularly in the latter case. There are also already known wall constructions or systems in which two independently supported wall panels are provided which have neither immediate nor mediate contact with one another. However, these systems have up to now been utilized only for erecting permanent or at most dismountable partitioning or other walls, not for slidable partitioning walls. In addition thereto, all the parts of which the wall system of this type is to be assembled have to be transported separately to the building site. Consequently, the erection of such a wall system requires utilization of highly skilled labor force and involves considerable time expenditure. Consequently, it would be advantageous to mount a pair of wall panels on a shared supporting frame to form a wall element since then the erection of a partitioning wall would only involve arranging a plurality of such wall elements in mutual alignment and interconnecting the same; however, all of the heretofore known wall elements of this type have invariably involved formation of bridges between the two associated panels mounted on the same frame, with attendant deterioration of the sound and heat insulation properties of the wall due to the fact that the two panels are mounted on the same supporting columns or transverse beams which together form the frame. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to avoid the disadvantages of the prior art wall systems. More particularly, it is an object of the present invention to provide a composite wall element to be used in a wall system which has excellent sound absorbing, thermally insulating and fire retarding properties. It is a further object of the present invention to provide a wall element comprising two wall panels mounted on a shared frame. It is an additional object of the present invention to provide a wall element which may be moved as a unit and easily and reliably connected with another wall element to together form a wall system. It is a concomitant object of the present invention to provide a wall element comprising two wall panels mounted on a shared frame without immediate connection of the two panels to one another. It is yet another object of the present invention to provide a wall element which can be used either as a part of a stationary partition wall or in a sliding wall. In pursuance of these objects and others which will become apparent hereinafter, one feature of the present invention resides in providing a wall element having a frame made of metallic, synthetic plastic or similar material and having two upright supports on which two simple or composite wall panels are mounted in such a manner that each panel is supported at only one of the upright supports of the frame while it is spaced a certain distance from the other upright support on which the other panel is supported. Connecting elements are provided which connect the upright marginal portions of the two associated wall panels to one another and, when more than one of the wall elements are arranged next to one another in mutual alignment to form a wall system, to connect the marginal portions of the two adjacent wall elements to one another. In the latter case, the marginal portion of the panel of one of the wall elements which is spaced from the upright support abuts and is connected to the marginal portion of the adjacent panel of the other wall element which is supported on its associated upright support so that proper alignment of the wall panels and wall elements is assured. In a currently preferred embodiment of the invention, the panels of each of the wall elements are also mounted on the horizontal or transverse bars interconnecting the upright supports and forming with the latter the frame in such a manner that at least one gap is provided between the respective wall panel and the associated transverse bar, so that no heat or sound transmitting bridges are provided between the panels of the wall element and the frame thereof. According to the currently preferred embodiment of the invention, the connecting elements which connect the two panels of the wall element to one another and possibly also to the adjacent panels are made of sound-absorbing material so as to prevent transmission of sound from one of the panels of each wall element to the other one through the connecting elements. If the wall element has to have fire-retarding properties, the wall panels and the frame are made of fire-proof materials. The wall element or a plurality of interconnected wall elements according to the invention may either be used as a stationary, possibly dismountable partitioning wall or, alternatively, may be mounted for sliding on overhead or bottom rails in a conventional manner so as to provide a sliding door or a disappearing partitioning wall. The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front elevational view of the wall element according to the invention with the front panel omitted; FIG. 2 is a side elevational view of the wall element according to the invention with the connecting elements omitted; FIG. 3 is a cross-sectional view of the wall system according to the invention comprising a plurality of interconnected wall elements of FIG. 1; FIG. 4 is a detail of the wall system illustrated in FIG. 3; and FIG. 5 is a cross-sectional view of the wall element according to the invention of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings and firstly to FIGS. 1 and 2 thereof, it may be seen therein that a composite wall element according to the invention comprises a frame 1 which includes two upright supports 2 and 3 which are interconnected by transverse bars 4 and 5. The upright supports 2, 3 and the transverse bars 4, 5 may preferably be made of interconnected profiled metallic or synthetic plastic material sections of rectangular or similar configuration. Two wall panels 6 and 7 are mounted on the frame 1 in a manner which will now be described in detail with reference to FIGS. 3 to 5. As shown in FIG. 3, the wall panel 6 is composed of an outer plate 8 and an inner plate 10 which are made of conventional building materials such as wood, plywood, wood agglomerates, synthetic plastic materials or similar materials. If the wall system has to have fire retardation properties, then the material of at least the outer plate 8 is selected from a group of fireproof materials, such as plasterboard or asbestos. Similarly, the wall panel 7 is composed of an outer plate 9 and an inner plate 11. An intermediate layer 12 or 13 is provided between the outer plate 8 or 9 and the inner plate 10 or 11, respectively, the intermediate layer 12 or 13 being preferably made of synthetic plastic material and the plates 8 to 11 being attached thereto either by press-bonding or by any other conventional bonding or attachment method. The two wall panels 6 and 7 in the assembled condition of the wall element extend in mutual parallelism and spaced from one another in the direction normal to their major surfaces, thus defining with one another an enclosed space into which the frame 1 is accepted with clearance from each of the wall panels 6 and 7. A cushion member 14 is accommodated in the clearance between the panel 6 and the upright support 2, supporting the wall panel 6 on the upright support 2, while the panel 6 and the upright support 3 define with one another a clearance 15. In a similar manner, a cushion member 16 is accommodated in the clearance between the panel 7 and the upright support 3, supporting the wall panel 7 on the upright support 3, while the panel 7 and the upright support 2 define with one another a clearance 17. A connecting member 18 which is shown in greater detail in FIG. 4 is provided at each of the upright marginal portions of the wall panels 6 and 7 and comprises a preferably corrugated projection 19 which is accepted in and bonded to the intermediate layer 12 or 13. The connecting member 18 further includes a portion 22 which abuts the outer plate 8 or 9, respectively, and is provided with a recess 21 into which the inner plate 10 or 11, respectively, is accepted. A further projection 20 of the connecting member 18 extends into the enclosed space defined by the wall panels 6 and 7 and bounds a groove in which a retaining projection 23 is provided. A connecting element 24, which is preferably made of resilient sound-absorbing material, includes two hook-shaped projections 26 and 27 which respectively extend into the grooves defined by the projections 20 of the connecting members 18 associated with the panels 6 and 7, respectively so that the tips of the projections 26 and 27 engage the respective retaining projections 23. Alternatively, instead of providing two separate connecting elements 24 each being associated with one wall element, a shared connecting element may be provided having twice as many projections as the previously described connecting elements, each of the hook-shaped projections 26 or 27 engaging one of the retaining projections 23 of the four connecting members 18 associated with the two adjacent wall elements whereby the wall elements are interconnected. If the sound-proofing properties of the connecting elements 24 are to be further improved, the connecting elements 24 may be formed with hollows 25 reducing the cross-sectional area of the connecting elements 24. The connecting member 18 is further provided with a recess 28 adapted to receive an aligning member 29. When the two adjacent wall elements are brought together so that the marginal portions of the panels 6 or 7 of the two adjacent wall elements abut one another, then each aligning member 29 extends into the recess 28 of the connecting members 18 of the adjacent wall panels 6 or 7, respectively, thus aligning the panels 6 of the two adjacent wall elements with one another and similarly aligning the panels 7. Preferably, the aligning member 29 has such dimensions as to be accepted into at least one of the recesses 28 with pressure-fit so that, prior to assembling the two adjacent wall elements, the aligning member 29 is accepted into one of the recesses 28 and retained in it by friction. If the aligning member 29 is so configurated as to be received with pressure-fit into each of the cooperating recesses 28, this gives the wall system an increased stability and resistance to unintentional disengagement of the two adjacent wall elements. In order to prevent relative movement between the frame 1 and the wall panels 6 and 7, the cushion member 14 or 16 is accommodated between an abutment surface 32 of the respective connecting member 18 and an L-shaped section 30 which is rigidly connected to the inner plate 10 or 11 of the respective panels 6 or 7. The separate wall elements are assembled either in the production plant and transported to the building site in their assembled condition, or directly on the building site but preferably prior to erection of the wall system. The assembling operation includes inserting the cushion members 14 and 16 between the abutment surface 32 and the L-shaped section 30 provided on the respective panel 6 or 7 and introducing the upright supports 2 and 3, respectively, into the channels defined by the cushion members 14 and 16 or, alternatively, attaching the cushion members 14 and 16 to the uprights 2 and 3, respectively and inserting the cushioned upright supports 2 and 3 between the abutment surface 32 and the L-shaped section 30 provided on the respective panel 6 or 7. In this manner, the respective panel 6 is supported in cantilever fashion on the upright support 2 and the panel 7 is supported in cantilever fashion on the upright support 3. Subsequently thereto, the panels 6 and 7 are interconnected by the connecting elements 24 engaging the retaining projections 23 of the connecting members 18 so that the mutual distance of the panels 6 and 7 is set and so are the clearances 15 and 17 between the panel 6 and the upright support 3 and the panel 7 and the upright support 2. Then the aligning members 29 are inserted into the recesses 29 of the connecting members 18. When a wall system is to be erected from a plurality of such assembled wall elements, the first one of the wall elements is connected to the existing structure extending in the direction of the contemplated wall system, and each successive adjacent wall element is moved in its upright position toward the first wall element so that the aligning members 29 enter into the free recesses 28 of the connecting members 18. When the entire wall system is erected, then all the panels 6 of the various wall elements will be mutually aligned and also all the panels 7 of the various wall elements will be similarly aligned. It is evident that in the assembled condition no sound-transmitting or thermally conductive bridges are present between the wall plates 6 and 7 but for the sound-absorbing and thermally non-conductive connecting elements 24. Despite the fact that clearances 15 and 17 are provided between the respective upright supports 2 or 3 and the panels 6 or 7, the construction is extremely stable due to the fact that the two respective adjacent panels are interconnected by the aligning members 29 so that even the cantilevered upright marginal portion of the panels 6 or 7 is prevented from yielding, being mediately, via the aligning member 29, supported on the respective upright support 2 or 3 of the adjacent wall element. The above-discussed arrangement is quite satisfactory for permanent, immovable walls, even for those wall elements which are adjacent to the corners of the thus formed compartment where no adjacent wall element is available since the clearance 15 or 17 may be obtained by mounting the respective wall panel 6 or 7 to the existing structure. However, it is also possible for the corner wall elements, and imperative for end wall elements of a slidable wall, to provide a modified arrangement as illustrated in FIG. 3, in which an additional cushion member is provided between the otherwise cantilevered marginal portion of the wall panel 6 or 7 and the associated upright support 2 or 3. In other words, the clearance 15 or 17 is eliminated and replaced by the cushion member 14 or 16. It is evident that this expedient is necessary since otherwise there would be no support for the cantilevered marginal portion of the wall element, particularly such wall element which is used in a slidable wall. If so desired, sound-absorbing strips 33 may be accommodated in the recesses 28 which, when the slidable wall abuts the adjoining structure, provide sound and heat insulation between the two neighboring compartments. The strips 33 may be made of any sound-absorbing and thermally insulating material, felt being currently preferred. The two associated wall panels 6 and 7 of each wall element define with one another a relatively large enclosed space. This space may be, if so desired, filled either entirely or partially with insulating material 34 or 35, preferably with glass fibres or like materials. It is currently preferred that two separate insulating layers 34 and 35 are provided, each associated with one of the panels 6 and 7, so that a gap is provided between the respective layers 34 and 35. Coming now to the embodiment shown in FIG. 5, it may be seen therein that a different kind of insulating arrangement may also be provided in the regions of the upper and lower end faces of each wall element. In the currently preferred embodiment of the invention, the formation of heat and sound conducting bridges between the wall panels 6 and 7 is prevented even in these regions by providing gaps between the panels 6 and 7 and the transverse bars 4 and 5. The lower transverse bar 4 of the frame 1 is connected to the upright supports 2 and 3 or made in one piece therewith. An L-shaped section is connected to the transverse bar 4 and/or the upright supports 2 and 3 in a conventional manner, for instance by welding, and has an upright arm 38 and another arm 39 extending outwardly from the frame 1. A support rib 40 which may be either unitary with, or connected to, the arm 39 extends parallel to the arm 38. Another L-shaped section is also provided having an upright arm 41 accepted and retained between the outer plate 8 or 9 and the inner plate 10 or 11 and another arm 42 extending outwardly underneath the outer plate 8 or 9, respectively, and supporting the same. A U-shaped section 43 is attached to the inwardly directed side of the arm 41 so that the inner plate 10 or 11 is supported thereon and being provided with a downwardly directed groove having such dimensions that the support rib 40 surrounded by an insulating element 44, which may be made of foam rubber or similar material, is snugly received therein. When the rib 40 and the insulating element 44 are fittingly received in the groove of the section 43, the arms 39 and 42 of the two L-shaped sections are spaced from one another by a gap 46, and the arm 38 is spaced from the section 43 by a gap 45. As a result of the presence of the gaps 45 and 46 and of the insulating element 44, excellent sound and heat insulating properties are obtained. The upper transverse bar arrangement generally corresponds to the just described lower transverse bar arrangement with one exception, namely that the inner L-shaped section 47, 48 is mounted for movement in the vertical direction, instead of being rigidly connected to the frame 1. This particular arrangement includes a counter plate 49 connected to the arm 47 of the L-shaped section by connecting bolts 50 which are accepted in a vertical elongated cutout 51 of the transverse bar 4 so as to be movable between an upper position shown in the left half of the FIG. 5 and a lower position illustrated in the right half thereof. A support rib 52 corresponding to the previously described support rib 40 is provided with an insulating element 53, and a U-shaped section 54 is connected to the inwardly directed side of an arm 55, the section 54 and the arm 55 being similar to the previously described section 43 and arm 41. As a result of this arrangement, it is possible to arrange the panels 6 and 7 on the lower support rib 40 as previously described while the L-shaped section 47, 48 is in its upper position, and subsequently thereto also attach the panels 6 and 7 in the upper regions thereof by lowering the L-shaped section 47, 48 so that the support rib 52 with the insulating element 53 attached thereto is received in the groove of the section 44. The particular advantage of this arrangement is that the assembly of the wall section from the various components thereof, such as the frame 1 and the two wall panels 6 and 7, may be accomplished without any special tools. Consequently, it is possible to deliver the above-mentioned components to the construction site in their disassembled condition to be assembled in situ. Another advantage obtained by this arrangement is that any one of the panels 6 or 7 can be easily removed from the assembled wall element for repair purposes or in order to be exchanged for a different one. According to a modified embodiment of the invention, which is not illustrated, a shared U-shaped section may be provided instead of the two separate L-shaped lower sections of the two separate L-shaped upper sections. Of course, the lower U-shaped section would be rigidly connected to the frame 1, while the upper U-shaped section would be mounted on the frame 1 for movement in the vertical direction. In that case, of course, the panels 6 and 7 will have to be mounted simultaneously. The above-described wall element is particularly suitable for use as a sliding wall, either by itself or in combination with several other wall elements. Of course, in this event, suitable supporting sliding arrangement will have to be provided, which is well known in the building industry. Such arrangement may, for instance, include an overhead rail and a plurality of supporting rollers mounted on the wall element and adapted to travel on the overhead rail, or a bottom rail and a plurality of rollers provided underneath or laterally of the lower marginal portion of the respective wall element and adapted to roll on the bottom rail. Instead of providing separate rollers, they may be grouped in overhead or bottom carriages. Also, as an alternative, the lower rollers may be replaced by a layer of synthetic plastic material whose surface is relatively smooth and, consequently, whose coefficient of friction is relatively low, so that when the layer slides along the bottom rail, which may also be made of, or provided with a layer of, such low-friction material, the frictional resistance to the sliding movement of the wall element will be minimal. It wil be understood that each of the elements described above, or two or more together, may also find a useful application in other types of wall systems differing from the types described above. While the invention has been illustrated and described as embodied in a wall system, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
A wall system comprises a plurality of supporting frames and a plurality of wall panels associated in pairs with each respective frame. The two panels of each pair are interconnected in the regions of their upright marginal portions so as to extend in mutual parallelism and to define a space in which the upright supports of the associated frame are accommodated with clearance from each of the panels. An insulating member is accommodated between one upright support and one of the panels, and another insulating member is accommodated between the other upright support and the other panel. The upright marginal portions of any two adjacent pairs of panels are interconnected in mutual alignment in such a manner that the insulating member associated with the upright support of one pair of panels is situated at the opposite side of the upright support from the side of the upright support of the other pair of panels at which the other insulating member is located so that mediate contact between the two panels of each pair is avoided without sacrificing the stability of the system. The upright supports of each frame are interconnected by transverse beams on which the pair of panels is supported with clearance. Additional rails and rollers may be provided when the wall system is to be used as a sliding partition.
4
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The invention relates to a device for actuating a lock on a vehicle door, wherein the term vehicle door includes any type of lid, hatch, flap, hood and the like on a vehicle. The device comprises: a support to be stationarily mounted on the door; a mount mountable on the support and configured either as a lock cylinder mount or as a lock cylinder-free mount (decoy); a shoulder on the mount that engages at least partially in the secured mounting position of the mount a counter shoulder provided on the support; a screw for securing the mounting position of the mount on the support; and an actuating end on the screw for a screwing adjustment of two end positions, i.e., a release position in which the mount can be mounted on or demounted from the support and a locking position in which the mount is secured in its mounting position on the support. In this configuration, the support to be mounted on the door not only supports the handle but also receives a lock cylinder mount or a lock cylinder decoy. The handle upon actuation acts on a lock in the door or the flap etc.; this holds true also for a lock cylinder when it is actuated by a matching key. These two alternatives, i.e., the lock cylinder mount and the lock cylinder decoy, will be referred to in the following simply as “mount”. [0003] 2. Description of the Related Art [0004] The devices of this kind are designed to enable, on the one hand, an easy and reliable mounting of the mount within the receptacle of the support and, on the other hand, to secure the mount after having been mounted properly on the support in a reliable way. For this purpose, the mount of the device has a shoulder that, at least in the secured mounting position of the mount, engages at least partially a counter shoulder provided on the support. For securing the mounting position in the mount, a screw is used whose actuating end is accessible from the narrow side of the door. [0005] In a known device of the aforementioned kind, disclosed in German patent DE 30 30 519 C, the screw is a component of the support. The support has a threaded receptacle in which the screw is received. The inner end of the screw serves for securing the mount. Before mounting, the support is already stationarily secured on the inner side of the door and the mount is inserted from the exterior through an opening provided in the outer door panel of the door and is then mounted on the support by a mounting movement. During this mounting process, the screw is unscrewed out of the threaded receptacle to such an extent that the mounting movement for mounting the mount can be carried out; this mounting movement is comprised of an insertion phase and a subsequent displacement phase that is parallel to the insertion position. During this displacement phase of the mounting movement, the shoulder of the mount moves into a position behind the aforementioned counter shoulder on the support. This engaged position of the shoulder and counter shoulder is secured by the screw in that the screw is threaded into the threaded receptacle to such an extent that its inner end is supported on the sidewall of the mount. In this way, a movement reversing the mounting movement for demounting the mount is blocked. The movement of the mount in a reverse movement relative to the mounting movement is prevented by the tightened screw. [0006] There are also devices where the securing action for the mounted mount on the support is not a direct action but is achieved indirectly, as disclosed in German patent application DE 199 50 172 A1. In this case, a slide is slidably received in guides of the support so as to be slidable in parallel. The slide has a threaded receptacle for a screw that is rotatably supported with its actuating end in an axially fixed position within the support. Before beginning the mounting process of the mount, the screw with its threaded inner end is screwed as far as possible into the threaded receptacle of the slide so that the slide is initially in a position remote from the mount. Then, the mount is inserted from the exterior side of the door into the support provided on the inner side of the door. When the screw is turned such that its threaded inner end is moved out of the threaded receptacle of the slide, the slide, because of the axially fixed rotational support of the screw, is moved more and more against the mount and the mount is parallel displaced within the support. This movement of the slide causes not only the mount to be displaced; moreover, the shoulders on the mount are moved behind the counter shoulders of the support and noses provided on the slide are moved into notches provided on the mount. The securing action is realized by the slide moved against the mount. SUMMARY OF THE INVENTION [0007] It is an object of the present invention to provide a reliable and space-saving device of the aforementioned kind that can be handled comfortably and quickly for mounting and demounting of the mount and that ensures a reliable securing action of the mounted position of the mount on the support. [0008] In accordance with the present invention, this is achieved in that the mount has a threaded receptacle for the screw and the screw is a component of the mount, in that the actuating end of the screw has correlated therewith a stationary support surface on the support, and in that, in the securing position, the actuating end of the screw is supported on the support surface of the support and secures the mounted position of the mount on the support. [0009] The special feature of the invention resides in that the threaded receptacle of the screw provided for securing the mount is not located within the support or in a slide mounted on the support but is provided within the mount itself. According to the invention, the mount and the screw for securing the mount form of pre-assembled module. The support itself only must provide a stationary screw support surface on which, in the locking position, the actuating end of the screw is supported. During mounting, the screw is screwed into the mount as far as possible until the shoulder on the mount engages behind the counter shoulder provided on the support. Subsequently, for securing this mounting position of the mount on the support, the screw is unscrewed from the mount to such an extent that, as mentioned above, its actuating end rests against the screw support surface on the support. Not the inner end of the screw, as in the aforementioned prior art devices, but the opposed actuating end of the screw secures the engagement of the mount shoulder at the counter shoulder on the support. BRIEF DESCRIPTION OF THE DRAWING [0010] In the drawing: [0011] FIG. 1 shows a side view of a first embodiment of the mount of the device according to the invention before being mounted on the support, wherein the mount does not have a lock cylinder to be actuated by a key and is only a mount decoy without lock cylinder; [0012] FIG. 2 shows the bottom side of the mount illustrated in FIG. 1 ; [0013] FIG. 3 is a support on which the mount according to FIG. 1 and FIG. 2 is mounted but not yet secured by the screw; [0014] FIG. 4 shows, in a view analog to FIG. 2 , a second embodiment of the mount of the device according to the invention; [0015] FIG. 5 shows in a view analog to the illustration of FIG. 1 a side view of the mount of FIG. 4 ; [0016] FIG. 6 is a longitudinal section of the mount of FIG. 4 along section line VI-VI; [0017] FIG. 7 shows a stabilization member of the mount illustrated in FIGS. 4 through 6 in a plan view; [0018] FIG. 8 is an end view of the stabilization member of FIG. 7 in the direction of arrow VIII; [0019] FIG. 9 is a side view of the stabilization member illustrated in FIGS. 7 and 8 in the direction of arrow IX of FIG. 7 ; [0020] FIG. 10 shows a screw used in both embodiments for securing the mounted position of the mount on the support; [0021] FIG. 11 shows in a view analog to FIG. 3 the yet unsecured position of the mount on the support where the screw is still in the release position so that the mount can still be inserted into and removed from the support; and [0022] FIG. 12 shows in an illustration corresponding to FIG. 11 the securing position where the screw has been turned within the mount to such an extent by a screwing tool (not illustrated) that its actuating end is supported on the support surface provided on the support. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0023] Only one end of the support 10 of the device is shown in FIG. 3 and FIGS. 11, 12 , respectively, for both embodiments. In both embodiments, the supports 10 are identical; the backside 11 of the support 10 mounted on the inner side of a door, not shown, is illustrated in the drawings. The fastening locations 13 for fastening means for fastening the door and the support 10 to one another are illustrated. The handle 15 for actuating a lock provided on the door is illustrated in dash-dotted lines only in FIG. 5 . The handle 15 is provided at the front side of the support 10 and is not illustrated in more detail; it is accessible from the exterior of the door for manual actuation. The elements that upon actuation of the handle 15 act on the lock pass through a cutout 18 provided within the support 10 . These elements of the handle 15 are not illustrated in FIGS. 3, 11 , and 12 . [0024] Such a handle 15 can also be mounted on the support 10 at a later time, i.e., after the support 10 has been mounted on the door, from the outer side of the door through openings in the outer door panel. In this connection, one end of the handle is coupled with a bearing provided on the support while the other end of the handle has the aforementioned elements that are to be positioned in the cutout 18 of the support 10 . he cutout 18 has a sufficiently large size so that in addition to the mounted elements of the handle a mount 20 can be mounted. It will suffice to explain the configuration and the function of the mount with the aid of the second embodiment of FIGS. 4 through 10 because this second embodiment differs from the embodiment of FIGS. 1 and 2 only in that the mount has a separate stabilization member 26 on the mount housing 21 ; this area is of a monolithic configuration in the first embodiment of the mount. The stabilization member 26 reinforces the mount. [0025] As can be seen best in FIG. 6 , the mount (decoy) 20 , as already mentioned, is comprised of a stabilization member 26 that is produced separately and receives the screw 30 illustrated in FIG. 10 and is inserted into a bore of the separately produced mount housing 21 . The mount 20 has a threaded receptacle 25 for the screw 30 illustrated in FIG. 10 . While in the first embodiment of FIGS. 1 and 2 this threaded receptacle is a component of the mount housing 21 , in the second embodiment, illustrated in FIGS. 7 through 9 , it is arranged in a bushing 28 of the stabilization member 26 . [0026] The stabilization member 26 has the following configuration. At the outer end of the bushing 28 an end member 35 that is all around widened like a flange is provided that, upon insertion of the stabilization member 26 into a bore 43 of the mount housing 21 for forming a preassembled unit, will abut by means of an inner profile 29 according to FIG. 9 a counter profile 23 on the mount housing 21 . This bore 43 is illustrated in dashed lines in the section view of FIG. 6 . In the insertion position of the stabilization member 26 , the stabilization member 26 projects with projections 46 , illustrated in FIG. 7 , from the end member 35 on opposed sides of the mount housing 21 . This is also illustrated in FIG. 4 . Slanted surfaces 24 that can be seen particularly well in FIG. 7 are provided at this location; as will be explained in more detail in the following, these slanted surfaces 24 cooperate with slanted counter surfaces 34 of the support 10 in the securing position. [0027] The module 21 , 26 , 30 of the second embodiment of FIG. 6 and the module 21 , 30 of the first embodiment according to FIG. 1 are mounted from the exterior side of the door through an opening in the outer door panel in the cutout 18 of the support 10 . This can be realized by an assembling movement 40 that has two movement phases illustrated by arrows 41 , 42 in FIG. 6 . In the first movement phase 41 , the mount is inserted substantially perpendicularly to the door plane; subsequently, a movement phase 42 moves the inserted mount 28 within the support 10 in a direction perpendicular to the first movement phase 41 . During this assembling movement 40 , the shoulders 22 provided on the mount 20 engage counter shoulders 12 on the support 10 ; the counter shoulders 12 are only schematically illustrated in FIGS. 3 and 11 . While the shoulders 22 are formed by a groove 27 in the mount housing 21 provided with inner surfaces, as illustrated in FIG. 6 , the counter shoulders 12 are in the form of ribs 17 formed on the support 10 . FIG. 3 and FIG. 11 , respectively, show the end position of the mount 20 after completion of mounting within the support 10 . The head 36 of the housing illustrated in FIG. 5 and FIG. 6 is now positioned on the exterior side of the door in front of the door panel 38 illustrated in FIG. 5 in dashed lines. Adjacent to the housing head 36 of the mounted mount 20 , a portion of the lock of the handle 15 is positioned as illustrated in FIG. 5 in dashed lines. In FIG. 5 , the position of the support 10 is not shown. [0028] Upon completion of assembly according to FIGS. 3 and 11 , the screw 30 is screwed into the threaded receptacle 25 in the mount housing 21 or in the stabilization member 26 to the maximum extent. This is indicated in FIG. 3 and FIG. 11 by the auxiliary line 30 . 1 ; this is referred to as the release position of the screw 30 . As shown in FIG. 10 , the screw 30 is provided with a flange 32 in the area of its actuation end 31 . The release position 30 . 1 can be secured in that the flange 32 is moved into a flange receptacle 39 in the widened end member 25 of the stabilization member 26 or the mount housing 21 and rest against the receptacle 39 . [0029] In the mounted position of the mount 20 , the actuation end 31 of the screw 30 that is in the release position 30 . 1 is aligned with a cutout 37 provided within the support end 14 ( FIG. 3 ) and providing an access to the actuation end 31 . From the narrow side of the door where a hole is provided, a screwing tool can be inserted into the tool receptacle in the actuation end 31 of the screw 30 . By means of the screwing tool, the screw 30 is then moved out of the mount 20 in the direction toward the support end 14 . On the support 10 , a stationary screw support surface 16 is provided that faces the screw 30 . The movement of the screw 30 in the outward direction will end when the screw 30 abuts the screw support surface 16 as shown in FIG. 12 . The unscrewed screw 30 is now in the locking position for securing the mount in the securing position; the locking position of the screw 30 is indicated by the auxiliary line 30 . 2 . In the present configuration, the stop function is realized in that the actuation end 31 itself will come to rest against the screw support surface 16 . The afore described flange 32 rests annularly against the surface 16 . This flange 32 is provided with a lock toothing 33 illustrated in FIG. 10 that digs or penetrates into the support surface 16 of the support 10 in the locking position 30 . 2 shown in FIG. 12 . Since the lock toothing 33 has a sawtooth profile, the return movement of the screw 30 out of its securing position 30 . 2 is made significantly more difficult. In this way, a particularly reliable locking of the mount 20 in its mounting position in the support 10 is provided. [0030] According to the prior art, a worker who must mount such devices on doors or flaps of vehicles, is used to rotate the tool in the clockwise direction in order to transfer the screw for securing the mounted mount 20 in the securing position. However, according to the invention, the screw, as described above, is moved out of the mount 20 with its actuating end 31 during this securing action. In the case of a conventional right-handed thread of the prior art, the screw 30 therefore would have to be rotated in the counter-clockwise direction. The worker therefore would be required to retrain mounting of the device according to the invention and rotate the screwing tool in the opposite direction. This would be confusing to a worker when, at times, he would have to mount also prior art devices in between. For this reason, it is proposed to provide the screw 30 and the threaded receptacle within the mount as so-called left-handed threads. In this case, the worker can actuate the screwing tool in the clockwise direction as usual because the screw will then be axially moved out of the mount 20 . This has the advantage that the worker must not pay attention whether the device to be mounted is configured according to the invention or according to the prior art. [0031] When the mount 20 is mounted, the slanted surface 24 shown in FIGS. 7 and 9 of the end member 35 of the stabilization member 26 and the slanted counter surface 34 of the support 10 cooperate. In the securing position 30 . 2 , there is not only the tightening action of the stabilization member 26 on the counter surface and of the flange 32 of the actuating end 31 on the support surface 16 but, in addition, a tightening or pulling action will result that is illustrated in FIG. 5 by arrow 19 . In FIG. 5 , the position of the slanted counter surface 34 is indicated in dashed lines. Upon tightening, the slanted surface 24 moves against the stationary slanted counter surface 34 of the support 10 and generates a torque causing the aforementioned pulling action 19 that pulls the mount 20 toward the support 10 and against the outer door panel 38 that is illustrated in FIG. 5 in dash-dotted lines. The screw axis 44 of the screw 30 , illustrated in FIG. 5 by a dashed line, has an angled position 45 relative to the support 10 that extends in this area substantially parallel to the outer door panel 38 (illustrated in FIG. 5 in dash-dotted lines). [0032] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
A device for actuating a lock on a vehicle door has a support mounted on a vehicle door. A lock cylinder mount, or a decoy, is mounted on the support. A screw secures the mount when mounted on the support. The mount has a shoulder engaging a counter shoulder of the support at least partially in the mounting position of the mount. The screw has an actuating end for moving the screw into a release position and a locking position. In the release position, the mount is removable from and mountable on the support. In the locking position, the mount is secured. The mount has a threaded receptacle for the screw so that the screw is part of the mount. The support has a screw support surface against which the actuating end of the screw rests in the locking position of the screw for securing the mount.
8
BACKGROUND OF THE INVENTION 1. The Field of the Art. This invention relates to an apparatus for sterilizing a root canal and more specifically to a root canal sterilization apparatus that uses bactericidal ultra-violet rays to sterilize bacteria in the root canal. 2. Description of the Prior Art. Bacteria in the root canal are important causal agents for apical periodontal inflammation. Therefore, for indodontal treatment, it is essential to remove bacteria from the root canal. Previously, for removal of bacteria from the root canal, the following method has been used. Initially, the root canal is spread with a reamer or the like while being washed. Then, for the purpose of sterilizing the bacteria remaining in the root canal, a cotton plug impregnated with a sterilizing disinfectant, such as form cresol, is inserted into the root canal. Thereafter, washing of the root canal, and replacement of the cotton plug are carried out one or two more times. After this treatment, if no clinical symptom is detected and no abnormal clinical condition is observed inside the root canal, the final treatment of root canal filling is carried out. However, the above-described method takes a relatively long time, one or two weeks, for sterilization, thus making the patient uncomfortable. Furthermore, using this sterilization method, a high probability exists that after the root canal is filled, the inflammation will reoccur. This is because conventional chemical sterilization cannot completely sterilize the bacteria in the root canal and some bacteria still remain. This difficulty may be eliminated by using a more effective germicide or by employing a method in which the root canal filling is carried out with a sterilizing disinfectant. However, these methods are undesirable because of the adverse effect of those chemicals when administered directly on the cells. It is also well known that bactericidal ultraviolet rays (light 200 to 300 nm in wavelength) can sterilize bacteria. Use of the bacteriocidal ultraviolet rays is advantageous in that it will cause no danger of residual medicines. However, the light source for generating such bacteriocidal ultraviolet rays is a bar-shaped lamp with an outside diameter of at least 10 mm and a length of 50 mm. With this size, it is impossible to insert it into the root canal spread (which has an inside diameter of about 1 to 1.5 mm). Also, a light source of this type usually incorporates mercury. Because of the toxicity of mercury, it is undesirable to insert it into the buccal cavity. Therefore, bacteriocidal ultraviolet rays have not been used to sterilize bacteria in the root canal. SUMMARY OF THE INVENTION It is an object of the present invention to provide an apparatus that uses bactericidal ultraviolet rays to sterilize bacteria in the root canal. It is another object of the present invention to provide an apparatus having that can be used for root canals that are located in various positions. It is a further object of the present invention to provide an apparatus that can sterilize root canals and not damage easily. In order to attain the above recited objects of the invention, among others, one embodiment of the present invention contains a light generating means that generates bactericidal ultraviolet rays that is connected to a light guide at one end. The other end of the light guide is coupled to a light emitting means with a hand piece that also allows easily handling of the light emitting means. The emitting means contains an optical fiber over which is disposed a fiber protecting pipe. The fiber protecting pipe can be bent at different angles and functions as a guiding means. At the end perimeter of the emitting means, the optical fiber is connected to a flexible tube that serves as a covering means to protect the optical fiber from being damaged. In another embodiment, the light guide and the emitting means use the same optical fiber and the hand piece then does not serve the coupling function. BRIEF DESCRIPTION OF THE DRAWINGS These and other advantages of the present invention may be appreciated from studying the following detailed description of the preferred embodiment together with the drawings in which: FIG. 1 is a perspective view showing the preferred embodiment of a root canal sterilizing apparatus according to the present invention; FIG. 2 is an enlarged sectional view of a hand piece for the apparatus shown in FIG. 1; FIG. 3 is a graph showing transmittance as a function of wavelength for a light guide in the apparatus shown in FIG. 1; FIG. 4 is a diagram showing sterilization of the root canal with the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 illustrates a root canal sterilizing apparatus according to the preferred embodiment of the invention. Illustrated are a bactericidal ultraviolet ray generating means 1, a light guide 2, a hand piece 3, and a light emitting means 4. The ultraviolet ray generating means 1 includes an ultraviolet ray generating section made up of a point light source that emits light in a wavelength range of from 200 to 300 nm to light guide 2 with high efficiency using a reflecting condenser mirror and a condenser lens in combination. The point light source may be a high pressure mercury lamp, a mercury xenon lamp, an extra-high pressure mercury lamp, a microwave discharge lamp an excimer laser emitting a light beam of, for instance, 249 nm in wavelength, or other means for producing light of this wavelength. The intensity and wavelength of the emitted light is controlled by a separate control section disposed within ultraviolet ray generating means I. FIG. 1 also illustrates power switch 22, which turns the whole apparatus on or off. Light guide 2 is an optical fiber that gives needed flexibility. As shown in FIG. 2, light guide 2 is inserted into a flexible metal tube 9 to prevent damage from excessively large external pressure. In order to minimize less of the bactericidal ultraviolet ray as they pass through light guide 2, a pure quartz core fiber (such as a series of large diameter fibers MS manufactured by Sumitomo Denki Kogyo Co., Ltd.) should be used. FIG. 3 is a graph showing the transmittance as a function of wavelength per meter of a pure quartz core fiber and a general germanium doped quartz core fiber in which the horizontal axis represents wavelength and the vertical axis transmittance. The pure quartz core fiber's characteristics are indicated by the solid line, and the germanium doped quartz core fiber's characteristics by the broke line. As apparent from FIG. 3, with respect to the light 0.2 to 0.3 μm in wavelength, which is in the range of wavelengths of bactericidal ultraviolet rays, loss is much smaller with the pure quartz core fiber than the germanium doped quartz core fiber. As shown in FIG. 1, the hand piece 3 is connected to one end of light guide 2, and contains a light emitting means 4 at its opposite end. The operator holds the hand piece 3 to control the areas of the root canal needing sterilization, an operation that will be described in detail later. FIG. 2 illustrates hand piece 3 and light emitting means 4 in one embodiment in which hand piece 3 acts as a coupling means between light guide 2 and light emitting means 4. Light emitting means 4 is detachably connected to the hand piece body 12 and includes an optical fiber 11 having a pure quartz core that is covered with a stainless steel fiber protecting pipe 18 that serves as a guiding means. Holder 14 slidably holds light emitting means 4 to hand piece body 12. The front end portion of the fiber protecting pipe 18 is bent at about 45°, and optical fiber 11 bends at a similar angle. The bending angle of θ of fiber protecting pipe 18 should be set to a value for easier insertion into a tooth to be sterilized. This will depend on the position of the tooth. In general, the bending angle is set to 0° for upper jaw anterior teeth and is set to about 45° when used for other teeth. If a plurality of light emitting means 4, different in the bending angle θ, are prepared and selectively used, depending on the teeth to be sterilized, the root canal sterilizing apparatus can be more effectively utilized. The front end portion of optical fiber 11 protrudes about 20 mm from fiber protecting pipe 18, but is covered with a metal or plastic tube 19 that serves as a covering means, which is flexible to some extent, so that optical fiber 11 is not damaged during use. The outside diameter of tube 19 is 1 mm or less. The configuration of the front end portion of the light emitting means 4 is based on the fact that, in general, the root canal spread has an inside diameter of 1 to 1.5 mm and a depth of less than 20 mm. Fiber sleeves 16 holds the rear end of the optical fiber 11 and is connected to the rear end of fiber protecting pipe 18 so that the rear end face of fiber sleeve 16 is flush with a rear end face of a fiber sleeve 13 that holds an end optical fiber 11. A compression spring 20 is interposed between fiber sleeve 16 and holder 14 to hold fiber sleeve 16 flush with fiber sleeve 13. Therefore, when light emitting means 4 is engaged with hand piece body 12 as shown in FIG. 2, the rear end face of optical fiber 11 firmly abuts a front end face of the optical fiber of light guide 2. Light emitting means 4 and hand piece body 12 are joined together with a C-ring 15 on holder 14, which is fitted in a groove formed in the inner wall of hand piece body 12. When holder 14, engaged with hand piece body 12 as shown in FIG. 2, is pulled in the direction of the arrow A, C-ring 15 is flexed, thus disengaging from the groove formed in the inner wall of the hand piece body 12. As a result, light emitting means 4 disengages from the hand piece body 12. Fiber sleeve 16 and fiber protecting pipe 18 secured to the fiber sleeve 16 are pushed inward as one unit by the elastic force of the compression spring 20 during disengagement until a stopper 17, fixedly mounted on fiber protecting pipe 18, strikes against the bottom of a recess formed in the holder 14. It is also possible to make optical fiber 11 and the optical fiber of light guide 2 from a single optical fiber. The advantage of this construction is that losses will be further reduced. In this case, hand piece 3 does not serve the coupling function of optical fibers in light guide 2 and light emitting means 4. However, the insertion of light emitting means 4 having a separate optical fiber and having different angled fiber protecting pipes 18 that can be attached to hand piece 3 is then more difficult. FIG. 2 also illustrates that hand piece body 12 is provided with a switch 5 for turning on and off bactericidal ultraviolet ray generating means 1. Switch 5 is connected through an electrical signal wire 8 to the control section of bactericidal ultraviolet ray generating means 1. A timer circuit is built in the control section so that when switch 5 is operated ultraviolet rays are produced for a period of time preset by radiation time setting knob 21, located on bactericidal ultraviolet ray generating means 1 as shown in FIG. 1. The ultraviolet rays thus produced travel through light guide 2, hand piece 3, and emerge from the end of light emitting means 4. Hand piece body 12 also contains an indication lamp 6, which turns rays. Therefore, after turning on switches, with the end of the light emitting means 4 already set at a desired position in the root canal, the operator can confirm the end of the radiation period because indication lamp 6 will turn off. When the switch 5 is turned off, even during a radiation period radiation is suspended although the timer circuit is in operation. FIG. 4 is a sectional view showing the end portion of light emitting means 4 inserted into root canal 23, which has been spread. The bactericidal ultraviolet rays emerging from the end of light emitting means 4 are applied deep in root canal 23, thus sterilizing the inside of the root canal. The following experiment performed by the inventors illustrates the utility of the above described invention. A 2 m pure quartz core fiber, 0.4 mm in core diameter (the large diameter fiber MS-04 manufactured by Sumitomo Denki Kogyo Co. Ltd.) was used as light guide 2 and optical fiber 11. One end portion, 20 mm in length, of the pure quartz core fiber was inserted into a flexible stainless steel tube having an outside diameter of 0.7 mm and about a 0.1 mm wall thickness, to form lite emitting means 4. The other end of the light emitting means 4 was coupled to a bactericidal ultraviolet ray generating light source, which was a 100 W mercury xenon lamp with a reflecting condenser mirror. In order to determine whether flexible tube 19 could be smoothly inserted into the root canal, it was inserted into a model of the spread root canal. As a result, it was found that the flexible tube 19 could be inserted smoothly into the model, even if it was a curved root canal because the reinforcing stainless steel tube had a small wall thickness and was flexible. To detect sterilization efficiency, the intensity of the emergent light was measured. In the measurement, the intensity of light 200 to 300 nm in wavelength was measured. The intensity of bactericidal ultraviolet rays emerging from the end of the light-emergent member was 20 mW/cm 2 at 5 mm from the light-emergent end. Bacteria sterilized in root canals are generally concatenate cacci and botryoid cacci, and sterilization of these bacteria require radiation with bactericidal ultraviolet rays of about 10 m W sec/cm 2 . Therefore, the obtained intensity was sufficient for sterilization in a short time. To confirm this, 0.1 m of botryoid cacci, which had 10 7 /m living bacteria was placed 5 mm from the end of the light guide, and the bactericidal ultraviolet rays was applied. All the botryoid cacci were sterilized in about sixty seconds. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is understood that the invention is not limited to the disclosed embodiment, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
An apparatus and method for sterilizing a root canal in which the apparatus contains an light source for generating bactericidal ultraviolet rays and an optical fiber coupled to the light source for transmitting the ultraviolet rays to and emitting the rays from an emitting end of the optical fiber placed in the root canal. Also included in a fiber protecting pipe that both protects the fiber and allows the fiber to be easily guided into the root canal. A flexible tube disposed over the emitting end of the root canal protects the exposed end of the optical fiber. Also, an arrangement of two optical fibers allows various shaped fiber protecting pipes to be used and a hand held coupling device couples two optical fibers.
0
This application is a continuation of application Ser. No. 07/909,045 filed Jul. 6, 1992, now abandoned. BACKGROUND 1. The Field of the Invention The present invention relates to mandrels used for fabricating hollow continuous filament wound vessels and tanks and methods of constructing such mandrels. 2. The Prior Art Methods of constructing filament wound vessels, tanks, and containers are well known in the prior art. Typically, a rigid mandrel made of aluminum, fiberglass, or other high strength and relatively lightweight material, or the like is prepared and mounted on a filament winding machine so that the mandrel may be selectively rotated. The surface of the mandrel is coated with an appropriate mold release preparation and then wound with resin impregnated or coated filaments, such as glass, KEVLAR®, graphite, nylon or boron fibers. Commonly, the winding progresses from end to end for an elongated shape or from side to side for a more spherical shape. When the desired thickness of the winding layers is achieved, the winding is stopped and the resin is cured. In many cases, the resulting filament wound vessel is removed from the mandrel by cutting the vessel about its circumference, generally at a location near the center thereof. The two halves of the vessel are then removed from the mandrel and the halves joined and bonded together to form the desired vessel or tank. A short helical wind of a resin coated filament strand or roving may be made over the joint of the vessel in an attempt to further secure the two halves together. Examples of prior art winding techniques and methods are disclosed in U.S. Pat. Nos. 3,386,872, 3,412,891, 3,697,352, 3,692,601, 3,533,869, 3,502,529 and 3,414,449. Because of the joint in the completed vessel, an inherent weakness exists which may be the first to fail or fracture when the completed vessel is subjected to pressure or stress. Because of the weakness in the resulting vessel and the added labor costs associated with cutting the vessel and rejoining the two halves of the vessel, techniques have been developed which allow the fabrication of hollow vessels without the need to cut the vessel to remove it from the mandrel. In some cases, for example, a hollow mandrel is designed to become an integral part of the completed fiber wound vessel. Disadvantageously, the intended use of the completed fiber wound vessel is often not compatible with retaining the mandrel as the interior of the vessel. Another technique involves using a mandrel which is destroyed once the vessel is formed. It will be appreciated that if a large number of a particular configuration of fiber wound vessel are to be fabricated, destroying the mandrel with each use is an exorbitantly expensive technique. Thus, reusable mandrels have been developed. In some cases, segmented metal mandrels, which can be disassembled into small sections and then removed through an opening in the completed vessel, have been used. Disadvantageously, building a reusable metal mandrel is costly and time consuming. The difficulty of building a reusable segmented metal mandrel makes it too expensive for all but the most demanding applications of high volume vessel fabrication. Another type of mandrel which has been used to produce seamless completed fiber wound vessels is a collapsible mandrel. Collapsible mandrels are hollow mandrels made of flexible, air tight materials such as a rubber which can be inflated while the vessel is being formed thereon and then deflated and removed through an opening in the completed vessel. One collapsible mandrel which can be removed through an opening in a completed vessel is disclosed in U.S. Pat. No. 4,684,423 to Brooks. While the method of forming the mandrel and, the resulting mandrel structure, which are disclosed in the Brooks reference represented a great advance in the art, several disadvantages still remain. The Brooks reference requires that the resulting mandrel be cut in half to remove it from a rigid mandrel. Cutting and splicing the mandrel structure results in an inherently weaker and less desirable mandrel. Since the area at the resulting joint is weaker than the remaining structure, the joint often fails sooner than the other portions of the structure. Thus, the usable life of the mandrel is often unduly limited because of the presence of the joint. Further drawbacks and disadvantages inherent in the structure and method disclosed in the Brooks reference include the additional labor which is required to cut and rejoin the mandrel. Moreover, since the outside surface of the mandrel determines the shape and uniformity of the interior surface of the completed fiber wound structure, a poorly formed seam in the collapsible mandrel can result in an inconsistent surface in the completed fiber wound hollow structure. Even though the use of collapsible mandrels to form seamless completed structures is known, for example as in the Brooks reference, the problems inherent in a mandrel which has been cut and spliced together has not been addressed in the art. In view of the forgoing, it would be an advance in the art to provide a seamless, collapsible, and reusable mandrel structure and an accompanying method of forming the same. BRIEF SUMMARY AND OBJECTS OF THE INVENTION In view of the above described state of the art, the present invention seeks to realize the following objects and advantages. It is a primary object of the present invention to provide a collapsible mandrel which is suitable for use in the fabrication of filament wound vessels and which is seamless, as well as, an accompanying method of making the same. It is also an object of the present invention to produce an improved collapsible mandrel which is suitable for use in the fabrication of filament wound vessels which maintains its proper shape as the vessel is fabricated upon it, as well as, an accompanying method of making the same. It is also an object of the present invention to provide an improved collapsible and reusable mandrel upon which high quality filament wound vessels can be consistently produced. It is another object of the present invention to provide a collapsible and reusable mandrel which has a long useful life and which can be fabricated at a relatively low cost. These and other objects and advantages of the invention will become more fully apparent from the description and claims which follow, or may be learned by the practice of the invention. The present invention provides a method for fabricating, and a resulting structure for, a seamless, reusable and collapsible mandrel suitable for forming a plurality of seamless and hollow fiber wound vessels upon. The method of fabricating the seamless reusable mandrel includes readying a destructible mandrel upon which the seamless reusable mandrel is formed. The destructible mandrel is the general shape of the seamless mandrel and is preferably formed from a material which can be destroyed by dissolving the material, for example, materials such as foam or plaster. The structure of the seamless, collapsible, and reusable mandrel of the present invention includes a plurality of different layers, each layer having a particular function. Different embodiments of the present invention require different numbers of layers in the seamless, collapsible, and reusable mandrel. Exemplary of the layers which are laid upon the destructible mandrel to fabricate the seamless, collapsible, and reusable mandrel of the present invention include: a first layer of generally fluid impermeable material; a second layer of continuous fibers wound about the destructible mandrel; and a layer which functions as a release surface forming the outermost layer of the seamless, collapsible, and reusable mandrel of the present invention. The release surface is formed in the shape of the interior of the completed seamless and hollow fiber wound vessel which will be formed on the seamless, collapsible, and reusable mandrel. The outer surface of the seamless, collapsible, and reusable mandrel is preferably machined so that it exactly matches the desired shape of the interior of a completed fiber wound hollow vessel to be formed thereon. The destructible mandrel is removed from the interior of the seamless, reusable and collapsible mandrel preferably by dissolving the material from which the destructible mandrel is formed. Thus, the integrity of the seamless, collapsible, and reusable mandrel is not disturbed by a seam. Previously available mandrels, which needed to be cut in half and spliced back together to remove them from the rigid mandrel upon which they were formed, are inherently weaker and less desirable than the seamless mandrels produced by the present invention. The seamless, reusable and collapsible mandrel of the present invention includes at least means for conducting a gas under pressure to the interior of the mandrel and a fluid impermeable layer capable of retaining a gas within the interior of the mandrel. Also included is a fiber reinforcement layer capable of limiting the expansion of the mandrel when pressurized gas is introduced therein such that as the pressure inside the mandrel is increased and the material forming the vessel is added to the outer surface of the reusable and collapsible mandrel, the mandrel maintains its desired shape. The fiber reinforcement layer is formed using continuous fiber winding techniques. Also included is an outer release surface. The outer release surface receives the materials of the seamless and fiber wound hollow vessel formed thereon. The seamless, reusable and collapsible mandrel of the present invention can be reused many times and consistently produces high quality fiber wound vessels at a relatively low cost. BRIEF DESCRIPTION OF THE DRAWINGS In order to better appreciate how the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to a specific embodiment thereof which is illustrated in the appended drawings. Understanding that these drawings depict only a typical embodiment of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: FIG. 1 is a partially cut away perspective view of the presently preferred embodiment of the completed seamless, collapsible, and reusable mandrel of the present invention. FIG. 2 is a cross sectional view of the mandrel of the present invention as it appears when mounted on a winding machine shaft ready to receive the filament windings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made to the drawings wherein like structures will be provided with like reference designations. It will be appreciated that as the number and kinds of applications for filament wound hollow vessels increases, the demand for easily fabricated, precision mandrels has also increased. The present invention provides the benefits of low cost which accompany the use of seamed inflatable mandrels as well as the added benefits of precision and long life which, prior to the present invention, only accompanied the use of segmented metal mandrels. Reference will now be made to the presently preferred seamless, collapsible, and reusable mandrel generally represented at 100 shown in a partially cut away perspective view in FIG. 1. The seamless, collapsible, and reusable mandrel 100 represented in FIG. 1 is fabricated using known materials and techniques in conjunction with inventive teachings set forth herein. Those skilled in the pertinent arts will readily recognize the materials and techniques described herein are also of the general type and class referred to in U.S. Pat. No. 4,684,423 to Brooks which is now incorporated herein by reference. FIG. 1 represents the various structural layers of the seamless, collapsible, and reusable mandrel 100 of the present invention. While the mandrel 100 illustrated in FIG. 1 is of a cylindrical shape, the mandrels of the present invention can be fabricated into any number of shapes needed to form hollow vessels. The steps set forth below are presently preferred for fabricating the seamless, collapsible, and reusable mandrel 100 illustrated in FIG. 1. A non-reusable mandrel 90 is first fabricated, on a shaft 92, upon which the seamless, collapsible, and reusable mandrel 100 will be fabricated. The non-reusable mandrel 90 is only partially represented in phantom image in FIG. 1 to show its relationship to the seamless, collapsible, and reusable mandrel 100. The shape of the non-reusable mandrel will determine the shape of the seamless, collapsible, and reusable mandrel 100. Utilization of a non-reusable mandrel is essential to the present invention in order to fabricate the resulting reusable collapsible mandrel 100 as a seamless mandrel. Such a non-reusable mandrel must be destroyed during use in order to remove the resulting seamless mandrel. Thus, such a mandrel is also referred to herein as a destructible mandrel. The non-reusable mandrel 90 can be formed from many different materials and procedures; those skilled in the art will realize that the herein described materials and procedures are merely preferred and that other materials and procedures can also be used. The important criteria is that the resulting mandrel 90 must be readily destructible in order to remove it from the small polar opening, 112 in FIG. 1, which remains in the seamless, collapsible, and reusable mandrel 100. To form the mandrel 90, it is preferred that a foam block be set up on a shaft 92 and formed using a turning mechanism. The foam block should be formed to slightly smaller than a shape which conforms to the finished shape of the non-reusable mandrel 90. A screeding template is formed which conforms exactly to the finished shape and size of the non-reusable master mandrel 90. The screeding template is set to the proper orientation on the turning mechanism. A mixture consisting of 80% plaster and 20% milled glass fibers (1/32 inch to 1/4 inch) is prepared. The plaster is preferably one which is readily dissolved or destroyed such as that available under the trademark EASY OUT. While the foam block is rotated on the shaft turning mechanism, glass cloth strips (7500 style or equivalent) and plaster is laid on the foam block. After a first layer of glass cloth strips and plaster has dried, a further layer(s) of glass cloth strips and plaster is added until the surface is about 1/4 inch from the surface of the screed. After the previous layers of cloth and plaster have hardened a final layer of only plaster is added using the screeding template to form the surface to the exact shape and size desired. The non-reusable mandrel 90 is then allowed to dry for 24 hours. After the non-reusable mandrel 90 is dried, it is preferably cured at 300° F. to 600° F. for two hours for each inch thickness of plaster mixture added to the surface of the foam block. Upon completion of the cure time, the non-reusable mandrel 90 should be cooled at a rate not exceeding 5° F. per minute. The non-reusable mandrel 90 should then be inspected and any rough areas smoothed with a fine grit sand paper as required. The surface of the non-reusable mandrel 90 is then sealing with any appropriate resin, tape, or soluble liquid sealant which will provide a suitable release surface for the non-reusable mandrel 90. The completed non-reusable mandrel 90 is mounted on a 3-axis winding machine having a fiber delivery system as is known in the art. With the surface of the non-reusable master mandrel prepared with a release material, an inner rubber layer 102 of uncured rubber is applied using methyl-ethylketone (MEK) sparingly as a tackifier. The sheet of rubber should be trimmed so that the sheets overlap by at least 1/8 inch. The rubber sheets will need to be trimmed so that the rubber lies evenly on the contours of the non-reusable master mandrel. A dispersion solution is prepared and used next. The dispersion solution preferably comprises small bits of nitrile sheet which have been soaked in MEK for at least 1 hour with mixing until the bits are well dissolved and the solution is the consistency of paint. This dispersion solution will be used for encapsulating the Kevlar fiber during winding. The dispersion solution should be agitated and thinned with MEK as needed to avoid clumping. The winding machine should be programmed to the required specifications as is known in the art. As is known in the art, the lowest angle helical is normally wound first to create helical fiber plies as represented at fiber wound layer 104 in FIG. 1. The resulting fiber band should be in a "space wind" configuration with a minimum of 1/8" spacing between tows. After the first helical winding is completed, the nitrile/MEK solution should be allowed to outgas at room temperature for at least 20 minutes. The winding machine can be used to apply winding angles in addition to the first helical winding to further complete the helical fiber plies comprising the fiber reinforced layer 104. Care should be exercised to avoid bridging the rubber layers between the fibers in order to achieve a strong rubber-to-rubber bond. In the case of small, seamless, collapsible, and reusable mandrels, both a hoop and helical ply may be needed together at this point for the helical fiber plies 104 to have the desired characteristics. Next, if desired, the winding machine can be programmed to wind another helical layer. After the helical plies have been completed to form the fiber reinforced layer 104, a first middle rubber layer 106 of uncured rubber is applied in a manner the same as or similar to that described for the inner rubber layer 102. As indicated earlier, the rubber sheets should be trimmed so that the sheets overlap so that the rubber lies evenly on the contours of the non-reusable mandrel 90. The winding machine should next be programmed to the hoop winding program to form another fiber reinforced layer 108, this time using a hoop fiber ply as represented in FIG. 1 and as indicated earlier. The hoop fiber ply, forming another fiber reinforced layer 108 is wound from tangent to tangent and, upon completion, the nitrile/MEK solution should again be allowed to outgas at room temperature for at least 20 minutes. Next, a second middle layer of rubber 114 is laid on as described earlier followed by the winding machine being programmed and executing a high angle helical wind forming a second fiber reinforced layer 116. Following the completion of the winding, the structure is outgassing at room temperature for at least 20 minutes. If desired, additional fiber reinforced layers (e.g., hoop or tangent windings) and rubber layers can be added to the mandrel 100 of the present invention followed by the outgassing steps. Next, the outer rubber layer 110 is applied as indicated in the earlier described steps. If desired, extra sheets of rubber can be applied to the outer rubber layer 110 to serve as a sacrificial machining layer. The surface of the outer rubber layer 110 will function as a release surface in the shape of the interior of the completed fiber wound hollow vessel. If needed, material such as glass cloth strips (7500 style or equivalent) can be used to reinforce the outer rubber layer 110 as required to achieve added strength and/or rigidity. The entire seamless, collapsible, and reusable mandrel is next wrapped in perforated TEDLAR® release film. The seamless, collapsible, and reusable mandrel is then preferably enveloped in a nylon vacuum bag equipped with an N-10 breather as is known in the art. Importantly, it should be assured that the interior of the seamless, collapsible, and reusable mandrel is evacuated. The greatest vacuum available should be applied to the seamless, collapsible, and reusable mandrel at room temperature for best results. Checks should be made to detect any leaks. Next, the bagged seamless, collapsible, and reusable mandrel is cured at 350° F. for 2 hours (minimum) or cured in accordance with the rubber manufacturer's recommendations. A lower temperature hold is permissible, if desired. Preferably, an autoclave (capable of pressures of at least 30 p.s.i.g.) should be used but internal pressure or thermal compaction techniques, as known in the art, may also be employed. After the cure time is complete, the seamless, collapsible, and reusable mandrel is allowed to cool down slowly and the bagging material is removed. After the bagging material is removed, the seamless, collapsible, and reusable mandrel should be trimmed in the appropriate areas. The non-reusable mandrel 90 should then be removed. Preferably, the non-reusable mandrel 90 is removed by destroying it and removing the resulting slurry and/or pieces through the small polar opening 112. An ultrasonic knife or very sharp trimming tools should be used to cut Kevlar. After the seamless, collapsible, and reusable mandrel 100 is free from the non-reusable mandrel 90 and finished, it should be mounted onto a winding shaft with all of its associated hardware (see FIG. 2) to verify that the seamless, collapsible, and reusable mandrel 100 is concentric to the shaft with very little runout (preferably less than 0.020 inch). A leak check at 2 p.s.i. minimum should also be performed. The outside of the seamless, collapsible, and reusable mandrel should be machined as necessary to contour the outer rubber surface. In preparation for fabricating a fiber wound filament vessel on the seamless, collapsible, and reusable mandrel, a 1-2 mil thick FEP release layer (as known in the art) can be sprayed onto the outer rubber layer 110, if required. Further inspection of the mandrel 100 using templates, tape, and dial indicators should be performed to ensure consistent quality. FIG. 2 is a diagrammatic cross sectional view of the seamless, collapsible, and reusable mandrel 100 mounted on a hollow winding shaft S commonly found in a winding machine (not shown) as known in the art. The winding shaft includes a passageway A which conducts a gas under pressure to the interior of the seamless, collapsible, and reusable mandrel 100. The seamless, collapsible, and reusable mandrel 100 is held in place on the winding shaft S by a polar boss 118, which will become part of the completed fiber wound hollow vessel (not shown), and various pieces of hardware 120 which retain the polar boss 118 and grasp the winding shaft S. Such structures can be those which are known in the art. With the seamless, collapsible, and reusable mandrel 100 mounted on the winding shaft S, the fiber wound hollow vessel is formed thereon. As more material is added to the mandrel 100, the pressure within the seamless, collapsible, and reusable mandrel 100 is adjusted to maintain the proper shape of the mandrel 100. When the fiber wound hollow vessel (not represented) is completed, the mandrel 100 is deflated and the hardware 120 removed, and the mandrel 100 removed through the end opening of the completed fiber wound hollow vessel (not shown). Since the mandrel 100 is seamless, it is inherently stronger than a corresponding mandrel which was cut and spliced while being formed. Thus, the mandrel 100 is reusable many times more than similar mandrels having a seam. Moreover, the represented seamless mandrel 100 is capable of producing more uniform completed fiber wound hollow vessels. It will be appreciated that the present invention provides a collapsible mandrel which is suitable for use in the fabrication of various filament wound hollow vessels and which is seamless. The present invention also produces an inflatable mandrel which maintains its proper shape as a hollow vessel is fabricated upon it as well as being reusable to consistently fabricate high quality filament wound hollow vessels and which is relatively low cost. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
A method for fabricating, and a resulting structure for, a seamless, reusable and collapsible mandrel suitable for forming a plurality of seamless and hollow fiber wound vessels upon is disclosed. A destructible mandrel is used to form the seamless reusable mandrel. The destructible mandrel is preferably formed from a material which can be destroyed by dissolving, for example, materials such as foam or plaster. The seamless, collapsible, and reusable mandrel includes a plurality of different layers including a gas impermeable layer, a continuous fiber wound layer, and a release surface forming the outermost layer of the seamless, collapsible, and reusable mandrel. The resulting seamless, reusable and collapsible mandrel has advantages over mandrels which include a seam. Such advantages include a longer useful life and consistently high quality fiber wound vessels at a relatively low cost.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to the field of is the well-known with digital audio encoding is the well-known Compact Disc system. Progress in storage technology and audio encoding technology allows increasing amount of audio information on a unitary medium such as conforming to the standard CD dimensions. A particular feature is variable-rate encoding, which requires an easy accessible indicator organization for subsequent read-accessing of the string of Audio Units. The above citations are hereby incorporated herein in whole by reference, those skilled in the art are directed to the following references: 2. List of Related Documents (D1) Research Disclosure number 36411. August 1994, page 412-413 (D2) PCT/IB97/01156 (PHN 16.452) 1 bit ADC and lossless compression of audio (D3) PCT/IB97/01303 (PHN 16.405) Audio compressor (D4) EP-A 402,973 (PHN 13.241) Audio compression (D5) ‘A digital decimating filter for analog-to-digital conversion of hi-fi audio signals’, by J. J. van der Kam in Philips Techn. Rev. 42, no. 6/7, April 1986, pp. 230-8 (D6) ‘A higher order topology for interpolative modulators for oversampling A/D converters’, by Kirk C. H. Chao et al in IEEE Trans. on Circuits and Systems, Vol 37, no. 3, March 1990, pp. 309-18. SUMMARY OF THE INVENTION It is an object of the present invention to allow a reader device to straightforwardly recover all information pertaining to an Audio Unit that may have been dispersed over various storage blocks or sectors. The invention also relates to a unitary storage medium produced by practising such method, and to a reader device for reading a unitary storage medium so produced. BRIEF DESCRIPTION OF THE DRAWING These and further aspects and advantages of the invention will be discussed more in detail hereinafter with reference to the disclosure of preferred embodiments, and in particular with reference to the appended Figures that show: FIGS. 1 a , 1 b a record carrier, FIG. 2 a playback device, FIG. 3 a recording device, FIG. 4, a layout of a linear physical storage space; FIG. 5, a storage format according to the invention; FIG. 6, a syntax of an audio stream; FIG. 7, a header format; FIG. 8, a data_type specification list; FIG. 9, an audio block header syntax; FIG. 10, a packet information syntax; FIG. 11, another data type definition. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 a shows a disc-shaped record carrier 11 with track 19 and central hole 10 . Track 19 is arranged in a spiral pattern of turns forming substantially parallel tracks on an information layer. The carrier may be an optical disc with a recordable or a prerecorded information layer. Examples of a recordable disc are CD-R, CD-RW, and DVD-RAM, whereas audio CD is a prerecorded disc. Prerecorded discs can be manufactured by first recording a master disc and subsequently pressing consumer discs. Track 19 on the recordable record carrier is indicated by a providing a pre-embossed track structure during manufacture of the blank record carrier. The track may be configured as a pregroove 14 to enable a read/write head to follow the track 19 during scanning. The information is recorded on the information layer by optically detectable marks along the track, e.g. pits and lands. FIG. 1 b is a cross-section along the line b—b of a recordable record carrier 11 , wherein transparent substrate 15 carries recording layer 16 and protective layer 17 . The pregroove 14 may be implemented as an indentation, an elevation, or as a material property deviating from its surroundings. For user convenience the audio information on the record carrier has been subdivided into items, which usually have a duration of a few minutes e.g. songs on an album or movements of a symphony. Usually the record carrier also contains access information for identifying the items, such as in a so-called Table Of Contents (TOC), or included in a file system like ISO 9660 for CD-ROM. The access information may include playing time and start address for each item, and also further information like a song title. The audio information is recorded in digital representation after analog to digital (A/D) conversion. Examples of A/D conversion are PCM 16-bit per sample at 44.1 kHz known from CD audio and 1 bit Sigma Delta modulation at a high oversampling rate e.g. 64×Fs called bitstream. The latter method represents a high quality encoding method, with the choice between high quality decoding and low quality decoding, the latter allowing a simpler decoding circuit. Reference is made in this respect to the publications ‘A digital decimating filter for analog-to-digital conversion of hi-fi audio signals’, by J. J. van der Kam, document D5 infra, and ‘A higher order topology for interpolative modulators for oversampling A/D converters’, by Kirk C. H. Chao et al, document D6. After A/D conversion, digital audio is compressed to variable bitrate audio data for recording on the information layer. The compressed audio data is read from the record carrier at such a speed, that after decompression substantially the original timescale will be restored when reproducing the audio information continuously. Hence the compressed data must be retrieved from the record carrier at a speed dependening on the varying bitrate. The data is retrieved from the record carrier at so-called transfer speed, i.e. the speed of transferring data bytes from the record carrier to a de-compressor. The record carrier may have uniform spatial data density, which gives the highest data storage capacity per unit of area. In such system the transfer speed is proportional to the relative linear speed between the medium and the read/write head. If a buffer is provided before the de-compressor, the actual transfer speed is the speed before that buffer. FIG. 2 shows a playback apparatus according to the invention for reading a record carrier 11 of the type shown in FIG. 1 . The device has drive means 21 for rotating record carrier 11 and a read head 22 for scanning the record carrier track. Positioning means effect 25 coarse radial positioning of read head 22 . The read head comprises a known optical system with a radiation source for generating a beam 24 that is guided through optical elements and focused to spot 23 on an information layer track. The read head further comprises a focusing actuator for moving the focus of the radiation 24 along the optical axis of the beam and a tracking actuator for fine positioning of spot 23 in a radial direction on the centre of the track. The tracking actuator may comprise coils for moving an optical element or may be arranged for changing the angle of a reflecting element. The radiation reflected by the information layer is detected by a known detector in the read head 22 , e.g. a four-quadrant diode, to generate a read signal and further detector signals including a tracking error and focusing error signals for the tracking and focusing actuators, respectively. The read signal is processed by a reading means 27 to retrieve the data, which reading means are of a usual type for example comprising a channel decoder and an error corrector. The retrieved data is passed to a data selection means 28 , to select the compressed audio data for passing on to buffer 29 . The selection is based on data type indicators also recorded on the record carrier, e.g. headers in a framed format. From buffer 29 , the compressed audio data are passed on to de-compressor 31 as signal 30 . This signal may also be outputted to an external de-compressor. De-compressor 31 decodes the compressed audio data to reproduce the original audio information on output 32 . The de-compressor may be fitted separately, e.g. in a stand-alone high quality audio digital to analog convertor (D/A convertor), as indicated by dashed rectangle 33 in FIG. 2 . Alternatively, the buffer may be positioned before the data selections means. The buffer 29 may be positioned in a separate housing or may be combined with a buffer in the decompressor. The device furthermore has a control unit 20 for receiving control commands from a user or from a host computer not shown, that via control lines 26 such as a system bus is connected to drive means 21 , positioning means 25 , reading means 27 and data selection means 28 , and possibly also to buffer 29 for buffer filling level control. To this end, the control unit 20 may comprise control circuitry, such as a microprocessor, a program memory and control gates, for performing the procedures described below. Control unit 20 may be implemented as a logic circuit state machine. Audio compression and de-compression of a suitable type are known. Audio may be compressed after digitizing by analyzing the correlation in the signal, and producing parameters for fragments of a specified size. During de-compression the inverse process is used to reconstruct the original signal. If the original digitized signal is reconstructed exactly, the (de-)compression is called lossless, whereas lossy (de)-compression will not reproduce certain details of the original signal which however are substantially undetectable by the human ear or eye. Most known systems for audio and video, such as DCC or MPEG, use lossy compression, whereas lossless compression is used for storing computer data. Examples of audio compression and decompression can be found in D2, D3 and D4 hereinafter, of which in particular the lossless compression from D2 is suitable for high quality audio. The data selection means 28 are arranged to discard any stuffing data, that had been added during recording. When the control unit 20 is commanded to reproduce an item of audio from the record carrier, the positioning means 25 are controlled to position the reading head on the portion of the track containing the TOC. The starting address for that item will then be retrieved from the TOC via the data selection means 28 . Alternatively the contents of the TOC may be read only once and stored in a memory when the disc is inserted in the apparatus. For reproducing the item, the drive means 21 are controlled to rotate the record carrier at the appropriate speed. The required rotation rate may be denoted as such for setting the drive means. Alternatively, the rotation rate may be ajdusted through time codes that are stored together with the audio data to indicate the associated replay duration. To provide continuous reproduction without buffer underflow or overflow the transfer speed is coupled to the reproduction speed of the D/A converter, i.e. to the bitrate after decompression. To this end the apparatus may comprise a reference frequency source for controlling the decompressor and the rotation rate may be set in dependence on the reference frequency and the speed profile. Alternatively or additionally the rotation rate may be adjusted using the average filling level of the buffer 29 , e.g. by decreasing the rotation rate when the buffer is more than 50% full on average. FIG. 3 shows a recording device for writing information according to the invention on a record carrier 11 of a type which is (re)writable. During a writing operation, marks representing the information are formed on the record carrier. The marks may be in any optically readable form, e.g. in the form of areas whose reflection coefficient differs from their surroundings, through recording in materials such as dye, alloy or phase change, or in the form of areas with a direction of magnetization different from their surroundings when recording in magneto-optical material. Writing and reading of information for recording on optical disks and usable rules for formatting, error correcting and channel coding, are well-known, e.g. from the CD system. Marks may be formed through a spot 23 generated on the recording layer via a beam 24 of electromagnetic radiation, usually from a laser diode. The recording device comprises similar basic elements as described with reference to FIG. 2, i.e. a control unit 20 , drive means 21 and positioning means 25 , but it has a distinctive write head 39 . Audio information is presented on the input of compression means 35 , which may be placed in a separate housing. Suitable compression has been described in D2, D3 and D4. The variable bitrate compressed audio on the output of the compression means 35 is passed to buffer 36 . From buffer 36 the data is passed to data combination means 37 for adding stuffing data and further control data. The total data stream is passed to writing means 38 for recording. Write head 39 is coupled to the writing means 38 , which comprise for example a formatter, an error encoder and a channel encoder. The data presented to the input of writing means 38 is distributed over logical and physical sectors according to formatting and encoding rules and converted into a write signal for the write head 39 . Unit 20 is arranged for controlling buffer 36 , data combination means 37 and writing means 38 via control lines 26 and for performing the positioning procedure as described above for the reading apparatus. Alternatively the recording apparatus may be arranged for reading having the features of the playback apparatus and a combined write/read head. FIG. 4 is a layout of a linear physical storage space. Upper trace 50 shows the distribution of the audio stream into so-called Audio Units. For the Audio Units, analog audio may be sampled to produce one-bit signals at a multiple of 44.1 kHz, which is the standard sampling frequency of Compact disc. When the multiplicity is 64-fold, stereo quality requires a data rate of about 5.6 Mbits/second. A tighter format is attained through loss-less audio coding to increase storage density by a factor of about 2, but as shown in FIG. 1, this will produce Audio Units N−1 to N+2 that can have mutually non-uniform sizes. On the other hand, storage on a unitary medium such as disc or tape, or transmission via a physical transmission medium is preferably organized in compartments that have mutually uniform dimensions, which has been indicated by blocks or sectors M−1 to M+4 on line 54 . For enabling fast access to the blocks, each block has a header h, which during reading will obviate the need to parse the audio stream. Various blocks, such as blocks M and M+1 accommodate an audio packet from only a single Audio Unit, such as in this case Audio Unit N. However, maximum storage density is attained as shown through joining various audio packets into a single storage block, such as joining audio packets N−1,1 and N,0 into block M, and also packets N, 3 , N+1,0 and N+2,0 into block M+3. In the Figure, the packets as shown on line 52 have as first index the number of their Audio Unit, and as second index the number within their audio block (running from 0 upwards). As shown, packets have a maximum size so that a packet will always fit into a single standard-sized block. On the other hand, minimum size of a packet is down to an applicable granularity level of the storage-per-block. The number of packets per Audio Unit has an upper bound that is determined only by the maximum size of an Audio Unit. Table 1 shows the storage format according to the invention, for the same configuration as shown in FIG. 4 . Here, each column pertains to a single block M to M+4. Each block starts with a header area, that may have a non-uniform size. Furthermore, each block contains an integer number of packets that may have mutually non-uniform sizes. In addition to the Audio Units, the storage may contain one or more Supplementary Data Units as accessory to a particular Audio Unit, and one or more padding or stuffing units as further accessory to a particular Audio Unit. Padding renders the bit rate constant, and represents dummy data for maintaining an appropriate buffer filling degree. Supplementary data may pertain to an arbitrary layer of functionality, such as the subcode. An Audio Unit or a frame may start on any position within a particular Block. Audio Units may transgress the edge of a Block, and in the embodiment, an Audio Unit will in general be larger than one Block. However, an Audio Unit may be so short that it would fit within a single Block. A single Block could therefore contain the starting point of a plurality of Audio Units. A frame relates to an actual duration of audio at replay, to wit, {fraction (1/75)} of a second. Next to audio, it contains various informations that pertain to its audio. A sector also has an integer number of packets. Table 2 illustrates the syntax of an audio stream according to the invention, written in the well-known Computer Language C. The first part relates to the Audio Mux Stream that contains a looped specification of Audio Blocks numbering 0 . . . N. Note that in the disclosure, N indicates an arbitrary parameter. The number of bits (right hand column) of the block in question is defined by the block length. The second part of the Table is again in C, and relates to a single Audio Block that contains an Audio Block Header and a looped specification of Packets numbering 0 . . . N. The number of bits of the packet in question is defined by its length. As recited, the data may have one of a plurality of respective data types. Table 3 shows a header format of a preferred but exemplary embodiment according to the invention, again written in C. The numbers of bits of the various parts have been specified in the right hand column. The first bit indicates whether the block in question contains the beginning point of an Audio Unit. If positive, the following 48 bits specify various parameters of this Audio Unit, to wit: a single bit that indicates the effective start of this Audio Unit, a 30-bit time code for use by a reader device to effect functions such as jumping by a prespecified amount of time. The second part of the header is always present. In the first place, it specifies the distance measured in number of blocks, up to 15, until the next Audio Unit start, to allow a logic jump to the next Audio Unit. Each unit is linked to a single time code, and vice versa. Functionally, the storage may be multiplexed among audio units, padding units, and supplementary data units. In consequence, going to a particular unit may simply be effected by waiting for a predetermined time interval until passage of the storage area of this next unit, through the continuing drive motion of a storage medium such as a disc. Often, cross-track jumping will speed-up this process, but it even applies if for some reason such cross-track jumping would not be allowed. Further, the header specifies the number of Packets within the block by 3 bits. Next, for each such packet, there is a looped specification of the data_type of that packet through 5 bits, and of its length in 11 bits. Also the number of packets is therefore codetermining for the length of the header in question. Generally, there is a two-level addressing organization: first the correct sector or block is addressed, through the next_unit_indicator. Subsequently, local addressing is effected, through the local block header that indicates the address, such as through signalling the lengths of one or more packets. Table 4 shows a data type specification through the 5bits indicated therefor by Table 3. Various ones of the 32 combinations have been reserved. Five are used for specifying various coding types. One indicates the occurrence of CD-text. The remainder has been reserved. Table 5 shows an audio block header syntax. The names of the various items, the numbers of bits, the format, and if applicable, the values have been indicated. The frame info can contain a time code. Note that the next unit indicator of Table 3 has been suppressed. Table 6 shows a packet information syntax. The names of the various items, the lengths in bits, the format, and if applicable, the values have been indicated. Table 7 shows a different data type definition, as varying from Table 4. The various types of audio packets can now be defined in the applicable area_TOC. Note that CD TEXT corresponds to a supplementary data packet. The invention has been disclosed with reference to specific preferred embodiments, to enable those skilled in the art to make and use the invention, and to describe the best mode contemplated for carrying out the invention. Those skilled in the art may modify or add to these embodiments or provide other embodiments without departing from the spirit of the invention. Thus, the scope of the invention is only limited by the following claims:
For mapping sampled digital audio information onto a linear physical mapping space that is partitioned in a string of uniform-sized blocks, in particular for variable-rate coded audio information that is distributed over successive audio units which are each composed from one or more audio packets, each block is supplemented with a block header for indicating an actual content of the block in question with respect to any constituent packet of the audio information.
6
BACKGROUND [0001] The invention concerns an actuator of an electrohydraulic gas exchange valve train of an internal combustion engine, said actuator comprising an actuator housing which can be fixed in the internal combustion engine, said actuator housing comprising a bore, a valve lash adjuster being received axially displaceable in said bore, said lash adjuster comprising a compensating housing for operating the gas exchange valve and further comprising an axial stop for limiting an outward travel of the compensating housing out of said bore and said axial stop comprising radially overlapping stops which are fixed in axial direction on said bore and on said compensating housing. [0002] It is known that the variability of the opening and closing times of gas exchange valves and of the maximum valve lift is achieved in electrohydraulic valve trains in that a so-called hydraulic linkage together with a pressure chamber is arranged between a cam of a camshaft and the gas exchange valve, wherein the volume of the pressure chamber can be continuously reduced through an electromagnetic hydraulic valve into a pressure relief chamber. Depending on the reduction volume of the hydraulic medium, the cam lift produced by the camshaft is converted fully, partially or not at all into a lift of the gas exchange valve. [0003] The present invention relates to that part of the valve train actuating system that is situated on the gas exchange valve side and whose movement corresponds to the lift of the gas exchange valve. An actuator of the pre-cited type is known, for example, from DE 10 2007 030 215 A1. The actuator housing in this case is a bushing that is screwed into a hydraulic unit that is fixed in the cylinder head of the internal combustion engine and in whose bore a hydraulically loaded slave cylinder and, adjoining this, a hydraulic valve lash adjuster of a known type are mounted for axial movement. In the disassembled state of the actuator or of the hydraulic unit, the compensating housing of the valve lash adjuster is not seated on the gas exchange valve, and the compensating housing is prevented from falling out of the bore of the actuator housing through the axial stop that is then active. The stops of the axial stop on the compensating housing are made in the form of a polygonal snap ring that is inserted into an annular groove on the outer peripheral wall of the compensating housing to protrude in radial direction therefrom, and the stops on the bore are constituted by a shoulder that is formed by a bore opening with a reduced diameter. SUMMARY [0004] The object of the present invention is to improve the structure of an actuator of the pre-cited type such that, with differently configured gas exchange valve trains that, in particular, create differently large maximum lifts on the gas exchange valve, appropriately adapted actuators comprising the largest possible number of identical parts (low-cost manufacture) can be used. [0005] The above object is achieved by implementing one or more of the features of the invention, whereas advantageous developments and configurations of the invention are the subject matter of the dependent claims. According to the invention, the stop on the compensating housing is a radially outwards extending collar of a bushing that surrounds the outer peripheral wall of the compensating housing. In contrast to the cited prior art, in which the stop on compensating housing is made in the form of a snap ring which is always situated at the same axial position relative to the compensating housing, the bushing of the invention serves as a simple to adapt bushing collar with a variable-positioning upper vertical stop in the form of the bushing collar. As a result, the axial movability of the compensating housing within the bore can be varied through the axial dimensioning of the bushing and can be adapted to differently configured gas exchange valve trains, while the compensating housings and, given the case, also the actuator housings always remain identical. [0006] According to a further development of the invention, the stop surface on the collar extends in a gas exchange valve distal direction outside of the axial dimension of the outer peripheral wall of the compensating housing. Through this configuration, it becomes possible to always use large series compensating housings with a uniform standard length even if the maximum lift to be transmitted by the actuator to the gas exchange valve is relatively high. [0007] The axial fixing of the bushing on the compensating housing can be realized on the one hand through positive engagement. For this purpose, the inner peripheral wall of the bushing, for instance, can comprise at least one bead that engages into an annular groove on the outer peripheral wall of the compensating housing. Alternatively, the bushing may engage behind the outer peripheral wall of the compensating housing on a radially tapering end section of the compensating housing near the gas exchange valve. [0008] On the other hand, the axial fixing of the bushing on the compensating housing can also be realized through force locking which creates an interference fit between the inner peripheral wall of the bushing and the outer peripheral wall of the compensating housing. The interference fit enables the bushing to be fixed on the compensating housing at largely variable axial positions of the stop. [0009] Further, the stop on the bore is a radially inwards extending collar of a further bushing that surrounds an outer peripheral wall of the actuator housing. In contrast to the cited prior art, it is not necessary to make the bore with a stepped configuration which necessitates a relatively complex undercut. In an alternative to this embodiment, the further bushing does not surround the outer peripheral wall of the actuator housing but is fixed on the inner peripheral wall of the bore. [0010] The axial fixing of the further bushing can be realized through force locking which creates an interference fit between the inner peripheral wall of the bushing and the outer peripheral wall of the actuator housing (or, according to the aforesaid alternative comprising a further bushing that lines the bore between the outer peripheral wall of the further bushing and the inner peripheral wall of the bore). The interference fit further enables the further bushing to be fixed on the actuator housing at largely variable axial positions of the stop on the bore. [0011] The stop on the bore may also be in the form of a ring, for instance an elastomer O-ring or likewise a snap ring that is inserted into an annular groove extending in the bore and protruding radially out of the annular groove. [0012] The bushings of the invention can be made particularly as thin-walled, drawn parts out of a sheet metal material or as injection molded parts out of a plastic material. BRIEF DESCRIPTION OF THE DRAWINGS [0013] Further features result from the following description and the appended drawings in which parts or details of examples of embodiment of an actuator are illustrated that are important for a better understanding of the invention. If not otherwise mentioned, identical or functionally identical features or components bear identical reference numerals. The figures show: [0014] FIG. 1 a , a first example of embodiment of the invention, in a longitudinal section; [0015] FIG. 1 b , the first example of embodiment of the invention in a non-sectional representation; [0016] FIG. 2 a , the compensating housing including a bushing of a second example of embodiment of the invention, in a longitudinal section; [0017] FIG. 2 b , the compensating housing including the bushing of FIG. 2 a , in a perspective representation; [0018] FIG. 3 , the valve lash adjuster of a third example of embodiment of the invention, in a longitudinal section; [0019] FIG. 4 a , a fourth example of embodiment of the invention, in a longitudinal section; [0020] FIG. 4 b , the compensating housing including the bushing of FIG. 4 a , as a detail; [0021] FIG. 5 , the compensating housing including a bushing of a fifth example of embodiment of the invention, as a detail; [0022] FIG. 6 , the compensating housing including a bushing of a sixth example of embodiment of the invention, as a detail; [0023] FIG. 7 a , a prior art actuator, in the operable assembled state, and [0024] FIG. 7 b , the actuator of FIG. 7 a in the disassembled state DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0025] For the sake of a better understanding, the invention may be described with reference to FIG. 7 a which discloses a section of a prior art electrohydraulic gas exchange valve train for a variable operation of a gas exchange valve 1 that is spring-loaded in closing direction. The section shows an actuator 702 that is fixed in a hydraulic unit 3 that in its turn is arranged in a cylinder head (not shown) of an internal combustion engine between a camshaft and the gas exchange valves and serves for a variable-lift transmission of a cam lift to the respective gas exchange valve 1 . [0026] The actuator 702 comprises a hollow cylindrical actuator housing 704 that is fixed through a screw connection 5 in a reception 6 of the hydraulic unit 3 , and further comprises a slave piston 7 and a hydraulic valve lash adjuster 708 , both of which are received axially movable in the central bore 709 under a choking valve 10 which serves as a hydraulic brake. The slave piston 7 which is loaded through hydraulic pressure in its turn actuates a pressure piston 711 of a known type that, through a compensating housing 712 which contacts the gas exchange valve 1 , forms a variable-height pressure chamber 13 of the valve lash adjuster 708 . [0027] In the operational state illustrated, the gas exchange valve 1 is closed and the slave piston 7 and the valve lash adjuster 708 are accordingly fully retracted into the actuator housing 704 . In contrast, FIG. 7 b shows the actuator 702 in the disassembled state of the hydraulic unit 3 in which the valve lash adjuster 708 is extended out of the bore 709 up to the limitation formed by an axial stop. The stops 714 and 715 constituting the axial stop are a snap ring disposed on the compensating housing 712 and a shoulder of the bore 709 arranged on the opening of the bore 709 that is made with an undercut. The snap ring 714 is inserted into an annular groove 716 which extends in the outer peripheral wall of the compensating housing 712 , and, due its polygonal shape, the snap ring 714 protrudes at points so far out of the annular groove 716 as to overlap the shoulder 715 in radial direction, and thus prevents the compensating housing 712 from falling out of the bore 709 in the shown stop position. In this stop position, the compensating housing 712 is extended slightly further outwards than during an operational maximum lift on the gas exchange valve 1 . Thus, if the compensating housing 712 remains unchanged but the maximum lift increases, it would be necessary to shift the shoulder which constitutes the stop 715 on the bore in direction of the spring collar 17 . However, this modification is subject to narrow limits because a minimum free axial motion of the actuator housing 704 relative to the spring collar 17 must be preserved. In addition, such a modification would not be compatible with the principle of using identical parts. [0028] Examples of embodiment of the inventive actuators of electrohydraulic gas exchange valve trains which, in particular, enable the use of identical valve lash adjusters 8 with different maximum lifts of the gas exchange valves are described in the following with reference to the appended FIGS. 1 to 6 . All embodiments comprise a bushing 18 that is made out of sheet metal material by deep drawing and surrounds the outer peripheral wall of the compensating housing 12 , wherein the stop 14 on the compensating housing is constituted by a radially outwards extending collar of the bushing 18 . [0029] FIGS. 1 a and 1 b show a first example of embodiment. The compensating housing 112 is taken from a construction kit for conventional standard valve trains with hydraulic valve lash adjustment and it accordingly comprises an annular groove 116 for a snap ring. In this case, however, the annular groove 116 has no function because the bushing 118 is fixed on the compensating housing 112 between the inner peripheral wall of the bushing 118 and the outer peripheral wall of the compensating housing 112 through force locking, i.e. through a longitudinal interference fit. To enable the manufacturing of the bore 109 without undercuts and at comparatively low costs, the stop 115 on the bore 109 is formed by a collar of a further deep drawn bushing 19 that surrounds the outer peripheral wall of the actuator housing 104 . The axial fixing of the further bushing 19 , too, is achieved through force locking in that, between the inner peripheral wall of the bushing 19 and the six circular arc-shaped surfaces 20 of the hexagon 21 that serves to screw in the actuator housing 104 , is formed an interference fit in which the radially inwards extending collar 115 bears against the gas exchange valve side front end surface of the actuator housing 104 . As an alternative to this, the dotted-line contour shown in FIG. 1 b is meant to indicate that the further bushing 19 can be pressed onto the front end surface of the actuator 104 up to a certain pre-determined axial position even without a stop in order to vary the position of the axial stop as required. [0030] FIGS. 2 a and 2 b show a second example of embodiment. The axial fixing of the bushing 218 on the compensating housing 212 is realized in this case by positive engagement in that the inner peripheral wall of the bushing 218 comprises three beads 222 that are uniformly distributed in peripheral direction, and said beads engage into an annular groove 216 that is modified with respect to FIG. 1 . [0031] In the third example of embodiment shown in FIG. 3 , the axial fixing of the bushing 318 on the compensating housing 312 is realized both through force locking and through positive engagement. The positive engagement is realized in that a diameter constriction 23 of the bushing 318 engages behind the radially tapering gas exchange valve proximate end section of the outer peripheral wall of the compensating housing 312 . Accordingly, in this case too, the annular groove 316 of the compensating housing 312 taken from the construction kit for conventional standard valve trains has no function. Force locking is realized through a comparatively light longitudinal interference fit between the inner peripheral wall of the bushing 318 and the outer peripheral wall of the compensating housing 312 . [0032] The stop 415 on the bore 409 in the fourth example of embodiment shown in FIG. 4 a is constituted by a snap ring that is inserted into an annular groove 24 that is worked into the bore 409 , and said snap ring protrudes radially out of the annular groove 24 . The axial fixing of the bushing 418 on the compensating housing 412 is realized through positive engagement of a circumferential bead 422 of the bushing 418 engaging into the annular groove 416 , said bushing 418 being optionally slit in axial direction for facilitating its mounting on the compensating housing 412 . [0033] FIG. 4 b is a detail view of the example of embodiment shown in FIG. 4 a , and FIGS. 5 and 6 disclose, as mentioned above, further structural design alternatives for the bushing 18 which serves as a stop adapter. As shown in FIG. 7 b , the symbolically illustrated stop 15 on the bore determines the extended position of the compensating housing 12 that is limited by the respective axial stop. [0034] The fifth example of embodiment shown in FIG. 5 corresponds to the first example of embodiment in FIG. 1 a , wherein, in place of the interference fit on the inner peripheral wall of the bushing 518 , a bead 522 in positive engagement with the annular groove 516 is used. [0035] The sixth example of embodiment shown in FIG. 6 likewise corresponds to the first example of embodiment, wherein, however, the compensating housing 612 does not comprise an annular groove. In these examples of embodiment, too, the stop surface 614 of the collar always extends in a gas exchange valve distal direction outside of the axial dimension of the outer peripheral wall of the compensating housing 612 . Or, to put it more simply, the stop 614 extends spaced by an axial dimension H from the gas exchange valve distal front end surface of the compensating housing 612 . This means that, in the case of both the compensating housings 412 and 512 comprising annular grooves 416 and 516 respectively, the maximum lift on the gas exchange valve with an unmodified compensating housing 12 can be enlarged by the dimension L relative to the example of prior art shown in FIG. 10 . In the case of the compensating housing 612 without an annular groove, the maximum lift on the gas exchange valve depends on the bushing dimension L and on the pressing dimension P of the bushing 618 on the compensating housing 612 . LIST OF REFERENCE NUMERALS [0000] 1 Gas exchange valve 2 Actuator 3 Hydraulic unit 4 Actuator housing 5 Screw connection 6 Reception 7 Slave piston 8 Valve lash adjuster 9 Bore of the actuator housing 10 Choking valve 11 Pressure piston 12 Compensating housing 13 Pressure chamber 14 Stop on the compensating housing 15 Stop on the bore 16 Annular groove 17 Spring collar 18 Bushing 19 Further bushing 20 Circular arc-shaped surface 21 Hexagon 22 Bead 23 Diameter constriction 24 Annular groove
The invention relates to an actuator of an electrohydraulic gas exchange valve drive of an internal combustion engine, comprising an actuator housing ( 4 ), which can be fixed in the internal combustion engine and which comprises a bore ( 9 ); a valve play compensation element ( 8 ) which is received in said bore in an axially movable manner and which comprises a compensating housing ( 12 ) for actuating the gas exchange valve ( 1 ); and an axial stop which limits the extending movement of the compensation housing out of the bore ( 9 ) and which comprises stopes ( 14, 15 ) that overlap each other radially. The stop ( 14 ) on the compensation housing-side is a collar of a sleeve ( 18 ) that surrounds the outer casing of the compensation housing said collar extending outwards in a radial manner.
5
CROSS-REFERENCE TO RELATED APPLICATION This patent claims priority to U.S. Provisional Patent Application Ser. No. 61/839,980, filed Jun. 27, 2013, which is incorporated herein in its entirety by reference. FIELD OF THE INVENTION This disclosure relates to devises and techniques for removing water from flexible covers for tanks, including covers for swimming pools. BACKGROUND Flexible, water impermeable swimming pool covers and similar covers for other tanks, pools and the like provide safe and effective covers. However, rain water often collects on such covers and can damage the cover and present a drowning hazard, particular for children and animals, because of water that pools on top of the cover. Accordingly, it is often desirable to remove such water that has collected on a cover or within a vault or other structure within which such a cover may be stored. Pumps for such water removal are available, but they must be placed on the cover by a user and removed before the cover is closed, which may be neither easy to remember nor to do, particularly, for instance, if it is raining. SUMMARY The terms “invention,” “the invention,” “this invention,” “the present invention” and “disclosure” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim. A water removal pump or pump inlet device may be automatically deployed when a cover is deployed across a pool or tank by friction between the device and the cover causing a portion of the device to travel, in some instances at the end of a pivoting arm, out to a central region within the cover where water may accumulate. Water, temperature and other sensors may be used together with appropriate control devices to enhance operation of such water removal devices. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partially schematized plan view of a water removal apparatus of this disclosure. FIG. 2 is an isometric view of one embodiment of a water removal apparatus of this disclosure. FIG. 3 is an enlarged exploded isometric view of the pump head portion of the apparatus shown in FIG. 2 . FIG. 4 is an enlarged isometric view of a knuckle hinge assembly shown in FIG. 2 . FIG. 5 is an enlarged exploded isometric view of the pivot apparatus shown in FIG. 2 . FIG. 6 is an enlarged exploded isometric view of an optional docking station attached to the pump head in FIG. 2 . FIG. 7 is an enlarged isometric view of the pump and pivot portions of the water removal device of FIG. 2 . FIG. 8 is an isometric view of another embodiment of a water removal apparatus of this disclosure. FIG. 9 is a partially schematized plan view of an alternative water removal apparatus of this disclosure. DETAILED DESCRIPTION FIG. 1 illustrates an exemplary swimming pool 12 having a cover 14 with a cover leading edge 16 shown not quite fully deployed, so that water 20 may be seen in the pool near the bottom of FIG. 1 . When the cover 14 is retracted, it may be stored under a vault 18 . The schematized water removal apparatus 10 depicted in FIG. 1 includes a generally rigid arm 22 attached at one end to a pivot structure 24 and having a pump head structure 26 attached to the other end of arm 22 . A knuckle joint 28 allows the pump head 26 to move vertically as may be necessary when water on cover 14 has formed a depression in cover 14 . A pump (not shown in FIG. 1 ), typically in the vicinity of the pivot structure 24 draws water from the pump head through the arm 22 and discharges it into a drain 30 . The pump may be actuated or turned on, and turned off, by control circuitry 108 ( FIG. 1 ). Pump head 26 automatically moves between its stored position within the vault 18 and its deployed position near the middle of cover 14 as cover 14 is stored or deployed. Such movement may be powered, power-assisted or solely as a result of friction between cover 14 and one or more wheels 32 mounted on pump head 26 and in contact with cover 14 . Such wheel or wheels 32 located at an appropriate angle such that contact with the cover exerts force on the pump head 26 causing it to move in the same general direction as the cover 14 is moving. This causes the pump head 26 to pivot out of the vault 18 when cover 14 is being deployed on the pool 12 and back into the vault 18 when the cover 14 is being stored. The most force will be exerted on pump head 26 by one or more wheels 32 when the axis of rotation of wheel 32 is parallel to, or at a fairly small fraction of ninety degrees)(90° relative to, the direction of movement of cover 14 . As the axis of rotation of the wheel(s) comes close to or is fully transverse (i.e., at ninety degrees))(90° to the direction of movement of cover 14 , the wheels will just rotate freely and exert little force on pump head 26 . A second drain inlet 102 located within vault 18 may be coupled by a pipe 106 to a valve 104 also controlled by control 108 when desired to withdraw water that has accumulated within the vault 18 and discharge it into drain 30 . Among other alternatives, valve 104 and the pump may be actuated in response to a signal from water a sensor 100 within vault 18 . A valve may also be positioned between pump head 26 and the pump and controlled manually or by control 108 . Another embodiment of a automatically deploying water removal apparatus of this disclosure is depicted as apparatus 34 in FIG. 2 . Pump head 36 portion of apparatus 34 in FIG. 2 is depicted in an exploded isometric view in FIG. 3 . As shown in FIG. 3 , top head and bottom head castings 46 and 48 hold a nozzle assembly 54 that attaches to tubing end 58 that communicates through tubing 60 and with pump 42 (visible in FIG. 2 ). Top and bottom head castings 46 and 48 also trap axles 50 of two pairs of wheels 52 , as may be appreciated by FIG. 3 . The head castings 46 and 48 also hold a sensor 56 which may include a water sensor, a temperature sensor and possibly other sensors such as a motion detector. Sensor 56 is attached to a control located, for instance and among other alternatives, within an alternating current (ac) to direct current (dc) converter and control box 108 (near pump 42 in FIGS. 2 and 7 ), through cable 66 that runs outside of tubing 60 but inside of pipe arm 64 . Pipe arm 64 may be a rigid material such as a metal or rigid plastic tube or pipe that encircles the tubing 60 . Alternatively, a flexible tube 60 and any cables could be secured with straps or the like to a rigid rod as an alternative to a rigid tube or pipe. Pipe arm 64 may not be needed if the tubing 60 itself is sufficiently rigid. As can be seen in FIGS. 2 and 3 , the pairs of wheels 52 have axles 50 mounted at a significant angle to each other. This facilitates the exertion of appropriate forces on pump head 36 by contact with cover 14 at different points in the travel of pump head 36 and during different directions of cover travel (opening or closing). Nozzle assembly 54 may also include a water filter through which the water being removed is drawn. Pump head 36 is attached to arm 40 by means of tubing 60 and pipe arm 64 , as well as knuckle assemblies 62 adjacent to pump head 36 and intermediate pump head 36 and pivot structure 38 . The knuckle assemblies 62 , as is illustrated in FIG. 4 allow fluid-tight fluid communication between tube 60 on opposite ends of the knuckle 62 while permitting articulation in a vertical plane. Water sensor functionality in sensor 56 in pump head 36 can be used to turn on the pump 42 when water is present on the pool cover 14 and to turn the pump 42 off when no more water is sensed on the cover. A water sensor with or near pump 42 may also be desirable to sense the absence of water while water is still present on cover 14 because, for instance, the filter in nozzle assembly 54 has become clogged. This may permit control circuitry to switch pump 42 off so that it will not be damaged by running “dry.” Furthermore, a water sensor 100 in FIG. 1 can be used by control circuitry in ac to dc converter and control box 108 to control valves (such as valve 104 ) so that water is removed from within vault 18 or some other location from which water removal is desirable. As may be appreciated by reference to FIGS. 5 and 7 , pivot structure 38 attaches to arm 40 (shown in FIG. 2 ) by capturing a portion 68 of pipe arm 64 (shown in FIGS. 2 and 7 ) between two pivot bearings 70 that rotate within an upper bearing plate 72 and a lower bearing plate 74 . As depicted in FIGS. 5 and 7 , bearing plate 74 is adapted for mounting to structure not shown by passing bolts or other appropriate fasteners (not shown) through flanges 75 and into such structure. Flexible tubing (not shown) communicates between the tubing within pivot bearings 70 and pump 42 inlet 109 so that water can be drawn through the pivot. Cable 66 communicates with control circuitry within an ac to dc convertor and control box 108 . Tubing 78 may be an alternative drain line for draining an area within the vault (as depicted schematically in FIG. 1 .). In an alternative embodiment depicting a water removal apparatus 120 in FIG. 8 , the same pump head 36 is used as in FIG. 2 , but a different but similar pivot structure 122 is utilized together with an ac pump 124 and a controller 126 . (No docking station is depicted in FIG. 8 .) Flexible tubing 128 may be used to accommodate the rotation of the arm 130 about pivot structure 122 . A water detection sensor 132 just “upstream” from pump 124 can communicate the presence or absence of water to control the pump 124 to prevent damage to it from running “dry.” An optional docking station 80 visible in FIG. 2 is further illustrated in FIG. 6 . In docking station 80 , a mounting dock 94 (that may be molded of plastic, among other alternatives) is secured to a mounting bracket 96 with plates 98 , and bracket 96 may be attached to structure not shown with bolts or other fasteners, not shown, passing through flanges 97 and into that structure. Top unlock pivot 86 and bottom unlock pivot 88 are mounted on mounting dock 94 and can rotate slightly about a bolt 81 . Coiled compression springs 90 secured in openings 92 (only one opening is visible in FIG. 6 ) in mounting dock 94 biases pivots 86 and 88 in a counter clockwise direction as viewed from the top of FIG. 6 . Pivots 86 and 88 have recesses 84 for receiving pins 82 on the top and bottom head castings 46 and 48 (pins 82 may be seen on the top head casting 46 in FIG. 3 ). When pins 82 are in recesses 84 , pump head 36 is secured in its docked position (as depicted in FIG. 2 ). Pressure exerted on arm 95 by, for instance, as a pool owner rotates pivots 86 and 88 out of contact with pins 82 when pump head 36 and arm 40 are to be released and pivoted out to their deployed position with pump head 36 in a central region of pool cover 14 as is depicted in FIG. 1 . Arm 22 or 26 could also be biased toward its deployed position by a spring or other force-exerting component to facilitate deployment of arm 22 or 26 when the cover 14 is deployed. While friction between a retracting cover 14 and the wheels 52 may not cause such a spring-loaded arm to retract or to retract fully, contact between the pool cover edge 16 and pump head 26 or 36 should nevertheless drive the pump head and attached arm into their stored position. Friction between moving pool cover 14 as it is deployed and wheels 52 causes the desired pivoting action driving pump head 26 or 36 out to its deployed position. Friction exerted in the opposite direction when pool cover 14 is closed likewise tend to urge pump head 26 or 36 and arm 22 or 64 to a stored position, typically within vault 18 . If such friction is inadequate to fully store the water removal apparatus, contact between pool cover edge 16 and pump head 26 or 36 , as the case may be, will forced the pump head and attached arm into their closed positions. While the wheels 32 or 52 depicted in FIGS. 2, 3 and 7 are not powered and simply rotate as result of contact with the pool cover against which they rest, in alternative embodiments, the wheels 32 or 52 could be powered to assist in deployment as described above or to enable deployment or storage of the pump head to occur without or separately from cover movement. Movement of arm 22 or 64 between stored and deployed positions could also be achieved or facilitated by force exerted on the arm 22 or 64 by an appropriate electrical or hydraulic rotary motor or one or more hydraulically actuated piston(s), among other alternatives. In addition to the water sensor 56 visible in FIG. 3 , which is associated with pump head 36 , a water sensor 100 (shown in FIG. 1 ) may be located in a location within vault 18 (shown in FIG. 1 ) where water accumulates, and a water inlet 102 (shown in FIG. 1 ) communicating with a valve 104 (shown in FIG. 1 ) through a pipe 106 (shown in FIG. 1 ) may be used to remove such water within the vault by controlling valve 104 and the pump to draw water from inlet 102 , when desired, rather than from pump head 36 . Additionally, a water sensor may be located proximate the pivot structure 24 or 38 or integrated with the pump 42 to sense the absence of water because the filter as part of nozzle assembly 54 has become clogged, all the water has been removed from pool cover 14 , or for any other reason so that pump 42 can be shut off. Other sensors can also be used such as a sensor detecting motion of pump head 26 or 36 consistent with a person or animal having fallen onto the pool cover. A temperature sensor as part of sensor 56 (shown in FIG. 3 ) or located elsewhere may be coupled to the control 108 (shown in FIG. 1 ) to prevent pump operation below certain temperatures at which the water may be frozen to prevent damaging operation of the pump. Alternative structures and components are possible such as embodiments of this disclosure in which the water pump is integrated with the pump head 26 or 36 or is in some other location, rather than being located proximate the pivot structure 24 and 38 , as depicted in the Figures. As reflected in the different embodiments described above, one pump 42 uses a direct current (dc) motor and the other pump 124 uses an alternating current (ac) motor. Different types of, and differently powered, pumps can also be used. Illustrating another embodiment, FIG. 9 is a schematized plan view of pool 12 (also shown in FIG. 1 ) having cover 14 and cover edge 16 shown almost fully deployed over the water 20 . In this embodiment, pump head 130 does not pivot on the end of a rigid pipe or other structure, and, as a result, no long, rigid pipes, rods or other potentially difficult-to-ship components are needed. Instead, pump head 130 is in communication with a pump 132 (that discharges into a drain 131 ) by a flexible pipe or hose 134 . Pump head 130 is tethered to a reel 136 within vault area 138 by a rope, cable, line or cord 140 that limits pump head 130 travel beyond approximately the middle of the pool cover. Pump head 130 travels along with the pool cover 14 during pool cover deployment so that pump head 130 is in approximately the middle of the pool cover 14 when the cover is fully deployed, as is almost the case in FIG. 9 . During such deployment of the pool cover 14 and pump head 130 , cord 140 is permitted to spool out of reel 136 until pump head 130 reaches a predetermined distance away from the vault area 138 with the pump head approximately in the middle of pool cover 14 (or some other desired location). When pool cover 14 is retracted into vault area 138 in order to make pool 12 usable, pump head 130 likewise retracts into the vault area 138 , and cord 140 helps insure that pump head is appropriately positioned for proper deployment the next time the cover 14 is deployed. Multiple reel 136 and retraction mechanisms are possible. For instance, reel 136 can be used solely for retracting cord 140 when pool cover 14 is stored, in which event, guided by cord 140 , pump head 130 moves back into the middle of vault area 138 as a result of friction between pump head 130 and cover 14 and as a result of contact between pump head 130 and cover leading edge 16 . In this case, reel 136 can simply contain a spring mechanism that retracts the cord 140 when the pump head 130 moves toward the vault area 138 . Alternatively, reel 136 can contain a retraction mechanism powered and controlled by control box 142 to which reel 136 is attached by cable 144 . Such a retraction mechanism may cause cord 140 to be retracted into the reel 136 , thereby pulling pump head 130 back to the vault area 138 . In this alternative, the pump head 130 can be retracted separately while the cover 14 remains deployed. In another alternative, cord 140 can include a power, sensor and/or control cable that provides power to pump head 130 so that a pump can be located in pump head 130 and data can be provided to the control box 142 from sensors in or on pump head 130 . In yet another alternative, one or all of such power, sensor and control cables may be positioned along with flexible pipe 134 or may travel separately to pump head 130 rather than along either of flexible pipe 134 or cord 140 . In alternatives in which power is supplied to pump head 130 , pump head 130 can include a powered deployment mechanism, such as powered wheels, that can move pump head 130 out onto the cover 140 after cover 140 has already been deployed. The sensors described above may be of any appropriate type for determining the conditions of interest, including without limitation electronic, magnetic, and electro-mechanic (e.g., float-type water) sensors. Such sensors and other system elements can be coupled to control circuitry through cables, but wireless coupling could also be employed, for instance, using existing wireless technology such as Wi-Fi, Bluetooth or infrared technology or using future wireless technologies. Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below.
An automatically deployed water removal apparatus for use with a solid, flexible swimming pool cover to remove rainwater caught by the cover. In one embodiment, a head with a water inlet pivots from a stored position along the edge of a pool to a deployed position near the center of a deployed cover as the cover advances to its deployed, pool-covering position. In another embodiment, a water inlet is attached to and positioned in part by a tether cord that may be reeled out during cover deployment and reeled in during retraction of the cover.
5
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates generally to the field of exercise equipment, and more specifically to exercise apparatus for aerobic, strength, and cardio vascular conditioning that permits a user to perform an upper body spinning bike exercise. [0003] 2. Description of the Related Art [0004] Cardio-pulmonary, cardiovascular, and strength training exercise equipment found in today's exercise and health centers as well as in the home seek to improve and maintain an individual's aerobic and strength fitness. Many types of exercise equipment, including treadmills, rowing machines, stationary bicycles, stair-stepping machines, skiing machines (cross country and alpine), and dry-land swimming machines are available for individuals who desire to maintain and improve their overall fitness and conditioning. [0005] Stationary bicycles provide users a means for exercising certain muscles, generally involving the legs, and to a much lesser extent, if any, the center core, i.e. abdominal and lower torso muscles that help cyclists balance, arms and upper body muscles, i.e. biceps, triceps, lateral oblique muscles and back muscles. The present invention in particular is directed at the spinning segment of the exercise market. A spinning bike is a stationary exercise bike that includes a frame, a seat, handlebars, pedals, and a large flywheel with a large moment of inertia. The large fly wheel is very important because it smoothes out the user's pedaling action and makes the stationary exercise bike feel like a conventional bicycle feels when ridden on the road. Spinning bikes prior to the present invention have been directed exclusively at the rider's lower body. Some stationary bicycles combine pedaling features that allow the rider to exercise both the legs and arms but these bikes are not suited for a spinning class setting and are never used in such a setting. The present invention is directed at spinning and spinning class settings and is specifically configured for upper body spinning. Some combined leg and upper body cycles allow for pedaling by the arms in a reciprocating manner where the hands engage pedals and turn both cranks in a reciprocating manner where the respective crank arms are locked in a fixed orientation such that as one crank arm is coming up and over the rotation the other side crank arm is rotating under and back toward the rider in a reciprocating motion. Other combined cycles have long lever arms attached to the wheel that the operator moves back and forth as in the Schwinn “Aerodyne”. In the Schwinn Aerodyne the lever arms are directly connected to the foot pedals such that the rider may either rotate the foot pedals to rotate the wheel or lever the cranks or both efforts combined. These devices provide resistance to the arms and cardiovascular conditioning to the rider but the fixed orientation of the cranks in a reciprocating rotary motion prohibit the rider from establishing a spinning rhythm with the upper body. These combined devices also involve the use of the rider's legs as well as arms and result in an unpleasant and awkward motion or movement of the entire body. This combination of upper and lower body movement is not desirable to participants in a spinning class or in a spinning situation. The rider is confined to a sometimes boring left right, left right motion of the hands, arms and upper body. [0006] The present invention allows the rider to use each hand and arm independently of the other; the rider can pedal with only one hand, both hands in tandem orientation, both hands in opposed or reciprocating orientation as in the Miller design or any combination or orientation. The rider can rotate one crank rapidly while letting the other pause similar to a boxer who jabs with his left hand quickly and repeatedly while his right hand is held back waiting; or the rider, using the present invention in an upper body “spinning class”, who can move his arms and upper body in a dancing or rhythmic motion to music or instruction. The combined foot and arm powered design of Miller allows the rider to exercise at his discretion either the rider's legs or the rider's arms but does not allow the rider to alternately and independently exercise each arm irrespective of the other arm while maintaining contact with the hand pedals. The present invention is specifically addressed to allow the user to comfortably exercise his upper body in a spinning class setting without involving his legs. [0007] There exists devices used for rehabilitation that utilize hand cranks and these devices are generally referred to as “UBE”'s for upper body exercisers. These devices are often mounted on stands or attached to walls and people, sometimes in wheelchairs, approach the “UBE” and pedal the cranks for exercise or rehabilitation. These machines use very small fly wheels weighing ten or twelve pounds of small moment of inertia and use a magnetic resistance to resist the user's pedaling motion. These machines also have both cranks in a locked or fixed orientation relative to each other such that the operator uses one arm or both but the operator cannot use both pedals independently of each other; that is the operator either pedals with both arms in a reciprocating manner or only with one arm at a time if it is desirable not to move the other arm. The crank arms could be mounted in either a tandem or side by side orientation or in an opposed or reciprocation orientation and each arm is locked in position relative to the other, but the present state of the art among “UBE's” does not provide a machine with the crank arms such that they can be moved independently of each other in an infinite array of orientations. This is because no one has yet to recognize the need for this type of motion except for the present invention and in the environment of a health club setting and in a spinning class where the operation of the machine is done to instruction or to music and the user needs free movement of both arms and the upper body. [0008] The current state of stationary bicycle designs have typically been limited to designs that affix a pair of handlebars, pedals, and seat to a single rigid platform, e.g. bolted in place and resting on a floor, configured to replicate only the spinning dynamic associated with pedaling a bicycle. In this arrangement, current designs are able to exercise only the legs and hips and to a very small extent the upper body. These bikes are often used in class settings where an instructor with the accompaniment of music directs the riders for a period of time for the purpose of cardio conditioning through the use of mostly the operator's legs and hips. This is know as “spinning” and is now a world wide activity that involves hundreds of thousands of devotees. The present invention is intended to address this vast audience and allow them to have the same experience with their upper bodies and arms that they have heretofore only been able to experience with their legs and hips. The present invention would often times be used in a class setting adjacent to “conventional” “spinning bikes” that exercise only the legs and hips. The present design is not intended to be limited to only this type of setting but would be a tremendously appreciated addition to spinning classes and would allow the participants to develop their upper bodies to the same level of conditioning as their lower bodies. [0009] The inability of today's stationary, leg actuated, “spinning bike” designs to involve the upper body, also limits the number and type of muscle groups involved. These designs do not engage many of the muscles in the upper body such as the back, arms, shoulders, nor do such stationary bikes address certain core muscles in the rider's trunk and oblique muscles. Such stationary bicycles can be considered undesirable and generally inadequate for training by cycling enthusiasts that want to develop their core and upper body while receiving cardio vascular conditioning. [0010] Historically, cycling has not been thought of as a means of exercising the upper body. The development of the handcycle, although mostly thought of as a cycle for the disabled, has increased awareness in the cycling community of the benefits of cycling with the arms to develop the upper body and there has been significant cross over from disabled hand cyclists to able bodied hand cyclists. This awareness of hand cycling among the able bodied is creating a desire for upper body spinning bikes just as bicycling has caused an interest in stationary “spinning bikes” that condition and develop the lower body. These “spinning bikes” are generally but not exclusively used in a class setting. The present invention is ideally suited to be an adjunct to this “spinning class” setting. [0011] UBE's as mentioned above are generally intended for disabled individuals seated in wheelchairs and lack a seat associated with the drive unit and wheel. Because the operator is seated in a wheelchair there is neither need for the exercise apparatus to have provisions structured to support the operator's feet not a seat to support the operator. [0012] A major reason for the lack of popularity of this type of exercise apparatus is the lack of accommodation for an able-bodied operator and the perception because of the lack of seat and foot supports that this type of apparatus is designed to be used by the disabled. These machines also lack a large enough flywheel to provide the feeling of riding a handcycle on the road the way a large flywheel provides the feeling or riding a conventional spinning bike on the road. Also, because this type of device is not designed to be used by able-bodied operators, UBE's do not appear in a “spinning class” setting but are often limited to an obscure location in a fitness facility if at all; or in a rehab facility. [0013] Current stationary bicycle designs tend to be relatively limited in that the user can only exercise his legs and only incidentally any of the muscle groups of the upper body and arms. The only significant dynamic interaction with the apparatus occurs at the pedals, limiting the exercise stimulation to the lower body during the pedaling action of the riding experience. Such designs are limited in the muscle groups involved and the quality of the upper body exercise that the spinning action may be produce. Users of such devices would likely be interested in an apparatus that stimulates the upper body during the cycling experience and users would likely desire to obtain the benefits of engaging a broader range of the muscle groups of the upper body as produced when using an upper body spinning device as opposed to a conventional stationary exercise spinning bike. [0014] It would therefore be beneficial to provide an exercise apparatus that more accurately simulates the operation of a hand cycle and provides an opportunity to exercise the upper body while in a “spinning class” situation and overcome the limitations found in current stationary “spinning bike” designs which only provide an opportunity to exercise the legs. SUMMARY OF THE INVENTION [0015] According to one aspect of the present design there is provided an apparatus that allows the user to perform an upper body spinning exercise. The design includes a frame with a wheel mounted to the frame configured to be rotatably connected to a drive unit and the drive unit is configured to include crank arms enabling the operator to impart rotation of the wheel by pedaling the hand pedals. The drive unit may be further configured to allow pedaling of each crank arm independently of the other to enhance the upper body spinning experience. Wider or narrower crank arms may be provided to enable the rider to vary the muscle groups used during the spinning activity and further enhance the muscle development associated with the spinning experience. A foot platform may be added to support the user's feet providing an anchor point for the user's body to further enhance the upper body spinning experience. [0016] These and other advantages of the present invention will become apparent to those skilled in the art from the following detailed description of the invention and the accompanying drawings. DESCRIPTION OF THE FIGURES [0017] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which: [0018] FIG. 1 is a top view depicting the independent crank arms with dual sprockets and chains; the right side crank arm and chain connected to the flywheel with a right hand freewheel clutch and the left side crank arm connected to the flywheel with a left-hand freewheel clutch; a flywheel tension knob is also shown; [0019] FIG. 2 is a perspective view of the upper body spinning bike depicting the independent crank arms and dual chains connecting each crank arm independently to a freewheel on each side of the flywheel; the left side chain in connected to the flywheel by means of a left hand freewheel and the right side crank arm is connected to the flywheel by means of a right hand freewheel. [0020] FIG. 3 is a top front view depicting the dual drive mechanism showing cantilevered, independently rotatable drive sprockets and crank arms connected by dual chains to a left-hand freewheel and a right hand freewheel imparting rotation to the flywheel; also shown are the footrests and adjustable resistance friction pads. [0021] FIG. 4 is a right side view of the upper body spinning bike. [0022] FIG. 5 depicts a left side view of the upper body spinning bike with the cranks shown in a tandem orientation relative to each other and showing the seat and showing foot rests [0023] FIG. 6 depicts a rider shown on the upper-body spinning bike with the seat adjusted low and rearward and with the feet on footrests; the cranks are shown in the tandem position and as shown are not able to rotate independently of each other. [0024] FIG. 7 depicts the wide cranks shown with the drive sprocket assembly, hand pedals and bearing area on shaft. [0025] FIG. 8 shows a jackshaft configured for means to allow independent rotation of each side crank arm and showing sprockets with integral roller clutches, driven shaft and final drive gear for transferring rotation to the flywheel. Roller clutches are shown with reversed orientation providing both left and right hand drive to the drive shaft. This allows one clutch to remain stationary and still allow the drive shaft to rotate while the other clutch drives the drive shaft and vice-versa. [0026] FIG. 9 is a right side view showing the vertical seat adjustment and locking pin as well as the horizontal sliding mechanism for adjusting the seat and locking in seat in place horizontally. [0027] FIG. 10 is a side view showing the rider on the upper body exercise cycle showing the seat adjusted to the rider's body size and the rider's feet on footrests and the crank arms are shown in a 90 degree orientation to each other. [0028] FIG. 11 is a front view of rider on the upper body exercise cycle showing the crank arms in the 180 degree opposed position. [0029] FIG. 12 is a view of the drive unit. DETAILED DESCRIPTION OF THE INVENTION [0030] The present design is a stationary upper body exercise apparatus, typically comprising a frame and components, i.e. pedals, crank arms, seat, chain drive and flywheel, affixed to a stationary frame typically positioned on a smooth surface, e.g. hardwood or concrete floor enabling a the operator to exercise his upper body in a similar manner to the operator of a stationary “spinning bike” configured to exercise the rider's legs but in the case of this invention configured to exercise the operator's upper body including the arms, upper and lower back and abdominals in a spinning type activity. [0031] In essence, the present design allows the operator to carry out a spinning activity for the upper body by pedaling hand pedals which are attached to the distal end of crank arms resulting in the rotation of a large flywheel in an effort to develop upper body strength and cardiovascular conditioning. [0032] In addition, the present design may include wide or narrow crank arms attached to the drive unit enabling the operator to exercise different muscle groups. The present design may include cranks that are as much as 26 inches wide from pedal to pedal enabling the operator to exercise his outer pectoral muscles and upper back and traps or the bike may include conventional bicycle crank arms that are narrow and place the operator's grip on the pedals approximately seventeen inches apart enabling the operator to exercise his inner pectoral muscles and his biceps, triceps and deltoids. Any configuration of the pedals and crank arm widths enables the operator to exercise his upper body and some configurations of the pedals and crank arms may exercise some muscle groups more directly than other configurations. [0033] The upper body spinning bike apparatus may include a drive unit that enables the operator to pedal each crank arm independently of the other crank arm enabling the operator to participate in a class setting under the direction of a class instructor. In this embodiment of the present design the operator may pedal several revolutions of one crank arm while the other crank arm is at rest and the switch to the other crank arm while the first arm rests. The crank arms may be configured through the drive unit to impart rotation to a flywheel enabling the operator to affect a smooth pedaling motion maintained by the flywheel. The upper body apparatus may include a friction device configured to apply resistance to the flywheel to simulate climbing a hill on the exercise device. The friction device may be configured to be adjustable by the operator and enable the operator to vary the resistance of the friction device being applied to the flywheel by a control device. The control device may be accessible to the operator when seated in the seat of the exercise apparatus. [0034] Apparatus [0035] The upper body spinning exercise apparatus is illustrated in FIGS. 1 and 2 . In combination, these figures depict relationships between major assemblies and subassemblies of one embodiment of the present design. [0036] FIG. 2 is a right hand side perspective view illustrating one aspect of the present design. Referring to FIG. 1 , an upper body exercise apparatus 100 may include a stationary frame 160 arranged to support the user. [0037] The bicycling exercise apparatus may include a variety of off-the-shelf parts, i.e. components, elements, devices, and combinations of individual components, to form sub-assemblies and complete assemblies used in constructing the present design. For example, the present design may include, and will be described for purposes of this disclosure, a stationary frame 160 , chain 114 , and seating assembly 140 . Driveline and seating assemblies are generally known, and, for example, the driveline may be chain or belt driven or otherwise designed to effectuate the functionality described herein. [0038] In general, the construction of the upper body exercise apparatus 100 is typically from metals, with other parts and components made from a variety of common materials, including but not limited to, aluminum alloys, carbon fiber, titanium, steel, composite materials, plastic, and wood and any combination thereof, to provide the functionality disclosed herein. Other materials may be employed in order to manufacture the parts and components to form assemblies used to construct the upper body exercise apparatus in accordance with the present design. [0039] From FIG. 2 , the present design's frame 160 may be constructed of multiple sections of formed steel. Although the construction technique described herein uses multiple sections, brackets 159 , and flanges, forming stationary frame 160 may entail providing a single piece having all the functionality described. In general, the materials used in assembly are required to support the frame, seat, and flywheel 110 and drive mechanism and enable the user or rider to pedal and effectuate the functionality discussed herein, and may differ from the assembly pictured. [0040] FIG. 2 illustrates the construction of the present design's frame 160 or frame assembly, involving multiple frame tubing elements of formed steel, e.g. bottom bracket assembly, seat support structure 150 , and foot support structure 120 , dropouts 111 to support the flywheel and friction resistance pad mounting structure 113 . Tubing elements 160 are typically attached by gluing or welding seams formed where two or more tubing elements are brought together to form frame 160 or other means sufficient to secure tubing elements of the frame when mated in accordance with the present design. [0041] The seat support structure 150 contains the seat post and supports the seat 140 and connects to the adjustable sliding bracket 159 . The bottom bracket shell is connected to the main support tube and the main support tube is connected to main tube 130 , the chain stays 121 run parallel to the chain and connects the main tube to the front dropouts 111 . The tube terminology used to describe the construction of the present design should be well understood by those skilled in the art. [0042] The present design may attach the driveline assembly to frame 160 . The drive-line assembly may support the pedal sub-assembly and provide a place to position the hands. The driveline assembly may comprise a pedal 161 and flywheel 110 arrangement. The pedal sub-assembly may include pedals 161 to provide the user a place to position his hands, a crank-arm 164 to attach the pedals to a chain-ring 163 and a bottom bracket bearing component and may connect a first crank-arm 164 to a second crank-arm component. The flywheel sub-assembly may include a fixed gear component 112 securely mounted and attached to flywheel. The fixed, i.e. single, gear may optionally be replaced with a cluster of gears (e.g. cassette), with appropriate shifting mechanism components allowing the user to change the amount of spinning resistance experienced while pedaling. [0043] A chain 114 or belt (not shown) component may transmit forces applied by the user spinning pedals from the pedal sub-assembly to the flywheel sub-assembly. The chain or belt component is typically configured to mate or connect a chain-ring component to the front fixed gear component by positioning the chain over the front chain-ring and over the fixed single gear, or optionally a cluster of gears, and affixing a key link (not shown) to form a single continuous chain loop, and such a design is generally known within the art. A cover 116 FIG. 5 atop the driveline assembly for purposes of protecting the user during operation and affording access to service the driveline components previously described may cover the chain, chain-ring, and fixed gear components. The present design may involve a free-wheel assembly 112 and 111 FIG. 3 or direct drive assembly (not shown) along with the chain, chain-ring 165 , and associated chain-drive components within driveline assembly to operate or spin flywheel. [0044] The present design may attach the drive unit assembly at the top of frame 160 main tube 130 as illustrated in FIG. 2 . The drive unit assembly may support the bottom bracket 168 , chain rings, crank arms and pedals allowing users a place to position their hands [0045] The present design may attach the seating assembly 140 behind the drive unit assembly located at the bottom frame element of frame 160 as illustrated in FIG. 2 . The seating assembly may support seat, or saddle 140 , and may provide users a place to position their body in accordance with the present design, while performing the simulated upper body spinning exercise. The seating assembly may include seat 140 fixed to seat post 150 sufficient to provide a sitting posture that may allow a user to properly position their body over frame 160 . The seating assembly 143 may include a seat back assembly 142 and 141 as illustrated in FIG. 4 . The seat back assembly may be connected to seat support tube 143 illustrated in FIG. 9 and may afford additional support for the rider's back and enable the rider to resist reactive force inputs generated in response to the resistance provided by the crank arms as the rider exerts force on the pedals to further accelerate the flywheel in accordance with one aspect of the present design. The seat back and seat assembly may be connected to lower main frame tube 158 and may include seat adjustment assembly 159 configured to enable the seat and back rest assembly to be moved toward or away from the drive unit assembly by means of a sliding engagement with lower main frame tube 160 . The seat adjustment assembly may be constructed of plates and connecting bolt connected to main seat support tube 150 . The adjustment assembly 159 is configured in such a manner that raising and rotating the seat and back assembly structure upwardly and forwardly releases the seat assembly and permits the seat and back rest assembly 143 to be moved either toward or away from the drive unit. After the seat assembly unit is adjusted to the preferred location the seat and back rest assembly is lowered back to the locked riding position. The seat and seat back assembly tube may be connected to telescoping tube 158 and telescoping tube is permitted to engage within main seat tube 150 in a telescoping manner such that the telescoping tube may be permitted to move collinearly within main seat tube to permit vertical adjustment of the seat and seat back assembly. A locking pin may 162 be used to secure the telescoping seat tube in position relative to main seat tube. A series of holes (not shown) may be located along the adjustment axis of telescoping seat tube 158 to enable locking pin 162 to engage respectively spaced holes and secure the seat tube in a locked position. The locking pin may be threaded and the main seat support tube may have a threaded sleeve (not shown) to permit the locking pin to be tightened against the sleeve and put pressure on the telescoping tube to prevent the tube from movement after the tube is locked in place. [0046] The seating assembly and back rest may be used in combination with the drive unit assembly to assist the user in maintaining power delivery to the flywheel while spinning the pedals to perform the simulated upper body spinning exercise. [0047] The present design may include a flywheel 110 attached to the brake stay tubes 121 in FIG. 2 at each side of the flywheel. The brake stays may include drop outs 111 attached to each brake stay tube at each side of the frame to receive the axle of the flywheel. The flywheel may be of substantial size with a substantial moment of inertia enabling the flywheel to maintain revolution against the friction device 113 and as powered by the operator to provide a smooth cycling experience for the operator. [0048] The present design may include a friction device attached to the brake stays and may be configured to contact the flywheel and exert pressure against the flywheel resisting the rotation of the flywheel and configured to enable the operator to impede the rotation of the flywheel enabling the operator to increase or decrease the amount of exertion necessary to conduct the upper body spinning exercise. The friction device may include a variably adjustable tensioning device 115 configured to be actuated by the operator while using the upper body spinning exercise device. This will be clearly shown in FIG. 1 . [0049] The present design may include rollers 119 in FIG. 2 attached to the front of the frame configured to contact the floor when the rear of the frame is lifted off of the ground to facilitate moving of the upper body spinning exercise device. [0050] FIG. 1 is a top view of the drive unit of the upper body spinning exercise device showing the bottom bracket assembly 190 , chainrings 165 and 163 , crank arms, pedals, tensioning device 115 and flywheel 110 . These parts are well known to anyone schooled in the arts of bicycles or spinning bikes. [0051] The present device may include a bottom bracket assembly attached to the main frame at the top of the main tube above the brake stay tubes. The bottom bracket device may include journaled bearings and matching shaft (not shown) configured to permit rotation of the shaft. In one embodiment of the present design the shaft may further be separated into two shafts (not shown) configured to be rotated independently of each other. In yet another embodiment of the present design the shaft 91 may be continuous FIG. 7 . The shaft or shafts are supported on bearings journaled to permit rotation of the shaft when torque is applied to the crank arms by means of the hand pedals. There may be at least one chainring attached to at lease one of the shafts configured to rotate with at least one of the pedals and at least one of the shafts enabling the operator to turn the chainring by applying torque to at least one of the pedals. The chainring may be drivingly connected to the flywheel by means of belt or chain or configured to transmit torque and rotation from the chainrings to the flywheel resulting in rotation of the flywheel when one or more of the pedals are rotated by the operator's hands. The transmission of torque from the chainring to the flywheel is not limited by the means of torque and rotation transmission. For example the transmission of torque and rotation could be conducted by a drive shaft and ring gear. The drive unit may include two independent shafts cantilevered outward from the center of the bottom bracket on both sides of the bottom bracket. A chainring may be attached to each respective shaft and a crank arm and pedal may be attached to each chainring and shaft and each combination of chainring, crank arm, pedal and shaft configured to permit rotation of each grouping of chainring, crank arm, pedal and shaft independently of the other enabling the operator to pedal in an infinite variation of torque and rotation transmitting actions from the pedals to the flywheel. [0052] FIG. 3 shows the top view of the upper body spinning exercise device. The upper body spinning device may include a flywheel 110 configured to rotate about axle. Axle may be secured in dropouts at each side of the flywheel by lock nut and washer. The flywheel may include at least one sprocket 112 configured to interact with the chain or belt enabling the operator by means of pedaling the hand pedals to impart rotation to the flywheel. The use of sprockets, chains, flywheel, freewheels, crank arms and pedals would be well understood by anyone schooled in the art of bicycles and exercise bikes. In one embodiment of the present design the flywheel may include a freewheel 111 and 112 attached to each side of the flywheel and each freewheel configured to impart rotation to the flywheel enabling an endless chain to transmit rotation of the pedals through the chainring to the flywheel enabling the operator to spin the flywheel with his arms and hands and engage in an upper body spinning exercise. In this embodiment the operator may be able to pedal either pedal and rotate the flywheel or he may pedal both pedals and rotate the flywheel in any cadence or orientation that he chooses. [0053] FIG. 4 shows a right side of the upper body exercise device with the crank arms and pedals in a 270 degree orientation relative to each other. FIG. 4 also shows the seat and seat back, the flywheel, main frame and footrests. [0054] FIG. 5 shows a left side of the upper body exercise device. In one embodiment of the device the bike may include a single set of crank arms 162 configured to attach to the drive unit at the bottom bracket. The bottom bracket is as described above and includes a single rotatable shaft secured by journaled bearings within the bottom bracket (not shown). A chainring may be attached to the shaft and crank arms 162 and pedals 161 may be attached to the shaft and chainring and configured to impart rotation to the chainring when the pedals are rotated. The chainring may be configured to engage with an endless chain 115 or belt. The endless chain or belt may be configured to engage a sprocket and the sprocket may be drivingly connected to the flywheel 110 enabling the operator to impart a rotation of the flywheel by rotating the pedals with his hands and arms. Bicycle crank arms are well known by anyone schooled in the art of bicycles. The present design may include a chain guard 116 configured to enclose the chain or belt. The chain guard shown is a partial cover of the chain and is not intended to exemplify the preferred embodiment of chain or belt protection. [0055] In one embodiment of the present design a magnetic resistance unit may 180 be attached to the frame and configured to contact the flywheel and further configured to resist rotation of the flywheel enabling the operator to increase of decrease the amount effort needed to execute the upper body spinning exercise. The magnetic resistance unit may be configured to enable variable resistance settings. The magnetic trainer may include a remote control device 181 configured to permit variation of the resistance settings by the operator while using the exercise bike enabling the user to match the resistance of the flywheel to the user's desired level of physical effort. [0056] FIG. 6 is a left side view of the upper body spinning exercise device with the user seated low and rearward on the device. In one embodiment of the upper body spinning device the drive unit may include crank arms 164 often used on and associated with conventional bicycles. Pedals may be connected to shafts journaled to engage bearings (not shown) enabling the pedals to rotate freely relative to the shafts and the shafts may be engaged with the crank arms with male threaded ends engaged in female threads in the crank arms (not shown). In one embodiment of the present device the crank arms may be in fixed orientation relative to each other and directly engaged by chain or belt with the flywheel by engagement of the drive chain or belt with a fixed sprocket or a freewheel hub configured to impart rotation to the flywheel when the user applies force to the pedals with his hands and arms. [0057] FIG. 7 shows a pair of wide cranks arms configured with chainrings 90 and pedals 94 and shaft 91 . In one embodiment of the present design the apparatus may include wide hand crank arms 93 and 92 rotatingly engaged with the bottom bracket assembly bearings. The wide crank arms may extend outwardly from the center of the upper body exercise device. This type of wide crank arms is well known to anyone schooled in the art of handcycles and they are referred to as “wide cranks” among hand cyclists. The pedals at the distal ends of the wide cranks may be thirteen inches or more from the central forward—aft axis of the exercise bike and may be nine inches in length from the axis of the bottom bracket shaft to the axis of the hand pedal. The present design is not limited to a particular length or width of crank arm but will be appreciated that the operator is able to exercise different muscles of the upper body by altering the width of the pedals and the length of the offset from the bottom bracket shaft to the pedal shaft. It will be appreciated that the wide cranks may be pedaled either in tandem or opposed further enabling the user to exercise different muscle groups. The wide crank arms may be configured to receive bearings (not shown) at their distal ends and the pedals may include a shaft (not shown) enabling the pedals to be rotatingly attached to the bearings and enabling the operator to spin the crank arms and maintain a relatively fixed orientation of the hand pedals in space as the crank arms are rotated. [0058] FIG. 8 shows a device for enabling the independent rotation of the crank arms relative to each other when the pedals are engaged by the rider and rotation is imparted by chain or belt to the flywheel. In one embodiment of the present design the drive unit may include a shaft 1 , sprockets, roller clutches 3 and 4 and drive sprocket 2 . A flange bearing 5 is journaled to accept the drive shaft and the flange bearing is configured to attach to the main frame (attachment not shown) at some distance from the bottom bracket and hand crank arms. A left hand drive 3 and a right hand drive 4 roller clutch are configured to engage the drive shaft and impart rotation the drive shaft 1 . The crank arms may be configured as above such that the drive shafts are cantilevered about the central axis of the apparatus at the bottom bracket (not shown) and each drive shaft is configured with a sprocket, crank arm and pedal as shown if FIG. 1 and each sprocket and crank arm are drivingly connected to respective left or right hand roller clutches by chain or belt and enable the rotation of either crank arm and sprocket to impart rotation to the respective roller clutches and engage the drive shaft and drive sprocket 2 and by means of chain or belt impart rotation to the flywheel. It will be appreciated that either crank arm may impart rotation singularly or in conjunction with the other crank arm. It will further be appreciated that the drive sprocket and drive shaft may rotate in either direction forwardly or rearward but may be driven only forwardly by the respective roller clutches. [0059] FIG. 9 shows a right side of one embodiment of the present design seat position. In one embodiment of the present design the upper body exercise device may include a seat bottom and seat back configured for vertical and horizontal adjustment. The seat may be configured to move horizontally toward or away from the crank arms or diagonally, vertically and horizontally up and away from the crank arms or down and towards the crank arms. It will be appreciated that there may be many means of adjustment of the seat and seat back position that would be considered part of the present design or the bottom bracket and cranks may be moved vertically or horizontally toward a stationary seat. Both embodiments may be part of the present design. [0060] FIG. 10 shows a right side one embodiment of the present design with a rider seated on the bike with his feet resting on the foot rests and his hands engaging the crank arms at a 270 degree orientation to each other. [0061] FIG. 11 is a front on view of the upper body spinning bike exercise device with the crank arms in an opposed position and the rider seated high and close to the crank arms. It will be appreciated that any seating position and crank arm orientation that engages the user comfortably with the crank arms and permits a comfortable operation of the upper body exercise device would fall within the present scope of the upper body spinning exercise device. [0062] FIG. 12 shows the bottom bracket assembly in one embodiment of the present design. Bearings 300 and 301 are shown on left and right sides of the bottom bracket shell 190 . Crank arms 162 and 166 are fixedly attached to chainrings 163 and 165 which are in turn fixedly connected by means of splined ends 302 and 303 to distal ends of splined shafts 304 and 305 respectively. It will be appreciated that rotation of crank arms 162 and 166 cause rotation of shafts 304 and 305 within bearings 301 and 300 respectively. Bearings 300 and 301 are secured in place by end caps 308 and 307 respectively. Outward movement of shafts 304 and 305 are prohibited by shoulders 306 and 307 respectively seating against inner faces of bearings 301 and 300 respectively. Through bolt 400 passes through shafts 304 and 305 respectively and is loosely secured within bearing assemblies 300 and 301 by locking nut 401 and washers 402 and 403 . It will be appreciated that through bolt 400 fits closely with the inner bore of shafts 304 and 305 in such a manner that permits rotation of shafts 304 and 305 relative to through bolt 400 . Bolt 400 acts to minimize flexing of itself and shafts 304 and 305 about their common axis and thus acts to resist wobbling of chainrings 163 and 165 when torque is applied to crank arms 162 and 166 . It will be further appreciated that the above arrangements of bearings 300 and 301 and shafts 304 and 305 permit independent rotation of cranks arms 162 and 166 and chainrings 163 and 165 to enable independent engagement of either crank arm with flywheel 110 . [0063] Operation [0064] FIG. 10 is a side view of the upper body exercise spinning device with the rider seated in the seat with his back against the seat back and the seat adjusted to permit a comfortable bend in the knees while the user's feet are resting on foot rests. The rider's hands and arms are extended forward and the rider hands are engaged with the pedals at each side of the bottom bracket. The seat and seat back are positioned such that the crank arms are mid chest and the arms are slightly bent. [0065] Thus in operation, a user may employ the present design by first adjusting the seat and seat back to a comfortable position. The user will then make a choice between wide crank arms or narrow crank arms, fixed crank arms or independent crank arms and long or short crank arms. The user will begin spinning the flywheel by engaging the hand pedals with his hands and rotating the crank arms. If the rider has chosen to ride the exercise device with fixed crank arms then he will decide on an orientation; side by side, opposed, or some angular orientation that bests suits the muscle group that the user desires to exercise at the time. The rider spins the flywheel with the respective crank orientation and adjusts the tensioning device to the desired resistance. The spinning flywheel acts to maintain motion of the crank arms and creates a smooth continuity to the spinning experience. The rider will continue to rotate the crank arms either rapidly or slowly depending on the resistance and the desired effect of the exercise; and exercise favoring strength conditioning of the upper body will favor a slow, strong and steady and rotation of the crank arms and a cardiovascular exercise will favor a rapid rotation of the crank arms against minimal resistance depending on the rider's physical condition. Riding with the wide crank arms will exercise the outer pectoral muscles and upper back and traps while riding with the narrower crank arms will exercise the biceps, deltoids and triceps. [0066] The user engaged in the operation of the upper body spinning bike in another embodiment of the present design would select a drive unit with cranks that are independently engaged with the flywheel. The user may use this configuration in a spinning class setting along with stationary bikes configured to be ridden with the user's legs. The user would pedal with one arm and then the other in varying orientations and motions; sometimes rapidly with one arm while slower with the other or both rapidly or with the pedals opposed and then in tandem switching back and forth and sometimes to the accompaniment of music or under the direction of the instructor. The rider then may switch from the upper body spinning device to a stationary spinning bike and continue exercising on the stationary spinning bike configured to exercise the legs in the class setting. [0067] The user will ride the upper body exerciser bike for some period of time depending on his physical condition for twenty minutes to more than an hour with a typical spinning class lasting forty minutes to and hour. [0068] The design presented herein and the specific aspects illustrated are meant not to be limiting, but may include alternate components while still incorporating the teachings and benefits of the invention, namely an upper body spinning exercise apparatus enabling an upper body muscle and cardiovascular exercise involving the rotation of crank arms in varying rotational orientation and varying widths engaged with a flywheel and pedaled against an adjustable resistance to enable an upper body spinning bike experience. While the invention has thus been described in connection with specific embodiments thereof, it will be understood that the invention is capable of further modifications. This application is intended to cover any variations, uses or adaptations of the invention following, in general, the principles of the invention, and including such departures from the present disclosure as come within known and customary practice within the art to which the invention pertains.
A method for doing an upper body spinning exercise whereby the operator rotates hand pedals attached to crank arms resulting in the spinning of a wheel for the purpose of exercising the upper body. This may be done in a class or group setting under the direction of an instructor and may be done to the accompaniment of music or verbal direction. The rotation of the wheel may be resisted by a friction or magnetic device and each crank arm engages the wheel independently of the other crank arm such that the operator can pedal with one hand while the other hand rests. The operator may also rotate each pedal at a different cadence than the other pedal. The operator may rotate the pedals such that the orientation of the crank arms is 180 degrees apart, 90 relative to each other or any angle of separation relative to each other.
0
This is a divisional of application Ser. No. 08/222,564, filed Apr. 4, 1994 now U.S. Pat. No. 5,466,300 which in turn is a divisional of application Ser. No. 07/970,330 filed Nov. 2, 1992 (now abandoned). BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to water-based paint booth flood sheet solutions, and more specifically to water-based paint booth flood sheet solutions with an aprotic heterocyclic oxygenate, an alkyl aryl glycol monoalkyl ether and a surfactant. 2. Description of the Prior Art It has been taught that various compounds materials can be used, in place of water, as atomized paint particle knock-down media in large industrial paint spray booths. The air in the paint spray booth that contains these paint overspray particles is pulled through grating in the bottom of the booth into and through a "curtain" or flood sheet of fluid that traps some of the paint particles as an initial step in purification clearing of the air prior to allowing the air to pass out through an exhaust stack into the outside environment. In general, water has been used as the medium in the large (100,000-200,000 gallons) flood sheet systems. However, U.S. Pat. No. 4,339,248 teaches the use of a water insoluble, high boiling plasticizer type of material as the paint-catching medium. The use of a long chain of polyether, as the paint-catching medium is disclosed in U.S. Pat. No. 4,102,303. In addition, U.S. Pat. No. 4,919,691 teaches the use of a high boiling oil and dibasic ester, and water emulsion as a flood sheet composition. The prior art attempted to improve over the use of water at cleaning paint particles out of the air stream that passed through it. However, in all cases, the materials used were high boiling materials. However, these methods do not work in the reclamation of uncured paint resin. The inclusion of these high boiling materials, which do not evaporate even at the temperatures that the paints normally crosslinked, does not work. The paint left in the "high boiling" sludge, after a distillation process, cannot be cured into a paint film. The result is cured chunks of paint floating in pools of the high boiling compounds. Rather than the expensive process of continually disposing of the high boiling paint catching compounds, once they had reached a paint saturation point, it has been known to include detackifying compounds to chemically cure the paint into hard powder particles which float to the surface of the paint catching medium and can then be easily separated. The detackified or chemically cured paint particles are no longer capable of being recycled and used as a paint. They are fully cured resin particles that are waste and require disposal. A further improvement over the use of these high boiling water insoluble compounds as the paint catching media, is disclosed in U.S. Ser. No. 07/445,314, herein incorporated by reference. A lower boiling water based solution of, for example, N-methyl pyrrolidone, tripropylene glycol mono methyl ether, di basic ester, and water is used. This type of water based solution allows the paint to be caught and solvated, without the inclusion of a detackifying agent. The paint resin is then easily recovered, via a distillation process at temperatures lower than those at which the paints cure, giving rise to a final product that is not disposed of as waste, but is in a form that can be re-used as a film forming paint. In view of the current environmental and regulatory climate, it is important to further reduce volatile organic emissions in the flood sheet spray booth. A large amount of agitation is associated with the keeping of the flood sheet fluid in continual motion. This causes an increase in the amount of volatile organic emissions being given off by the flood sheet fluid. Therefore, in spite of these disclosures, there is a need for a water-based flood sheet solution that would trap paint overspray particles, without the inclusion of a detackifying agent, and at the same time have a lower volatile organic emissions. BRIEF SUMMARY OF THE INVENTION A composition and process for reclaiming paint and volatile organic paint carrier from industrial paint spray booths without increasing VOCs and without the use of a detackifying agent has been developed. The improvement over the existing booths in which hydrophilic based fluids are recirculated is the inclusion of a water based solution containing about 10 to 45 per cent by weight of an N-alkyl pyrrolidone; about 15 to 40 percent by weight of an alkyl glycol mono alkyl ether, a surfactant present in the amount of about 0.1 to 2.0 percent by weight and the balance water. This type of flood sheet fluid, allows for the reclamation of the paint, that is removed from the air, via a distillation process at temperatures that do not cure the paint, thus allowing the paint resin to be re-used. By using this fluid, a lower level of volatile organic emissions is attained than when other hydrophilic fluids, which also allow for paint reclamation and re-use, are used. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As used herein paint spray booth(s) mean a device having a paint spraying chamber, an air movement/duct system that allows for air to pass through the chamber thereby catching in the air any paint and carrier that does not attach itself to the substrate being painted, a sump system at the bottom of the booth that recirculates a hydrophilic fluid to catch the paint and solvent carrier that is in the air prior to the air exiting the spray booth construction. We have discovered a composition and process for the improvement of the state of the art water flood sheet technology that allows for the reclaiming of paint for re-use as film forming coatings. The new process involves the replacement of the water flood sheet fluid, containing compounds which chemically alter the paint, so that the paint cannot be further used as a "paint" or film forming coating. In the present invention, the solvated paint in the solvent water solution will remain as a dissolved resin system, which is still capable of being used as a film forming paint. The solvent/water solution of the present invention may be continually fed into an on site distillation unit. This allows for the re-use of the flood sheet solution components as well as for the collection of the paint resin system for eventual re-processing into film forming paint. The composition of the present invention eliminates the need for the addition of chemical defoamers to the flood sheet fluid. The current water flood sheets, as well as the emulsion flood sheet of the prior art, require defoaming agents to be added to the flood sheet sump on a continuous basis. The vapor pressure of the solution in the present invention is lower than that of the prior art solutions. The result of this lower vapor pressure is a reduction of the volatile organic compounds being emitted into the atmosphere from the solution. One of the differences between the current invention and the prior art, concerns the fact that the paint overspray is being trapped out of the air, and then concentrated via a method that does not destroy the ability of the paint to chemically crosslink into a cured polymer. The prior art required that a detackifying agent be added to the water, that was catching the paint, so that the paint resin which was water insoluble would not attach itself to all surfaces that it came into contact with. These detackifying agents usually created alkaline conditions that chemically cured the paint. The paint resin was no longer tacky, but it could not be re-used as a resin in a paint or adhesive formulation. When the paint is added to the flood sheet outlined in the present invention, the resin is solvated by the solution, and is rendered non-tacky. No chemical reaction occurs. Thus, the paint resin is still in a form that can be utilized as a paint or adhesive resin. When this resin is concentrated in a manner that does not subject the resin to a temperature of 145° C., the resin system does not crosslink, leaving open the option for using the concentrated resin for re-formulating into other products. The flood sheet solution used in this process comprises a solution of N-alkyl pyrrolidone, and most preferably N-methyl pyrrolidone (NMP). For convenience of description, this component will be identified as NMP. The preferred solvents should be economical and have the appropriate volatility. The solvent used should be volatile, and hence, the most completely recovered during the distillation process. It is preferred that the N-alkyl pyrrolidone be present in the composition in an amount of about 10.0 to about 45.0 percent, by weight, and more preferably about 20.0 to about 30.0 percent, by weight. The vapor pressure of NMP is depressed when mixed with water, but this phenomenon is reversed as the water is removed during the initial part of the distillation. The result of the vapor pressure of NMP and its relationship to moisture content, allows for both low NMP evaporation rates while the paint booth circulation system is in operation, as well as for a cleaner separation of the NMP and water during the distillation. During use of the flood sheet spray booth, water begins to evaporate out of the flood sheet solution, the vapor pressure of the NMP begins to increase at a rate that is proportionate to the amount of water left in the distillate. The NMP will thus not begin to distill over, until most of the water is already separated out. In addition to NMP, it is preferred that compounds having propylene oxide monomer units terminated at each end with a hydroxy group be used in the composition. Suitable compounds include one or more alkyl glycol mono alkyl ethers, having an alkyl glycol oligomer portion containing 1, 2 or 3, C 1 to C 8 repeating units which are terminated at each end by a hydroxy group, and wherein the alkyl moiety of the alkyl ether portion has 1 to 4 carbon atoms. For example, mono alkyl ether derivatives having one to four carbon atoms in the alkyl moiety may be used. More preferably, tripropylene glycol mono methyl ether is used. The amount of the alkyl glycol mono alkyl ether used is generally from about 15 to about 40 percent by weight, preferably from about 20 to about 30, by weight. Solvents that are also suitable include n-butoxy ethanol, triethylene glycol phenyl butyl ether, propylene glycol phenyl butyl ether, and dipropylene glycol-N-butyl ether, dipropylene glycol mono methyl ether and the like. It is most preferred that the N-alkyl pyrrolidone and the alkyl glycol mono alkyl ether be present in the composition in an amount substantially the same by weight. The most preferred amounts for each of the components are about 20 to about 30 percent by weight. The surfactant constituent is present in the invention because it was unexpectedly discovered that with the surfactant present in the solution, the actual vapor pressure of the fluid was less than the actual vapor pressure of the solution with the surfactant not present. The non-ionic surfactant type preferred is biodegradable and should be compatible with NMP and alkyl glycol mono alkyl ether. It is most preferred that the non-ionic surfactant be a linear alcohol alkoxylate. The linear alcohol alkoxylate of choice is commercially available as PLURAFAC® RA-40 (BASF Corporation), and is generally used in the amount of from about 0.1 to about 2.0 weight percent, preferably from about 0.5 to about 1.0 weight percent. In using the above-described composition and process, the chemicals which are placed into the current water flood sheets will not be required for the maintenance of a stable paint booth re-circulation system. However, these chemicals, which include, for example, fungicides, bactericides, defoamers, flocculates and detackifers, should be readily soluble in solutions of the present invention, with no decrease in the chemical activity associated with said chemicals. Thus, they can be used as desired and/or needed, without changing the scope of the instant invention. The following examples serve to further illustrate the present invention and should in no way be construed as limiting the scope thereof. EXAMPLE 1 A flood sheet fluid having the following formulation was prepared. ______________________________________ Weight Percent______________________________________N-Methyl Pyrrolidone 29.0 × 20 580.0.sub.gTripropylene glycol mono methyl 29.0 × 20 580.0.sub.gether (TPM)Plurafac ® RA-40 0.6 × 20 12.0.sub.gWater 41.4 × 20 828.0.sub.gTOTAL 2000.0.sub.g______________________________________ Preparation The N-methyl pyrrolidone, TPM, and Plurafac® RA-40 were added to the mixing vessel. The order of addition was not critical. These components were mixed at a slow speed for approximately 15-20 minutes. After these components were mixed, the water was then added to the mixing vessel and the entire formulation was then mixed at a slow speed for an additional 2 minutes. EXAMPLE 2 Four hundred grams of the solution described in Example 1 was weighed into a 1000.0 ml pyrex beaker. A 2 inch magnetic stirring bar was added to the beaker also. Weighed into the flood sheet solution was 40.0 g of BASF Corporation automotive clear coat paint #E04CK303 (a melamine crosslinked thermoset acrylic, containing as part of its solvent package xylene, Aromatic 100, n-butanol, and methyl ethyl ketone). The mixture of paint and flood sheet solution was blended at a medium speed with a magnetic stirrer, for 20 minutes. After 20 minutes, the mixing was discontinued, and the mixture was poured into a 500 ml pyrex distillation pot. A one inch stirring magnetic was added to the pot also. The pot was then placed into an insulated electric heating jacket, and the jacket assembly was placed onto a magnetic stirrer. The pot/heating jacket assembly was attached to a 12 inch tall pyrex reflux column that was insulated with fiberglass matte. The top of the reflux column emptied into a 12 inch long water jacketed, distillate condensation tube, that emptied into a 500 ml condensate collection pot assembly in order to apply a vacuum on the whole system. A vacuum of 50 mm Hg was applied to the system, and the temperature was gradually raised up to 120° C.±2° C. The temperature was maintained at 120° C.±2° C. for 80 minutes, and then the distillation process was shutdown. During the entire process of heating and distilling the paint/flood sheet mixture, the distillation pot was agitated with the magnetic stirrer at a medium speed. The 50 mm Hg vacuum was applied to the system for the entire duration of the heating and distillation process. Some of the paint and solvent (122.7 g) was retained in the distillation pot at the end of the distillation. This paint was saved in a sample bottle for use in a paint cure test. EXAMPLE 3 Four hundred grams of the solution described in Example 1 was weighed into a 1000.0 ml pyrex beaker. A 2 inch magnetic stirring bar was added to the beaker also. Weighed into the flood sheet solution was 40.0 g of BASF Corporation automotive paint, Flame Red #E55RD021 (a crosslinked thermoset polyester urethane with part of its solvent package consisting of water, n-butanol, and Aromatic 100.) The mixture of paint and flood sheet solution was blended with a magnetic stirrer, at a medium speed for 20 minutes. After 20 minutes, the mixing was stopped, and the mixture was poured into a 500 ml pyrex distillation pot. A one inch stirring magnet was added to the pot also. The pot was then placed into an insulated electric heating jacket, and the jacket assembly was placed onto a magnetic stirrer. The pot/heating jacket assembly was attached to a 12 inch tall pyrex reflux column, that was insulated with fiberglass matte. The top of the reflux column emptied into a 12 inch long, water jacketed, distillate condensation tube, that emptied into a 500 ml pyrex condensate collection pot. A vacuum hose was attached to the condensate collection pot assembly in order to apply a vacuum on the whole system. A vacuum of 50 mm Hg was applied to the system, and the temperature was gradually raised to 121° C.±2° C. The temperature was maintained at 121° C.±2° C. for 120 minutes, after which time, the distillation process was shutdown. During the entire duration of the heating up and distilling of the paint/flood sheet mixture, the distillation pot was agitated with the magnetic stirrer at a medium speed. Also, the 50 mm Hg vacuum was applied to the system for the entire duration of the heating up and distillation process. Some of the paint and solvent (112.97 g) was retained in the distillation pot at the end of the distillation. This paint was saved in a sample bottle for use in a paint cure test. EXAMPLE 4 Four hundred eight grams of the solution described in Example 1, was weighed into a 1000.0 ml pyrex beaker. A 2 inch magnetic stirring bar was added to the beaker also. Weighed into the flood sheet solution was 40.8 g of BASF Corporation automotive paint, Flash Red #E174RE022 (a melamine crosslinked thermoset acrylic, containing as some of its solvent package xylene, Aromatic 100, n-butanol and methyl ethyl ketone). The mixture of paint and flood sheet fluid was blended with a magnetic stirrer, at a medium speed for approximately 20-25 minutes. After the 20-25 minutes of mixing, the magnetic stirrer was shut off, and the mixture was poured into a 500 ml pyrex distillation pot. A one inch stirring magnet was added to the pot also. The pot was then placed into an insulated electric heating jacket, and the jacket assembly was placed onto a magnetic stirrer. The pot/heating jacket assembly was attached to a 12 inch tall pyrex reflux column, which was insulated with fiberglass matte. The top of the reflux column emptied into a 12 inch long, water jacketed, distillate condensation tube, that emptied into a 500 ml pyrex condensation collection pot. A vacuum hose was attached to the condensate collection pot assembly, in order that a vacuum could be applied to the whole system. A vacuum of 50 mm Hg was applied to the whole system, and the temperature was gradually raised to 120°-122° C. The temperature was maintained at 120°-122° C. for 105 minutes, after which time, the distillation process was shutdown. During the entire duration of the heating up and distilling of the paint/flood sheet fluid mixture, the distillation pot was agitated with the magnetic stirrer at a medium speed. Also, the 50 mm Hg vacuum was applied to the system for the entire duration of the heating up and distillation process. Some of the paint and solvent (135.0 g) was retained in the distillation pot at the end of the distillation. This paint was saved in a sample bottle for use in a paint cure test. EXAMPLE 5 The following paint cure test were carried out to demonstrate the fact that the paint, which had been added to the flood sheet solution and concentrated via distillation, still maintained the ability to crosslink into polymeric films. Thus, it still is in a form that is useful for re-formulation into coatings or adhesive systems. Three 3 inch×5 inch× 1/8 inch pieces of mild steel were placed into a room temperature (25° C.) bath of N-methyl pyrrolidone to clean any rust or grease off the surface. The steel panels were removed from the bath after 15 hours. After rinsing with tap water, the panels were wiped dry with a paper towel, and quickly rinsed with acetone to prevent any flash rusting from occurring as the water evaporated off of the panels. The panels were set out at room temperature to air dry for 48 hours prior to any paint being applied to their surfaces. A thin film (about 0.010 inch thick) of the paint/solvent retained that was saved from the distillation carried out in Example 2, was applied in a 2-3 inch wide strip down the middle of one of the mild steel panels described above. The paint was applied with a polyester bristle brush. The paint was of the panel long enough to allow for it to flow together and fill in any open spaces or brush marks on the film surface, prior to being placed into the oven for curing. The panel was labeled 5B. A thin film (about 0.010 inch thick) of the paint/solvent retained that was saved from the distillation carried out in Example 3, was applied in a 2-3 inch wide strip down the middle of one of the mild steel panels described above using the method described above with respect to panel 5B. This panel was labeled 5C. A thin film (about 0.010 in thick) of the paint/solvent retained that was saved from the distillation carried out in Example 4, was applied to one of the mild steel panels described above, in a 2-3 inch wide strip down the middle of the panel using the method described above with respect to panel 5B. This panel was labeled 5D. Panels 5B, 5C and 5D were placed onto the bottom shelf of a forced air convection oven, that had the temperature already pre-heated, and set at 140° C.±5° C. The samples were removed from the oven after 1 hour and 40 minutes time. The samples were allowed to cool down to room temperature, and in 2 hours time after exiting the oven, the following observations were made: Paint 5B--cured into a hard polymeric film. Paint 5C--cured into a hard polymeric film. Paint 5D--cured into a hard polymeric film. Whereas particular embodiments of the invention have been described above for purposes of illustration, it will be appreciated by those skilled in the art that numerous variations of the details may be made without departing from the invention as described in the appended claims.
A composition for reclaiming paint and volatile organic paint carrier from industrial paint spray booths without increasing VOCs has been developed. The improvement over the existing booths recirculating hydrophilic based fluids, is the inclusion of a water based solution containing about 10 to about 45 per cent by weight of one or more N-alkyl pyrrolidones, about 15 to 40 percent by weight of one or more alkyl glycol mono alkyl ethers, a surfactant present in the amount of about 0.1 to 2.0 percent by weight, and the balance water.
2
BACKGROUND OF THE INVENTION The present invention is directed to the field of wells such as water wells, and is more specifically directed to a method and apparatus for effecting an opening in the well casing of such a well which is surrounded by grouting in the form of a wall of cement or the like. For wells such as water wells which are sunk vertically into the ground, the state laws of the various states require that the casing of the well be surrounded by grouting in the form of a cylindrical wall of cement or the like to a depth below the horizontal take-off pipe, the exact depth and width of the grouting being determined by the law of the particular state. Heretofore, it has been necessary to effect the connection between the horizontal take-off pipe and the vertical pipe of the well by first drilling through the cement grouting at the location where the horizontal take-off pipe is to be placed, and then drilling an opening through the pipe casing. It is not sufficient to drill straight through the grouting into the interior of the well casing, as an adapter having a diameter larger than that of the opening is commonly used on the outside of the well casing to effect the connection between the horizontal take-off pipe and the vertical pipe. Therefore, an area having a diameter larger than both the opening to be made in the well casing and the adapter must be cleared in the cement wall, and then the opening must be drilled in the well casing. This procedure is time-consuming and requires special tools and is therefore expensive. A further complication is that several different, standard sizes of pipe, e.g. 5 inches and 8 inches, can be used for the well casing. It is the solution of this and other problems which the present invention is directed. SUMMARY OF THE INVENTION Therefore, it is the primary object of this invention to provide a method and apparatus for effecting an opening in a well casing which avoids the necessity of clearing the cement grouting wall from the site of the opening. It is another object of the invention to provide a method and apparatus for effecting an opening in a well casing which can be used with well casings of different sizes. The foregoing and other objects are achieved by provision of a casing attached implement for placement at the site of the opening in the well casing comprising a tubular fitting having a circular cross-section, a holding element attached thereto for holding the fitting in place against the well casing, and first and second covers matingly engaging the ends of the fitting. The first end of the fitting has a cylinder portion surface adapted to matingly receive a portion of the side of a first cylinder having a first axis of curvature and a first diameter, while the second end of the fitting has a cylinder portion surface adapted to matingly receive a portion of the side of a second cylinder having a second axis of curvature substantially perpendicular to the first axis of curvature of the first cylinder and a second diameter different from the first diameter. The fitting also includes first and second pairs of internally-threaded, opposed apertures. The holding element is attached to the fitting at one pair of opposed apertures, and a pipe fitting for receiving the conduit which houses the electrical cable of the well pump is attached to one of the other pair of opposed apertures. The remaining aperture is closed by a plug. The method for effecting the opening in the pipe casing is achieved by disposing the well casing in a well shaft in the ground concentric with the well shaft and providing on the outer surface of the well casing in the vicinity in which the opening is to be made a casing element substantially as described above for protecting the outer surface of the well casing and the surrounding area thereof. A grouting wall of cement or the like is formed in the well shaft around the well casing, an access shaft is excavated in the ground next to the retaining wall to expose the outwardly facing cover of the casing element, the exposed cover of the casing element is removed, and the remaining cover of the casing element and the well casing are drilled to effect the opening. A better understanding of the subject invention will be achieved when the following written description is considered in conjunction with the appended drawings. DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation, partially cut away and in section, illustrating a preferred embodiment of the invention in connection with a water well of standard configuration; FIG. 2 is an exploded, perspective view of the embodiment of the invention illustrated in FIG. 1; FIG. 3 is a perspective view of the embodiment as illustrated in FIG. 2, assembled and placed on the well casing; FIG. 4A is a side elevation which illustrates an initial step in the practice of the invention as shown in FIG. 3 with the pipe casing disposed in the ground and the grouting being poured; FIG. 4B is a side elevation view, partially cut away, illustrating a subsequent step including provision of an access shaft excavated in the ground next to the casing element of the invention, the exposed cover of the casing being removed and a drill inserted into the casing element; FIG. 4C is a side elevation, partially in section and exploded illustrating a step subsequent to that of FIG. 4B; FIG. 4D is a cross-sectional view of the well casing and embodiment of the invention illustration a subsequent step to that illustrated in FIG. 4C, with the vertical water pipe of the well being placed in the adapter; FIG. 5 is a cross-sectional view of the invention in connection with a water well taken along lines 5--5 of FIG. 1; FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 5; FIG. 7 is a side elevational view, partially in section, taken along lines 7--7 of FIG. 6; and FIG. 8 is a side elevational view of the embodiment illustrated in FIG. 7 with a ground wire connected to the bottom of the casing element. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1, there is illustrated a water well 10 of a standard configuration well known in the art installed in the ground G, but employing a casing fitting 100 according to the invention for effecting an opening in the well casing of the well. Water well 10 comprises a cylindrical casing 12, a vertical water pipe 14 positioned concentrically in well casing 12, a horizontal take-off pipe 16 through which water W is removed from water pipe 14, and a pitless adapter 18 for connecting water pipe 14 to take-off pipe 16 through an opening 20 in well casing 12. A pump 22 is connected to water pipe 14 below the water line L for pumping water W through water pipe 14. A motor 24 is connected to the bottom of pump 22 for operating pump 22, an electrical cable 26 is connected to an electrical supply (not shown) at one end and to motor 24 at the other end to supply power to motor 24, and a torque arrestor 28 is positioned around water pipe 14 above pump 22 to absorb the thrust of motor start-ups and keep water pipe 14 centered in well casing 12. A well cap 30 removably covers the top of well casing 12 for protecting the interior of well 10 and providing access thereto. An electrical conduit 32 for protecting electrical cable 26 underground is positioned adjacent and parallel to well casing 12. As previously stated, these parts are well-known in the art, and their construction and operation as also well-known. In accordance with the laws of the various states, well casing 12 is surrounded by a grouting wall R of concrete or the like down to a depth below the point where take-off pipe 16 is connected to water pipe 14. The exact depth and width of wall R are specified by the particular state law. In order to effect an opening in well casing 12 through retaining wall R, the casing element 100 according to the invention is used. Referring now to FIGS. 2 and 3, casing fitting 100 comprises a tubular fitting 102 having a circular transverse cross-section and having first and second ends 104 and 106, a holding device or means 108 including a coil spring 130 attached to fitting 102 for adjustably holding fitting 102 in place against well casing 12, and first and second covers 110 and 112 for matingly engaging first and second ends 104 and 106, respectively. First end 104 of fitting 102 has a cylinder portion surface 114 adapted to matingly fit against or engage a portion of the side (i.e., a portion of the outer surface) of a first cylinder having a first axis of curvature and a first diameter, while second end 106 of fitting 102 has a cylinder portion surface 116 adapted to matingly fit against or engage a portion of the side of a cylinder having a second axis of curvature substantially perpendicular to the first axis of curvature of the first cylinder and a second diameter different from the first diameter. The first and second diameters of the first and second cylinders, respectively, correspond in length to the outside diameters of standard size pipe casing, for example, 5 inches and 8 inches. Thus, casing fitting 100 can be used on two different sizes of standard pipe casing, depending upon whether first cover 110 or second cover 112 is placed against the outer surface of the well casing. Casing fitting 100 can be used on other sizes of pipe casing by attaching an adapter, such as foam pad 113, to whichever of covers 110 or 112 is placed against the outer surface of the well casing, as shown in FIG. 2. By making the adapter of a thick (e.g. approximately 1/2-1 inch) compressible and resilient material, such as foam, a great number of variations in pipe diameter can be accommodated. Because first and second surfaces 114 and 116 are adapted to matingly engage cylinders of different diameters the length of fitting 102 between ends 104 and 106 will vary slightly over the circumference of fitting 102. However, this variance is sufficiently small that the width of fitting 102 can be made to substantially equal to the width of grouting wall R. Where the well shaft has been made too wide, an adapter pad 113 can be used as shown in FIG. 2 to take up the extra space between fitting 102 and the wall of the well shaft. A tunnel in grouting wall R can thus be created between the area in which opening 20 is to be effected and the ground G surrounding retaining wall R, with at most a thin, easily removable shell of cement over whichever of covers 110 and 112 is outermost. Fitting 102 also has a first pair of internally-threaded opposed apertures 118 and 120 positioned on a diameter of fitting 102 parallel to the first axis of curvature of the first cylinder, and a second pair of internally-threaded opposed apertures 122 and 124 of the same size of the first pair and positioned on a diameter of fitting 102 parallel to the second axis of curvature of the second cylinder, for a purpose to be described in detail hereinafter. First and second pairs of apertures 118 and 120 and 122 and 124 are therefore diametrically positioned substantially mutually perpendicular to each other on fitting 102, i.e., apertures 118, 120, 122, and 124 are evenly spaced around the circumference of fitting 102. However, first pair of apertures 118 and 120 need not be on the same circumference of fitting 102 as second pair of apertures 122 and 124. In fact, if each pair of apertures is centered between ends 104 and 106 as shown in FIGS. 2 and 3, then they must be on different circumferences of fitting 102. Holding device 108 comprises a pair of externally-threaded plugs 126 and 128 adapted to matingly engage either of first and second pairs of apertures 118 and 120 and 122 and 124 (as illustrated herein, first pair of plugs 118 and 120), coil spring 130 of sufficient length when attached to fitting 102 to encircle pipe casing 12, and rotary coupling means 127 for attaching coil spring 130 to plugs 126 and 128. As illustrated in FIGS. 2 and 3, a block 132 is attached to the end of each plug 126 and 128, block 132 having a hole 134 extending therethrough, and a cotter pin is attached to each rotary coupling means 127 for insertion into hole 134. It should be understood that holding device 108 is not to be limited to a coil spring, but that the resilience of coil spring 130 enables the position of fitting 102 to be easily changed in either direction along the vertical axis of well casing 12, while providing engagement between well casing 12 and either of first and second covers 110 and 112 of casing fitting 100. The rotary couplings 127 permit the spring 130 to roll down the casing when moved from the top of the casing to its use position illustrated in FIG. 1. An externally-threaded plug 138 is provided to matingly engage one of the second pair of apertures 122 and 124, while an externally-threaded pipe fitting 140 is provided to matingly engage the other of the second pair of apertures 122 and 124 to matingly receive electrical conduit 132. Because mating plugs 118, 120, and 138 and pipe fitting 140 are all interchangeable in apertures 118, 120, 122, and 124, the orientation of casing fitting 100 with respect to well casing 12 can easily be changed to accommodate well casings of two different diameters. Specifically, if first cover 110 were to be placed against well casing 12, plugs 126 and 128 would be placed in apertures 122 and 124 to attach holding device 108, and plug 138 and pipe fitting 140 would be placed in apertures 122 and 124. Likewise, if second cover 112 were to be placed against well casing 12, fitting 102 would be rotated 90 degrees, and as shown in FIGS. 2 and 3, plugs 126 and 128 would be placed in apertures 118 and 120 and plug 138 and pipe fitting 140 would be placed in apertures 124 and 122. It should be understood that apertures 118, 120, 122, and 124, plugs 126, 128, and 138, and pipe fitting 140 need not be threaded as long as some kind of sealing engagement is made between them, for example by gluing, so that unset cement cannot enter fitting 102 when plugs 126, 128, and 138 and pipe fitting 140 are in place. First and second covers 110 and 112 are attached to fitting 102 by an adhesive or by molding or by other means which provides a relatively good seal between covers 110 and 112 and fitting 102 but which still can be cut through by a knife or similar sharp-edged implement to allow cover 110 or 112 to be pried off using a screwdriver or the like. By a relatively good seal is meant a seal sufficient to prevent covers 110 and 112 from popping off or becoming dislodged if a rock or other small obstruction is encountered while casing fitting 100 is being positioned. Preferably, fitting 102, plugs 126, 128, and 138 are made from PVC plastic. However, other materials for fitting 102 which can easily be cut or otherwise formed to the necessary configuration and stand also the weight of the surrounding grouting cement, are suitable, and plugs 126, 128, and 138 can be made of any material compatible with fitting 102. Pipe fitting 140 (and conduit 32 which is attached thereto) preferably are formed of a metal which will not melt when subjected to heat from a torch as discussed hereafter. First and second covers 110 and 112 also preferably are made of PVC plastic, although other materials are suitable. In choosing a material for covers 110 and 112, it is preferable to choose a material which is flexible, so that covers 110 and 112 can be cut or otherwise formed from a planar piece of material, then bent upon assembly to engage surfaces 114 and 116. However, this characteristic only makes assembly of covers 110 and 112 easier, and is not absolutely necessary. If covers 110 and 112 are molded then they should be sufficiently thin to be readily cut through by a sharp tool for removal from fitting 102. Each cover 110 and 112 can also include a center mark 146, embossed in the material or added using a marking device, for a purpose to be described hereinafter. Referring now to FIGS. 4-8, and more particularly to FIGS. 4A-4D, there is illustrated the method of the invention. In the method of the invention, a well shaft is provided in the ground G, the bottom portion 150 of which corresponds substantially in diameter to the diameter of well casing 12, and the top portion 152 of which has a diameter greater than the diameter of well casing 12 to provide an open clearance space between the outer surface of well casing 12 and the surrounding earth, the depth and width of the top portion 152 being dictated by the depth and width of the grouting wall R to be formed. Well casing 12 is then disposed in the hole, and casing fitting 100 is positioned on well casing 12 so that fitting 102 covers the exact location in which opening 20 is to be effected and pipe fitting 140 faces the top of the well, with electrical conduit 32 connected to pipe fitting 140. Alternatively, casing fitting 100 can be placed on well casing 12 before well casing 12 is disposed in the well shaft. Conveniently, electrical conduit 32 can be used to move casing fitting 100 vertically and horizontally on well casing 12 to its precise position. Grouting cement is then poured into upper portion 152 of the hole and allowed to harden, forming grouting wall R. As shown in FIG. 4B, once grouting wall R has been formed, an access shaft 154 is excavated next to grouting wall R parallel to electrical conduit 32 down to the depth of casing fitting 100, exposing outward facing first cover 110 (see FIG. 3). If a thin shell of cement is present, it can easily be chipped away with hand tools, such as a chisel. Cover 110 is then removed, for example by loosening the adhesive with a knife and prying cover 110 away with a screwdriver. A drill 156 having a circular bit 158 can then be inserted into access shaft 154 with circular bit 158 placed inside fitting 102. An opening is then drilled through cover 112 and well casing 12, using center mark 146 as a guide for placement of circular drill bit 158. A torch can be used in place of drill 156 to effect the opening through cover 112 and well casing 12. Because a torch will melt PVC plastic, all parts which are needed and must remain intact after the opening is effected, i.e. fitting 140 and conduit 32, must be made of a metal which will not melt when subjected to the heat from the torch. Once opening 20 has been effected, adapter 18 can be installed according to standard procedures. As shown in FIGS. 4C and 4D, the opening in grouting wall R provided by fitting 102 is large enough to receive the outer washer 160, outer contoured spacer 162, and outer nut 164 of pitless adapter 18; these are then used to secure inner washer 166 and inner sleeve 168 of pitless adapter 18 inside pipe casing 12. At this stage, electrical cable 126 is threaded into electrical conduit 32; and joint 170, which holds water pipe 14, can be inserted into inner sleeve 168. It should be noted that electrical conduit 26 can be fed into the ground G via fitting 102, as shown in FIGS. 4D and 6, or via electrical conduit 32 above fitting 102, as alternatively shown in FIG. 6. Thus, it will be seen that all embodiments of the present invention provide a unique method and apparatus for effecting an opening in the casing of a well surrounded by a grouting wall of cement or the like. Moreover, the operation of the device is both effective and easy to accomplish so as to render use of all embodiments convenient to users. While preferred embodiments of the invention have been disclosed, it should be understood that the spirit and scope of the invention are to be limited solely by the appended claims, since numerous modifications of the disclosed embodiments will undoubtedly occur to those of skill in the art.
A device for easily permitting effecting an opening in a well casing having a grouting wall therearound comprises: a tubular fitting having a circular transverse cross-section and having a first end and a second end, the first end configured to matingly engage the outer surface of the well casing, the length of said tubular fitting between the first and second ends thereof being substantially equal to the thickness of the grouting wall, a closure over the second end, and a coil spring attached to the tubular fitting for urging the first end of the tubular fitting against the outer surface of the well casing and for holding the tubular fitting in position on the casing. A method of providing a well casing to which access through surrounding grouting can be easily effected comprises the steps of positioning a well casing in the earth with an open clearance space between the outer surface of the well casing and the surrounding earth extending downwardly from the surface, positioning and holding a tubular fitting against the casing with one end of the fitting matingly engaging the surface of the casing and an opposite closed end being adjacent the surface of the surrounding earth, filling the clearance space with grouting, and permitting the grouting to harden.
4
FIELD OF THE INVENTION The present invention relates to the production of natural gas from coal seams penetrated by a plurality of wells. More particularly, the present invention pertains to a method of recovering natural gas from a coal seam that prevents or inhibits water invasion of the coal seam. BACKGROUND OF THE INVENTION The natural gas found in coal is believed to have originated from the coal during its formation; and as such, coal is both the source and the reservoir rock. The natural gas in coal is typically composed of methane, more so than natural gases from other sources. Hence, this resource is commonly called coalbed methane. Coal has the ability to hold large quantities of natural gas despite its low porosity. The reason for this large storage capacity is that the natural gas is stored as an adsorbed gas at near liquid density. This adsorption capacity is related to the fine pore structure of coal, where the majority of the porosity exists as micropores whose size is just slightly greater than molecular dimensions. These micropores result in a large internal surface area which can easily exceed 100 m 2 /gm, and it is on this large surface area where the natural gas molecules are held by adsorption. This fine pore structure is nearly absent in sandstone and carbonates. For example, a sandstone has an internal surface area closer to 1 m 2 /gm. In these types of reservoirs, the natural gas is stored in less concentrated form as free gas. As a result, much greater porosities than those found in coal are required in sandstones or carbonates in order to store an equivalent amount of natural gas. For example, a 20 ft coal seam having a density of 1.5 gm/cc and a gas content of 500 SCF/ton contains over 13 BCF/section. A sandstone or carbonate of the same thickness would need a porosity of over 34% to have the same amount of gas-in-place at reservoir conditions of 1000 psia and 100° F. While gas is primarily stored in the micropores of the matrix, water is stored in the natural fractures of the coal--called cleats. It is through this cleat system that the microporous matrix is connected to a well drilled into the coal seam. Usually, the coalbed methane production process begins by drilling at least one wellbore into the coal seam. At first a well typically produces water, contained in the cleat networks of the coal seam, and a small proportion of gas from the coal matrix. As the cleats are dewatered, the reservoir pressure near the wellbore is reduced. This lowering of reservoir pressure releases some gas from the surface of the coal. The gas migrates from the micropores of the coal matrix into the cleats. As water is produced from the coal, the water saturation in the cleats is reduced and the ability of the gas to flow in preference to water improves, i.e., the relative permeability to gas increases. Most coal seams are also water aquifers. Consequently, an important consideration in a coalbed methane recovery project is the rate at which water migrates from the flanks of the coal seam into the coal cleats adjacent to the wellbore. In order to maintain or improve gas deliverability of a well, continuous production of fluids can be essential. If several wells in a field are shut-in for a considerable period of time, it is possible that water can invade the dewatered portions of the coal seam. Therefore, when the wells are put back on production, resumption of gas recovery at rates comparable to those achieved prior to shut-in may take considerable time and effort. The water influx to a coal well can have significantly reduced the gas relative permeability of coal during the shut-in period. In commercial coalbed methane recovery projects, lack of demand for gas often forces operators to temporarily shut in some or all of the wells. Over time, the cleat networks in the coal adjacent the shut-in wells will be invaded with water originating from the flanks of the coal seam. As a result, the cleats in the coal adjacent to the wellbore have to be dewatered again before significant gas production resumes. Under some circumstances, it can take several months for the gas rates to return to the pre-shut-in production rates. Unfortunately, this lag period usually occurs when high gas rates are required to meet demand. If the demand for gas fluctuates routinely during the life of a coalbed methane recovery project, then shutting in wells during low demand and producing them during high demand can become a very inefficient method of operating a coalbed methane recovery project. An alternative to shutting in the wells is to flare the excess gas. This has the desirable effect of keeping the cleat networks in the coal adjacent the well saturated with gas, but it has the undesirable effect of reducing total amount of natural gas available for sale, thereby wasting precious natural resources. There is a need for an alternative to shutting in wells during low demand for natural gas produced from coal seams without flaring the gas. U.S. Pat. No. 4,544,037 to Terry discloses a method of initiating production of methane from wet coalbeds. The abstract states, "Rather than pumping water to lower the hydraulic head on the seam to permit desorption of methane within the coal, high pressure gas is injected into the seam to drive water away from the wellbore. Gas injection is terminated, and the well is open to flow". This patent does not disclose or suggest any method to handle fluctuations in gas demand in a coalbed methane project. Nor does it address means to minimize water influx during well shut-in. In an article published in Ninth World Energy Conference Transaction, Vol. 2, 1975, pp. 103-118, the use of abandoned coal mines for gas storage is recommended. Although storing surplus gas in the void areas created in a coal seam after mining operations have been completed can be a feasible alternative to shutting in coalbed methane wells when gas demand is low, an abandoned coal mine may not be located close to a coalbed methane recovery project. U.S. Pat. No. 4,623,283 to Chew discloses methods for preventing the introduction of water from a sandstone above the coal seam into a mine cavity from which combustion process gases are removed. All of the methods provide a barrier between the water sand and the mined coal cavity to prevent excessive water influx. The Chew patent does not disclose or suggest any techniques for inhibiting the migration of water within the coal seam itself during well shut-in. There is a need for an efficient method of operating a coalbed methane recovery project when the demand for gas fluctuates during the life of the project without allowing the migration of water to invade the coal cleats adjacent to a wellbore. There is a need for an efficient method of producing gas from a coal seam at reduced rates during low demand without flaring the gas produced, and subsequently producing at high rates during high demand. SUMMARY OF THE INVENTION The present invention involves a method for producing gas from a coal seam penetrated by at least two wells, comprising removing natural gas and liquid from the coal seam through at least one of the two wells, separating natural gas from the liquid, and injecting at least a portion of the separated natural gas into the coal seam through a second of at least two wells while continuing to remove natural gas and liquid from the coal seam. By utilizing the present invention, the operator of a coalbed methane recovery field can avoid dewatering the coal seam each time the demand for natural gas produced from the coal fluctuates without the need for flaring the natural gas. By continuing to produce natural gas from the coal seam, a high relative permeability to gas can be maintained in the coal cleats adjacent to the producing wells. While gas is continuously flowing through the coal cleats it is difficult for water at the flanks of the coal seam to invade the coal cleats adjacent to the producing wells. By reinjecting the natural gas back into the coal seam, the gas can be temporarily stored until demand increases. BRIEF DESCRIPTION OF DRAWING FIG. 1 is a schematic diagram illustrating that the volume of natural gas contained in coal is a function of reservoir at a fixed temperature. FIG. 2 is a schematic diagram illustrating how the relative permeability to gas and water in a coal seam may vary as a function of water saturation in the coal seam. FIG. 3 is a schematic diagram illustrating a five-spot well pattern the demand for gas is high and all of the wells in the coal field are producing. FIG. 4 is schematic diagram illustrating a five-spot well pattern where demand for gas is curtailed and partial recycling of gas occurs. FIG. 5 is a schematic diagram illustrating a 5 spot well pattern where demand for gas is reduced and complete recycling of gas occurs. FIG. 6 is a schematic diagram illustrating the comparison of gas rates from a coal field comprising 5 wells after the gas production was shut in and after the field is put on complete recycle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT In the degasification of a coal seam, a plurality of wells are drilled through the coal seam to produce natural gas contained within the coal adjacent to the wells. Initially, the wells produce as a major portion water and as a minor portion gas, because the high initial water saturation in the coal cleats adjacent to the wells reduces the relative permeability to gas and the high reservoir pressure inhibits the desorption of natural gas from the surface of the coal adjacent the wellbores. As is known to those skilled in the art, the amount of natural gas stored in a coal seam at a fixed temperature is dependent upon reservoir pressure, as shown in FIG. 1. As the reservoir pressure decreases, the amount of gas stored in the coal seam likewise decreases. FIG. 2 illustrates that when the water saturation in the coal seam is relatively high in comparison to the gas saturation, the relative permeability to gas is low. Correspondingly, when the water saturation in the coal seam is low, the relative permeability to gas is high, and the gas saturation is high. After the water saturation in the coal cleats adjacent to the wellbore has been reduced, the mobility to the natural gas adsorbed within the coal improves. At the same time, the reservoir pressure is reduced thereby allowing greater amounts of natural gas to desorb off the surface of the coal and migrate through the coal cleats into the wellbore. Unfortunately, the reservoir pressure drops simultaneously which will inevitably reduce the gas production rate. The inventors have discovered a method of operating a coalbed methane project that restores some of the reservoir pressure lost during production, slows water influx from any surrounding aquifer, and improves the gas relative permeability of the cleat system. The benefits of this method is that when gas demand improves, the gas rate can be increased immediately rather than having to wait (in some cases up to several months) for the coal to rid itself of water that invaded the coal cleats adjacent to the well while the well was shut in. FIG. 3 illustrates a top view of a five-spot well pattern penetrating a coal seam. The wells, numbered 1 through 5, are indicated by filled-in circles, to show that all of the wells are on production due to high demand for the natural gas produced. The pressure in the coal seam is being reduced and the coal cleats adjacent to all of the wells are partially saturated with gas. The invasion of water from the flanks of the coal seam does not cause operational problems, so long as gas production is not disrupted. FIG. 4 illustrates the top view of a five-spot well pattern penetrating the coal seam where the net gas rate to sales has been curtailed due to low demand for gas. In this situation, Well No. 1 has been converted to an injection well (indicated by an open circle) and surplus gas from the field, produced from Well Nos. 2, 3, 4, and 5 or any combination thereof, is being injected into Well No. 1. Surplus gas is defined as any natural gas produced from a well penetrating the coal seam and cannot be sold due to low demand for it. During this recycling process, the coal cleats adjacent Well Nos. 2, 3, 4 and 5 are being dewatered since the production of gas has not been disrupted. This has the beneficial effects of maintaining the coal seam's ability to flow gas. At the same time, the coal matrix and cleats adjacent to Well No. 1 are being filled with gas under pressure so that later, when the net gas rate to sales can be increased, the gas stored in the coal matrix and cleats will be produced at a rapid rate, as will be described below. FIG. 5 illustrates the top view of a five-spot well pattern penetrating a coal seam where the demand for gas is at its lowest point. In this scenario, no gas is being sent to the gas sales line. However, the gas production from Well Nos. 1, 2, 4 and 5 continue without disruption. In this example, Well No. 3 has been converted to an injection well (indicated by an open circle) and surplus gas from the field, all of the gas produced from Well Nos. 1, 2, 4 and 5, is being reinjected for temporary storage into the same coal seam from which the gas was produced. During this recycling process, the cleats adjacent to Well Nos. 1, 2, 4 and 5 are continuing to be dewatered, since the production of gas and water has not been disrupted. Therefore, a high relative permeability to gas is maintained around the wellbores. At the same time, the coal matrix and cleats adjacent to the injection Well No. 3 are being filled with gas under pressure so that later, when Well No. 3 is converted back to a producing well, the gas stored in the coal matrix and cleats adjacent Well No. 3 will be produced at a rapid rate. Reinjection of surplus gas during low demand and later production of surplus gas during high demand will minimize water invasion problems caused by shutting in wells by maintaining a high relative permeability to gas in the coal cleats adjacent to the producing wells. If the production of natural gas is interrupted, such as shutting the wells in due to low demand, the coal seams preference for flowing water increases, and it becomes easier for water at the flanks of the coal seam to invade the coal cleats adjacent to the wells. As an example case, a computer simulation was conducted on a coal field penetrated by five wells. The simulated coal degasification field was operated at a maximum rate for 720 days, then demand subsided to zero for 180 days, and resumed to full demand thereafter. FIG. 6 illustrates how the net gas rate to sales varied over time. Curve 1 represents the situation where all of the gas produced from the field, in accordance with the present invention, was reinjected for 180 days into the coal seam from which it was previously produced and Curve 2 represents the situation where all of the wells were shut-in for the same period, i.e., no gas was produced from the coal seam. Both curves track each other exactly for the period of 720 days preceding the no demand period. For the first 15 days the net gas rate to sales is zero. During this period the wells are in the process of dewatering. At this time, the coal seam's pressure and relative permeability to water are high. Therefore, the natural gas adsorbed onto the coal surface is inhibited from releasing and flowing through the coal cleats into the wellbores. By the first 450 days of operation, the gas rate has climbed steadily to a rate of 1350 MSCF/day, at which it approximately remains for the next 270 days. After 720 days of operating at full capacity, the demand for gas to sales is suddenly reduced to zero. Curves I and II again track each other exactly, i.e., both show zero net gas rate for the next 180 days. In Curve I where recycling is occurring, all of the gas produced is injected into the coal seam from which it was produced so that it may be temporarily stored for recovery at a later time. In Curve II, all the wells are shut-in, therefore, no gas is being produced from the coal seam. In this example, to accomplish recycling, gas produced from four of the five wells is injected into the fifth well at a pressure that is higher than reservoir pressure. After 180 days of permitting no gas to sales, the demand for gas increases to a point such that the field can be operated at full capacity. It is at this point that Curves I and II begin to depart from each other. It is this departure which indicates the benefits of recycling gas produced from the field, in accordance with the present invention, rather than shutting in the wells. As illustrated in Curve I, after recycling, the gas rate increases at a sharp rate, up to 2400 MSCF/day for the first 30 days then levels off to a rate similar to the pre-recycling rate. However, as illustrated in Curve II, after shutting the field in, the gas rate to sales increases at a very slow rate and fails to reach the pre-shut-in rate even after 360 days, twice the period of time that the wells were shut-in. The reasons for the difference in gas rates between Curves I and II can best be explained by reference to FIG. 6. The shaded areas in FIG. 6 represent the additional amount of gas produced as a result of reinjecting all of the gas produced back into the coal seam. Section A can be attributed to the continuous production of water and presence of gas in the cleats adjacent to the production well. Due to the presence of gas in the cleats, the coal seam's preference to flow gas is maintained. Section B can be attributed to the storing of surplus gas in the coal matrix and cleats adjacent to the injection well. After recycling has ceased and the injection well is converted back to production, a large amount of gas that had previously been stored in the matrix under high pressure is suddenly released resulting in a sharp increase in the rate immediately after the injection well begins producing. In summary, the reasons for the increased gas rate after reinjecting all of the produced gas for 180 days are the coal's preference to flow gas in the immediate area surrounding the producing wells is maintained, and coal seam pressure is increased around the injection well. In other words, the gas reinjection process prepares the coal seam for high deliverability in the future by dewatering the coal seam even when the demand for gas is low. When all of the wells in the field are shut-in, as depicted in Curve II, the water saturation in the coal cleats adjacent to the wells increases with time because of water migration from the flanks of the coal seam and because dewatering of the coal by the wells has been stopped. The reservoir pressure around the wellbores increases due to the influx of water during the shut-in period. Consequently, when the wells are put back on production, the reservoir pressure and water saturation of the coal adjacent to the wellbores must be reduced to levels achieved prior to shut-in in order to produce gas at high rates. In other words, if the demand for gas fluctuates considerably over the life of the field the water influx problems illustrated by this prior art method get progressively worse. The operation of recycling during low demand and producing during high demand can continue for the life of the field. The number of producing wells drilled in the field can vary depending on the size of the field and the demand for gas. The number and location of producing wells converted to injection wells can vary depending upon, among other things, the size of the field and the amount of time the field has been operating. The injected gas can originate from the same coal seam where the gas is injected or from a coal seam other than the one where the gas is injected or from a reservoir other than a coal seam. The gas can be injected at a pressure higher than coal seam pressure, but lower than fracture pressure of immediately adjacent formations above or below the coal seam, or at a pressure dictated by prudent operating procedures. Since some water is usually produced with the gas, conventional methods of separating the two can be used before the gas is injected into the coal seam. Obviously, many other variations and modifications of this invention, as previously set forth, may be made without departing from the spirit and scope of the invention as those skilled in the art will readily understand. Such variations and modifications are considered part of this invention and within the purview and scope of the appended claims.
Disclosed herein is a method of degasification, wherein gas and water production from a coal field are maintained at high rates regardless of temporary changes in market demand. While all the produced water is disposed, surplus gas is reinjected in coal by converting some of the producers to injectors. When the demand for gas improves, the injection wells are put back on production. Recovery of gas from wells used as injectors is rapid because of increased reservoir pressure and high gas relative permeability near the wellbore.
4
The present application claims the priority of German Utility Model Application No. 102007020095.3 filed Apr. 26, 2007 under 35 U.S.C. §119. The disclosure of that priority application is hereby fully incorporated by reference herein. TECHNICAL FIELD The invention relates to apparatus and methods for dispensing a foamed material onto a substrate surface. BACKGROUND In general, dispensing a foamed material is desirable where it is necessary to dispense a material but where as little dispensing material as possible is to be applied for reasons of cost or weight, for example, but without the thickness of the coating being less than a certain value. Foamed materials are dispensed, in particular, in industrial applications in which the aim is to glue together two substrates or components, but by using as little adhesive as possible in order to reduce the amount of costly adhesive consumed and to minimize the increase in weight of the glued substrates or products due to such gluing. If uniform gluing is to be achieved, it is necessary to dispense the foamed material as uniformly as possible. Uniform dispensing is understood in this context to mean that the material may be dispensed along a precisely predetermined contour with regard to the edges of the applied coating in the longitudinal direction and direction of width, on the one hand, and on the other hand that the thickness of the applied coating correspond with as much precision as possible over the entire coating region to a predetermined contour of coating thickness, in particular that it run as uniformly as possible in the longitudinal direction and the direction of the width, and particularly that the same thickness prevail at each point of the dispensed coating. Methods are known from DE 197 57 237 and DE 197 57 238 in which a mixture of gas and adhesive is dispensed from an exit opening onto a substrate in order to apply the coating. The mixture of gas and adhesive is previously generated in a mixing device and conveyed by means of a pump to the exit opening. One specific problem encountered when foamed material is applied in this way is that variations arise when conveying the foamed material and that, as a result, the desired uniformity of applied coating is not ensured in all forms of application and differently dimensioned variants of the coating. Particularly when foamed coatings having a large width are to be applied, for example a width of more than half a meter, in particular more than one meter, a coating is produced with the known method that is subject to substantial local variations, with the result that the quality of coatings and hence the quality of an adhesive bond obtained by means of the coating is not sufficient for many applications. SUMMARY The invention provides a method which achieves greater uniformity of the foamed coating than known methods, particularly in respect of the coating thickness. More specifically, the dispensing material is kept under such a pressure in the adjacent region upstream from the discharge cross-section of the exit opening that the dispensing material in this region has a foaming rate that is less than 10% of the foaming rate which ensues at the end of the foaming process. The term “foaming rate” within the meaning of the invention is meant the volume of the gaseous portion of the foam expressed as a percentage of the total volume of the foam material. The invention is based on the realization that uniform dispensing of the foamed material can be achieved when the material in the adjacent region upstream from the discharge cross-section of the exit opening has a gaseous volume fraction that is as small as possible. When passing through the exit opening, the material has a substantially liquid or liquid-pasty volume fraction, as a result of which uniform conveying and dispensing of the dispensing material from the exit opening can be achieved. This realization is applied, according to the invention, in such a manner that the dispensing material in the adjacent region upstream from the discharge cross-section of the exit opening is put under such a pressure that the gaseous components of the dispensing material are compressed to a large extent or dissolve in solution, i.e., change into or remain in the liquid state by physical change of phase or by chemical reaction or by suppression of such a phase change or reaction. According to the invention, the dispensing material is thus conveyed through the exit opening in a state that is almost completely a liquid phase and is depressurized thereby, as a result of which the foam can form to the desired extent in the region downstream from the exit opening and generates a uniform, foamed coating. The discharge cross-section is understood here to be that part of the flow path of the dispensing material which is relevant for the flow resistance of the exit opening. This relevant part is generally represented by the region of narrowest cross-section. The discharge cross-section typically lies in the plane of the exit opening. However, it must be noted that the discharge cross-section may also lie upstream therefrom, since the flow resistance adjusts according to the properties of the material. It needs to be understood that the pressure in the adjacent region upstream from the discharge cross-section of the exit opening, and necessary for the inventive method, is influenced on the one hand by the size of the discharge cross-section, and on the other hand is dependent on the volume of material conveyed through said discharge cross-section per unit of time and finally on the viscosity of the dispensing material. Hence, the pressure can essentially be influenced via these three parameters, i.e. the pressure in the desired region may be raised by increasing the conveying speed or the viscosity, or by reducing the size of the discharge cross-section. The pressure necessary for performing the inventive method depends on the chemical and physical properties of the mixture of dispensing material. The pressure required depends, in particular, on the pressure at which the gaseous phase of the dispensing material dissolves in solution or liquefies, by a chemical or physical process, and at which it is kept in this state. As a further possible parameter for implementing the teaching of the invention, the dispensing material may be embodied such that it has a foaming rate of less than 10% of the foaming rate that is set at the end of the foaming operation, for certain other parameters defined, in particular, by a predefined dispensing speed, size of dispensing cross-section and viscosity. According to a first preferred embodiment, the dispensing material is kept under such a pressure in the adjacent region upstream from the discharge cross-section of the exit opening that the dispensing material in this region has no gaseous portion. It has been found that the uniformity of the foam coating dispensed can be further increased when the dispensing material in the adjacent region upstream from the discharge cross-section contains exclusively liquid or liquid-pasty portions and therefore no gaseous portion. In this case, the throttle effect of the exit opening is especially constant locally and over time, and can therefore be well regulated, and the volume of dispensing material being discharged is highly constant, as a result of which uniform dispensing can be achieved. According to another preferred embodiment, the dispensing material is kept under such a pressure in the region upstream from the discharge cross-section of the exit opening that the dispensing material in said region either has a foaming rate that is less than 10% of the foaming rate which ensues at the end of the foaming process, or has no gaseous portion. It has also been found that the uniformity of the dispensed foam can be further increased not only when a small or zero gas portion is present in the dispensing material in the region adjacent to the discharge cross-section of the exit opening, but also when no gaseous portion is present in the dispensing material in the entire region upstream from the discharge cross-section of the exit opening. By this means, a phase that is largely or completely liquid or liquid-pasty phase is conveyed across the entire region extending from the mixing device to the exit opening, as a result of which the conveyed volume per unit of time is kept highly constant, thus allowing the uniformity of the applied material to be substantially increased. According to another preferred embodiment, the viscosity of the dispensing material is increased at least in the region of the discharge cross-section of the exit opening in order to increase the flow resistance in the discharge cross-section. By increasing the viscosity, it is possible to increase the flow resistance exerted by a discharge cross-section against the flow of the dispensing material through it, thus likewise increasing the pressure in the region upstream from the discharge cross-section. In this way, the suppression of gaseous phase portions in the dispensing material, as aimed at with the invention, can be achieved or at least supported. Various methods are available for increasing the viscosity, such as adding highly viscous components to the dispensing material. It is particularly preferred that the dispensing material be cooled in order to increase the viscosity of the dispensed material. By cooling the dispensing material, the viscosity of normally all dispensing materials used nowadays can be significantly reduced by approaching the solidification temperature of the dispensing material, or by suppressing or delaying a chemical reaction that reduces the viscosity. According to the invention, it is possible to achieve the temperature reduction in the dispensing material by active cooling, for example by means of a heat exchanger having a coolant which is reduced in temperature relative to the ambient temperature. However, since the dispensing material is warmed in many cases to a temperature above the ambient temperature by the conveying operation and the pressurization, cooling within the meaning of the invention can be achieved by providing heat exchanging areas exposed to the ambient air and in heat flow contact with the desired cooling region when there is an efficient heat flow between these areas and the dispensing material. Increasing the viscosity is particularly suitable when using hot-melt dispensing materials, since these undergo a substantial increase in viscosity when cooled to a range just above their subsequent utilization temperature (in which they are present in the solid phase). It is also preferred when the volume of the dispensing material fed to the exit opening is regulated in response to the pressure in the adjacent region upstream from the discharge cross-section of the exit opening, in particular in such a way that a constant pressure is maintained in the adjacent region upstream from the discharge cross-section of the exit opening. Rapid regulation of the pressure in the relevant region upstream from the discharge cross-section of the exit opening is achieved by such a pressure-dependent volumetric feed rate. If it is necessary to compensate for the greater discharge volume per unit of time from the exit opening resulting from the faster conveying speed, the relative speed between the substrate and the exit opening in proportion to the speed at which the dispensing material is conveyed must be controlled in order to maintain the uniformity of the applied material. It is also preferred when the dispensing material is conveyed to the exit opening by means of a volumetric feed pump. Since the inventive method achieves a precisely defined throttle effect in the discharge cross-section of the exit opening, a volumetric feed pump may be used to feed the material against this throttle effect. A volumetric feed pump is understood here to be a pump which, depending on its control input variable, such as the rotational speed of a gear pump, feeds a certain volumetric stream that is in a preferably proportional ratio to said control input variable. One or a plurality of gear pumps are preferably used for the method of the invention, in order to achieve a volumetric feed rate. According to one particularly preferred embodiment of the invention, the dispensing material is dispensed onto the substrate surface through a slot disposed as a discharge cross-section of the exit opening and parallel to the substrate surface to be coated, and the substrate surface and the exit opening move relative to each other during the dispensing process, in a direction which is transverse to the direction of slot extension. As explained at the outset, the problem of non-uniform application of a coating arises particularly when the substrate is to be coated with a layer in a direction that is longitudinal with respect to the foamed dispensing material, and which has a width which is more than half a meter transverse to the longitudinal direction, in particular more than one meter. When conventional dispensing methods are used in such applications, substantial variations in the thickness of the dispensed layer can occur in many cases, not only in the longitudinal direction of the coating, but also in the direction of its width. The inventive method thus provides special advantages, especially when used in coating operations involving a large width, and can be implemented in such a manner that a slot nozzle is used as the dispenser nozzle and provides a sufficient reduction in cross-section to achieve the pressure increase, required for the inventive method, in the region upstream from the discharge cross-section of the slot nozzle. It is particularly preferred in this regard when the dispensing material is conveyed by means of a plurality of dispensing material feed pumps to a corresponding plurality of slot sections, wherein each slot section is assigned a dispensing material feed pump. It has been found that, despite applying the method of the invention, variation in uniformity can occur in the direction of width when the foamed dispensing material is dispensed in large widths. The aforementioned development is based on the realization that these variations in uniformity are substantially attributable to the fact that the dispensing material is not distributed uniformly over the full width of the slot nozzle when using a single feed pump. According to the invention, it is therefore provided that the slot of the slot nozzle be subdivided into a plurality of slot sections, and that each slot section be separately supplied with dispensing material by a feed pump assigned to said section. A slot section in this context is understood to be a section of the entire nozzle slot which is actually physically delineated, or merely as one section of the slot that is defined in a merely virtual sense. Whereas in the first configuration the individual slot sections are subdivided by a boundary formed between them, and behind which the stream of dispensing material combines downstream to form a common stream of material, the material is guided in the latter configuration such that it forms a contiguous stream of material upstream from, downstream from and in the slot, wherein said stream is not subdivided. The inventive embodiment comprising a plurality of slot sections and with a dispensing material feed pump being assigned to each of the slot sections can be developed, in particular, by each slot section extending for less than 20 cm, in particular for 15 cm. This dimension has proved to be particularly advantageous in achieving uniform dispensing for a number of dispensing materials. It is also preferred when the material is mixed in a mixing device to form a foam material, is conveyed to the dispensing head by means of a feed pump disposed in the mixing device and is conveyed inside the dispensing head to the exit opening disposed at the dispensing head by means of at least one second feed pump and preferably by a plurality of second feed pumps disposed inside the dispensing head. By providing a first and at least one second feed pump disposed at a distance from each other, it is possible, on the one hand, to achieve particularly well the degree of pressure control according to the invention in the pressure region required for the inventive method, below the pressure where foam is formed or the relevant foam is formed, without there being any necessity to mix the foam and dispense the foam from a single module. Instead, the arrangement allows the foam to be mixed and processed in a mixing device, and the foam to be dispensed from a dispenser head whose dimensions can therefore be kept very compact. Both the first feed pump and the second feed pump may be embodied here as one or as a plurality of individual feed pumps, wherein the first feed pump, in particular, may be embodied by two feed pumps operating fluid-mechanically in series with each other, and the second feed pumps may, in particular, be a plurality of feed pumps adjacent to one another and operating fluid-mechanically parallel to each other. It is further preferred in this regard when the material inside the dispensing head is conveyed to a plurality of exit opening sections, each one of which is assigned to a second feed pump, by means of a plurality of feed pumps, preferably gear pumps, that are disposed in the dispensing head and operate in parallel. This development of the invention further improves in a decisive manner the uniform dispensing of the foam material over a large width, by subdividing the exit opening into a plurality of section which are each assigned to one of a plurality of second feed pumps operating in parallel. Due to this arrangement, each feed pump assigned to one of the exit opening sections can be controlled such that material is dispensed with a uniform thickness on the whole across the entire dispensing width. It should be understood in this regard that the exit opening sections may be sections that are actually physically separated from each other, or may also represent sections which are defined within one entire exit opening and only virtually assigned, without there being an actual physical separation between the exit opening sections exit, i.e. a virtual assignment of sections to their respective feed pumps. It is further preferred in this regard when the pressure of the material inside the dispensing head, in the region between the feed pumps disposed in the dispensing head and the exit opening, is detected using one or more pressure sensors, and that the feed rate of the feed pumps disposed in the dispensing head is regulated in response to the detected pressure in such a way that the dispensing material in this region either has a foaming rate that is less than 10% of the foaming rate which ensues at the end of the foaming process, or has no gaseous portion. This development of the invention achieves precise regulation of the feed pump feed rate required for controlling the pressure according to the invention, in that a direct control loop is configured for controlling the pressure from the relevant regions to feed pumps that directly affect the pressure in these regions. Another aspect of the invention is an apparatus for dispensing a foamed material onto a substrate surface, comprising: a mixing device which is in fluid connection with at least two sources of material and comprising a mixing unit for mixing the material components fed from said two sources of material to form a free-flowing, foamable dispensing material, a feed pump for generating a pressure differential between the mixing device and a dispensing region located downstream in the direction of flow from a discharge cross-section of the exit opening, an exit opening provided with a discharge cross-section which provides a flow resistance to the dispensing material flowing through said cross-section, wherein the discharge cross-section is dimensioned in such a way that the dispensing material in the adjacent region upstream from the discharge cross-section of the exit opening is kept under such a pressure that the dispensing material in this region has a foaming rate which is less than 10% of the foaming rate which ensues at the end of the foaming process. The apparatus according to the invention is particularly suitable for dispensing a foamed dispensing material in the manner of the inventive method. For details, specific advantages and the ways in which the inventive apparatus operates, reference is made to the above description of the respective aspects of the method and the development thereof. With reference to the first feed pump, in particular, it must be noted that said first feed pump may be embodied by one feed pump or by a plurality of feed pump operating in parallel or in series in order to provide the feed rate that is required. The second feed pumps may be disposed fluid-mechanically inside the dispensing head and may each supply a virtually or physically separated section of the exit opening with the dispensing material. Said second feed pumps operate fluid-mechanically in parallel and are preferably arranged on the dispenser in a parallel construction. They are preferably controlled individually so that individual control of their respective feed rates and hence of the dispensing material discharged from exit opening sections assigned to them is possible. As a result, any differences in the coating height of the dispensing material that arise across the width of the exit opening section, caused for example by different flow resistances in the supply sections, can be equalized and a uniform dispensing profile produced on the whole. BRIEF DESCRIPTION OF THE DRAWINGS A preferred embodiment of the invention shall now be described with reference to the Figures, in which FIG. 1 shows a perspective view, from the side and from above, of the dispensing head of a dispensing device according to an embodiment of the invention, FIG. 2 shows a frontal view of the dispensing head in FIG. 1 , FIG. 3 shows a plan view of the dispensing head in FIG. 1 ; FIG. 4 shows a side view of the dispensing head of FIG. 1 ; FIG. 5 shows an exploded view of the main components of a dispensing head according to an embodiment of the invention; and FIG. 6 shows a schematic view of the material flow inside the dispensing apparatus according to an embodiment of the invention. DETAILED DESCRIPTION Referring to FIGS. 1-4 , a preferred embodiment of a dispensing apparatus according to the invention comprises a dispensing head 1 that has a closure housing 2 a in which a pivotable shaft driven by a motor/transmission unit 2 is disposed. The pivotable shaft has a longitudinal slot through which a mixture comprising two components of a foamable material can pass through, when in a first pivot position, and cannot pass through, when in a second pivot position. Dispensing head 1 comprises a total of eight material feed pumps 90 a - h. A slot nozzle 4 extending across the width of the dispensing head and transversely to the feeding direction of a substrate conveyed under the slot nozzle is disposed on dispensing head 1 . Slot nozzle 4 extends over a width of 1.5 m. The discharge cross-section of the slot nozzle is dimensioned such that, between material feed pumps 90 a - h and slot nozzle 4 , a pressure is maintained which totally or almost totally prevents gaseous portions occurring in the dispensing material in the stream of material between material feed pumps 90 a - h and slot nozzle 4 . The pressure is so high that all or almost all gaseous portions dissolve in this section or are compressed to such an extent that a negligible gaseous volume fraction, in particular less than 10%, occurs in the dispensing material. Not until the material is discharged from slot nozzle 4 does the actual foaming and the concomitant expansion of the dispensing material occur. FIG. 5 shows an exploded view of an embodiment of a dispensing apparatus for carrying out the dispensing method according to the invention. The dispensing head comprises the closure housing 2 a in which closure shaft 2 b provided with a longitudinal slot is pivotably mounted. Closure shaft 2 b can be pivoted by motor/transmission unit 2 in order to block or release the flow of material. Below and in the direction of flow downstream from closure shaft 2 b , a slot nozzle 4 which is defined by two defining edges 4 a , 4 b and through which the material can be discharged is disposed in housing 2 a. Laterally above, and upstream in the direction of flow from closure shaft 2 b in housing 2 a , a total of eight gear feed pumps 90 a - h are disposed, each of which is driven by a separate electric motor 91 a - h . Gear pumps 90 a - h are each driven via an angular gear. Gear pumps 90 a - h are supplied with dispensing material from one feed line connected to the left end and one feed line connected to the right end of the dispensing head. Thus, outer gear pumps 90 a and 90 h each have a practically resistance-free source of dispensing material. In the respective regions where these two supply lines enter the dispensing head, a pressure sensor 73 , 74 is disposed which measures the pressure upstream from the gear pumps. FIG. 6 shows in a schematic flow diagram of the dispensing apparatus according to the invention. The apparatus shown schematically in FIG. 6 comprises a material source 10 inside which a liquid dispensing material is kept. Material source 10 is connected via a first connection line 11 to a material feed pump 20 , which conveys the material from the material source 10 into a second connection line 21 . The conveyed material passes out of second connection line 21 into a third connection line 22 and is mixed with air from an air supply line 31 at a T-piece 23 . The air which is fed to T-piece 23 via air supply line 31 is regulated in respect of its volumetric flow rate by an air control valve 30 and is connected at T-piece 23 to a nonreturn valve 32 which prevents material from being pressed out of line section 22 into air supply line 31 . A controlled throttle valve 33 provides a constant input pressure for the air control device 30 . The mixed air/material mass is fed via a fourth connection line section 24 to a foam conveyor pump 40 which conveys the volume of air/material on its outlet side into a fifth connection line section 41 that opens into a mixing device 50 . Mixing device 50 is a rotary mixer in which the air/material volume is homogenously mixed, for example in the manner described in EP 0 220 450 B1. Reference is made here to EP 0 220 450 B1, in particular to the disk mixer according to column 4, line 21-column 5, line 51 and FIGS. 2-4 with the associated description. The homogenously mixed foam material is fed from the mixing device through a sixth line section 51 of a throttle 60 . Upstream and downstream from throttle 60 in the direction of flow of the foam, pressure sensors 71 , 72 of a pressure measurement device 70 are arranged and can detect the pressure difference across throttle 60 . Pressure sensors 71 , 72 are connected to a controller (not shown) in order to transmit their pressure measurement signal to said controller. The controller is connected to the gas flow control valve 30 in order to regulate the volumetric stream flow of the gas through line 31 , depending on the pressure measurement signals from pressure sensors 71 , 72 Downstream from throttle 60 , the homogenously mixed material is conveyed through another line section 61 and a flexible hose 81 to a foam dispensing head 1 . Foam dispensing head 1 comprises a plurality of foam dispensing sections 82 a,b,c, . . . , h , from which the foam material is dispensed onto a substrate which runs below the exit openings of said foam dispensing nozzles. Foam dispensing head 1 also has a throughhole opening 83 which is connected to a flexible hose portion 84 . Said flexible hose portion 84 opens into a shut-off valve 85 which is connected to a line section 86 . Between the second and third line sections 21 and 22 , said line section 86 opens into the feed line between the material conveying pump 20 and T-piece 23 , where air is added. The foam can be circulated via hose 84 and line section 86 by operating the foam conveying pump 40 , without dispensing foam from foam dispensing sections 82 a - h. Shut-off valve 85 is also provided with a flexible hose 12 which is connected to hose section 84 and opens via a valve 13 into the upper, air-filled part of material source 10 . Via said hose line 12 , the material can be circulated through the entire system when material conveying pump 20 is in operation, without producing a critical increase in pressure in the system when no foam is dispensed from the foam dispensing nozzles 82 a,b,c , . . . . To this end, valve 13 is opened when the dispensing of foam is stopped for a certain period of time. In addition, the entire system can be flushed via hose line 12 by closing the foam dispensing nozzles, opening valve 13 and allowing circulation to occur until, for example, the entire system is filled with a new quality of foam. A total of eight gear feed pumps 90 a - h , which convey the dispensing material fed via hose line 81 and a distribution channel 81 a to foam dispensing sections 82 a - h , are flanged to dispensing head 1 . A pressure sensor 73 is disposed on dispensing head 1 in order to detect the pressure in the feed line. The sensor signal from pressure sensor 73 is used to control the feed rate of gear pumps 90 a - h , in order to generate in this way the required pressure, according to the invention, for suppressing foam formation. According to the invention, a pressure is maintained in the entire region downstream from the mixing device 50 as far as the exit opening of the foam dispensing sections 82 a - h that completely suppresses the formation of foam in the dispensing material, or reduces such formation to such an extent at least that the foaming rate in this region is no more than 10% of the foaming rate which ensues at the end of the foaming process. The foam generating and dispensing method according to the invention runs as follows: Material dispensing pump 20 conveys material from material source 10 to foam conveyor pump 40 . In a first operating mode, no air is added to said material, so the material is fed to dispensing head 80 by mixing device 50 without being mixed with air, with the consequence that unfoamed material from the material source is dispensed. In bypass operation via flexible lines 84 , 12 , the material can be recycled when material dispensing pump 20 and foam conveyor pump 40 are being operated. Alternatively, in a second operating mode, the material can be circulated in a small loop via flexible line 84 and line section 86 when only foam conveyor pump 40 is being operated. In a third operating mode, air or a different gas, such as nitrogen, is added to the conveyed material at T-piece 23 , such that a gas/material mixture enters foam conveyor pump 40 and is conveyed from there to die mixing device 50 . Pre-mixing of the material and the gas occurs in the foam conveyor pump. In mixing device 50 , this gas/material mixture is mixed to form a homogenous material mixture and is ultimately fed to dispensing head 1 . At dispensing head 1 , said foam material is dispensed from dispensing nozzles 82 a - c onto a substrate. If the dispensing operation is to be temporarily interrupted, then dispensing nozzles 82 a - c are closed and the dispensing material is circulated via flexible line 84 with foam conveyor pump 40 in operation. In this situation, either the material dispensing pump can be switched off, or the material dispensing pump is likewise operated in the bypass mode, but returning the dispensing material via flexible lines 84 , 12 into material source 10 . The foam generation and dispensing method is controlled by pressure sensors 71 , 72 detecting the pressure differential across throttle 60 and sending it to the controller. The controller compares the measured pressure differential with a predetermined pressure differential set for the desired foam quality and, depending on the difference between the actual pressure differential and the reference pressure differential, supplies the gas flow control valve 30 with a signal for increasing or decreasing the supply of gas, or controls the material conveying pump, the foam conveyor pump and/or the mixing device accordingly. Another controlling or regulation effect is achieved by material dispensing pump 20 being embodied as a gear pump and generating a speed-dependent signal that is likewise supplied to the controller. In response to this speed-dependent signal, the controller now controls gas flow control valve 30 such that an increasing amount of gas is also fed to T-piece 23 if the rotational speed of material conveying pump 20 increases, and vice versa. Material conveying pump 20 , foam conveyor pump 40 convey the material, or the material containing the foam producing agent, at such a pressure into mixing device 50 that a pressure is produced downstream from mixing device 50 and as far as gear feed pumps 90 a - 90 h which completely suppresses or extensively prevents the formation of foam. Gear feed pumps 90 a - 90 h convey the dispensing material thus supplied, for their part, at such a pressure and as far as the discharge cross-section of the exit opening of foam dispensing sections 82 a - 82 h that no formation of foam or only slight formation of foam occurs downstream from gear feed pumps 90 a - 90 h and as far as the discharge cross-section. While the present invention has been illustrated by a description of various embodiments and while these embodiments have been described in some detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The various features disclosed herein may be used alone or in any combination depending on the needs and preferences of the user. The invention itself should only be defined by the appended claims.
A method for dispensing a foamed material onto a substrate surface, including: generating a relative movement between the substrate surface to be coated and an exit opening of a material dispensing apparatus, mixing at least two material components in a mixing device to provide a free-flowing, foamable dispensing material, generating a pressure differential between the mixing device and the dispensing region located downstream in the direction of flow from a discharge cross-section of the exit opening, conveying the dispensing material from the mixing device for the dispensing material to the exit opening, and discharging the dispensing material from the exit opening onto the substrate surface. The dispensing material be kept under such a pressure in the region adjacent to and upstream from the discharge cross-section of the exit opening that the dispensing material in this region has a foaming rate that is less than 10% of the foaming rate which ensues at the end of the foaming process.
1
CROSS REFERENCES TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 10/802,866, filed on Mar. 18, 2004, now allowed. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a toner useful, for example, for visualizing an electrostatic latent image formed on an image bearing member by a method such as electrophotography and electrostatic recording methods. In addition, the present invention also relates, without limitation, to a developer including a toner, a developing method using a toner and a method of preparing the toner. Additional advantages and other features of the present invention will be set forth in part in the description that follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present invention. The advantages of the present invention may be realized and obtained as particularly pointed out in the appended claims. As will be realized, the present invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the present invention. The description is to be regarded as illustrative in nature, and not as restrictive. 2. Discussion of the Background Electrostatic latent images and magnetic latent images, which are formed on an image bearing member of an electrophotographic image forming apparatus or electrostatic recording apparatus are developed with a toner to be visualized. For example, in electrophotography visual images are typically formed as follows: (1) an electrostatic latent image is formed on a photoreceptor; (2) the electrostatic latent image is developed with a developer including a toner to form a toner image on the photoreceptor; (3) the toner image is transferred onto a receiving material such as papers; and (4) the toner image on the receiving material is fixed upon application of heat, etc. to form a hard copy. Recently, a need exists for an electrophotographic image forming apparatus and a developer therefor, which can produce high quality images. In order to produce high quality images, it is essential for the toner included in a developer to have a sharp particle diameter distribution because each of the toner particles can exhibit uniform performance and thereby fine dot images can be well reproduced. The toners used for developing electrostatic latent images are colored particles typically including a binder resin, and a colorant, a charge controlling agent and additives which are dispersed in the binder resin. The methods for manufacturing the toners are broadly classified into pulverization methods and suspension polymerization methods. Pulverization methods typically include the following processes: (1) mixing a colorant, a charge controlling agent, an offset preventing agent and the like materials with a thermoplastic resin upon application of heat thereto to knead the toner constituents; (2) cooling the kneaded mixture; (3) pulverizing the kneaded mixture to form a color powder; and (4) classifying the color powder to form a toner. The toners prepared by pulverization methods have fair characteristics. However, the pulverization methods have a drawback in that only limited materials can be used as the toner constituents (particularly, as the binder resin). Namely, the kneaded mixture has to be easily pulverized and classified by conventional low-cost pulverizers and classifiers. From this point of view, the kneaded mixture has to be so brittle as to be pulverized. Therefore, the color powder, which is prepared by pulverizing a kneaded mixture, tends to have a broad particle diameter distribution. In order to prepare toner images having good resolution and half tone properties, the color powder has to be classified so as to have a particle diameter of from 5 to 20 μm. Therefore the toner yield is very low in the classification process. In addition, it is impossible to uniformly disperse a colorant and a charge controlling agent in a thermoplastic resin when the pulverization methods are used. Uneven dispersion of toner constituents adversely affects the fluidity, developing properties, durability and image qualities of the resultant toner. In attempting to solve such problems, suspension polymerization methods have been proposed and practically used now. The techniques for manufacturing a toner utilizing a polymerization method are known. However, the particles of toners prepared by suspension polymerization methods have a spherical form and therefore the toners have a drawback of having a poor cleaning property. When toner images have a low image area share (i.e., the percentage of the area of a toner image in a copy sheet is low), the amount of the toner particles remaining on a photoreceptor is small, and therefore a cleaning problem hardly occurs. However, when toner images have a high image area share (for example, copies of photograph images) are produced or when a toner image remains on a photoreceptor without being transferred to a receiving material due to paper jamming problems or the like, a large amount of the toner particles remains on the photoreceptor, resulting in occurrence of background fouling in the resultant or following images. In this case, when a contact charging roller is used, the toner particles remaining on the photoreceptor contaminate the charging roller, resulting in deterioration of the charging ability of the charging roller. In attempting to solve such a problem, Japanese Patent No. 2,537,503 discloses a method in which resin particles prepared by an emulsion polymerization method are associated to prepare toner particles having an irregular form. However, the toner particles prepared by such an emulsion polymerization method include a large amount of a surfactant on or in the toner particles even after the toner particles are washed with water. Therefore, the resultant toner has poor charge stability when environmental conditions change and in addition the distribution of the charge quantity of the toner particles is broad, thereby causing background fouling in copy images. In addition, the remaining surfactant contaminates the photoreceptor and charging roller, developing roller and the like elements used in image forming apparatus, resulting in deterioration of the abilities of the elements. Japanese Laid-Open Patent Publication No. 11-133665 discloses a toner including modified polyester having a Wadell practical sphericity of from 0.90 to 1.00. Japanese Laid-Open Patent Publications Nos. 11-149180 and 2000-292981 disclose a dry toner and a method of producing the toner including a binder formed from an elongation and/or a crosslinking reaction of a prepolymer including an isocyanate group, and a colorant, wherein the dry toner is formed of particles formed from an elongation and/or a crosslinking reaction of the prepolymer (A) by amines (B) in an aqueous medium. However, the toner does not have both the transferability and cleanability. Adding an inorganic particle such as a silica or titanium as the way of giving a charging to toner particles is known. However, these minute particles are buried inside the toner particles by being stirred in the developer for a long time, and the charging stability with the passage of time isn't assured. Making an inorganic particle fixed on the surface of the toner by mechano-chemical disposal is known, too. However, a bad influence is given to a fixation character because the surface of the toner becomes a film by the minute particle. In addition, toners comprising a charge control agent in the toner composition are known. However, the charge control agent does not disperse in uniformly. Therefore, the electrostatic charge is unstable. The use of fluorine in adjusting charge is known. For example, there is an approach to alter the toner surface with fluorine by adsorption or chemically or physically, for example using a fluorine-type surfactant. Such treatment can alter the electrostatic charge stability of toner particle, but the amount of carbon atom and fluorine atom as measured by XPS is important. When F/C is less than 0.01, there is little or no benefit, and 0.50 may be too high. SUMMARY OF THE INVENTION The present invention provides a high fluidity toner having good low-temperature fixing properties and good hot offset properties. At the same time, electrostatic charge stability is good. The invention toner further provides image sharpness over the long term. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS At first, the physical properties and main toner constituents used in the present invention will be explained in detail. The present invention toner has fluoring on the surface thereof, providing electrostatic charge stability over time. The amount of F as compared to C on the toner surface as measured by XPS is important. Preferably, F/C is 0.01≦F/C≦0.50, preferably 0.05≦F/C≦0.30, most preferably 0.10≦F/C≦0.20, including values of 0.15, 0.3.4, etc and all values and subranges between all values. To introduce fluorine to the toner face, the granulated body after particle formation of the toner composition may be agitated in an aqueous dispersion of a fluorine-containing surfactant. The surfactant can be cationic or anionic, for example, and can be used in combination with an electrostatic charge control agent. The size of the dispersion is preferably less than 1 μm as is the size of any fine particles of electrostatic charge control agent. Resin fine particles are preferable as electrostatic charge control agents when provided on the toner face. By using a surfactant having a fluoroalkyl group, dispersion having good dispensability can be prepared even when a small amount of the surfactant is used. Specific examples of anionic surfactants having a fluoroalkyl group include fluoroalkyl carboxylic acids having from 2 to 10 carbon atoms and their metal salts, disodium perfluorooctanesulfonylgl-utamate, sodium 3-{omega-fluoroalkanoyl (C6–C11)oxy}-1-alkyl(C3–C4) sulfonate, sodium 3-{omega-fluoroalkanoyl(C6–C8)-N-ethylamino}-1-propanes-sulfonate, fluoroalkyl(C11–C20) carboxylic acids and their metal salts, perfluoroalkylcarboxylic acids and their metal salts, perfluoroalkyl(C4–C12)sulfonate Moreover, their metal salts, perfluorooctanesulfonic acid diethanol amides, N-propyl-N-(2-hydroxyethyl-)perfluorooctanesulfone amide, perfluoroalkyl(C6–C10)sulfoneamidepropyltri-methylammonium salts, salts of perfluoroalkyl (C6–C10)-N-ethylsulfonyl glycin, monoperfluoroalkyl(C6–C16)ethylphosphates, etc. Specific examples of the marketed products of such surfactants having a fluoroalkyl group include SURFLON S-111, S-112 and S-113, which are manufactured by Asahi Glass Co., Ltd.; FRORARD FC-93, FC-95, FC-98 and FC-129, which are manufactured by Sumitomo 3M Ltd.; UNTDYNE DS-101 and DS-102, which are manufactured by Daikin Industries, Ltd.; MEGAFACE F-110, F-120, F-113, F-191, F-812 and F-833 which are manufactured by Dainippon Ink and Chemicals, Inc.; ECTOP EF-102, 103, 104, 105, 112, 123A, 306A, 501, 201 and 204, which are manufactured by Tohchem Products Co., Ltd.; FUTARGENT F-100 and F150 manufactured by Neos; etc. Specific examples of the cationic surfactants, which can be used for dispersing an oil phase including toner constituents in water, include primary, secondary and tertiary aliphatic amines having a fluoroalkyl group, aliphatic quaternary ammonium salts such as perfluoroalkyl(C6–C10)sulfoneamidepropyltrimethylammonium salts, benzalkonium salts, benzetonium chloride, pyridinium salts, imidazolinium salts, etc. Specific examples of the marketed products thereof include SURFLON S-121 (from Asahi Glass Co., Ltd.); FRORARD FC-135 (from Sumitomo 3M Ltd.); UNIDYNE DS-202 (from Daikin Industries, Ltd.); MEGAFACE F-150 and F-824 (from Dainippon Ink and Chemicals, Inc.); ECTOP EF-132 (from Tohchem Products Co., Ltd.); FUTAKGENT F-300 (from Neos); etc. A preferred material is the fluorine component ammonium salt compound shown with general formula (1). X:—SO 2 — or —CO—; R 1 , R 2 , R 3 , R 4 : hydrogen atom, alkyl group or aryl of carbon number 1–10, Y: I or Br, r, s: an integer of 1–20. Other useful surfactants that can be used in addition to fluorine-containing surfactants include: alkylbenzene sulfonic acid salts, α-olefin sulfonic acid salts, and phosphoric acid salts; cationic surfactants such as amine salts (e.g., alkyl amine salts, aminoalcohol fatty acid derivatives, polyamine fatty acid derivatives and imidazoline), and quaternary ammonium salts (e.g., alkyltrimethyl ammonium salts, dialkyldimethyl ammonium salts, alkyldimethyl benzyl ammonium salts, pyridinium salts, alkyl isoquinolinium salts and benzethonium chloride); nonionic surfactants such as fatty acid amide derivatives, polyhydric alcohol derivatives; and ampholytic surfactants such as alanine, dodecyldi(aminoethyl)glycin, di(octylaminoethyle)glycin, and N-alkyl-N,N-dimethyl ammonium betaine. In the present invention the ratio (Dv/Dn) (volume average particle diameter/number average particle diameter) is controlled. The volume average particle diameter (Dv) of the toner of the present invention is preferably from 3 to 7 μm, and the ratio of Dv/Dn of the volume average particle diameter (Dv) to the number average particle diameter (Dn) is preferably not greater than 1.25, more preferably from 1.03 to 1.15. When such a toner is used for a two component developer while a cyclic operation of consumption and replenishment of the toner is frequently performed, the particle diameter of the toner particles in the two component developer hardly changes, and thereby stable development can be performed (i.e., good images can be stubble produced) for a long period of time even if the toner is agitated in the developing device. In addition, when the toner is used as a one component developer, the toner does not cause problems such that a toner film is formed on the developing roller used and the toner adheres to a member such as blades configured to regulate the toner to form a thin toner layer. Therefore, even when the toner is used for a long period of time in a developing device while agitated, stably development can be performed and good images can be stably produced. In general, the smaller a particle diameter a toner has, the better the image qualities of the resultant toner images. However, the smaller particle diameter a toner has, the worse transferability and cleaning property the toner has. When the toner has a volume average particle diameter less than 3 μm, the toner tends to adhere to the surface of the carrier included in a two component developer if the developer is agitated for a long period of time, resulting in deterioration of the charging ability of the carrier. When such a small toner is used as a one component developer, the toner tends to cause problems such that a toner film is formed on the developing roller used and the toner adheres to a member such as blades configured to regulate the toner to form a thin toner layer. The same is true for the case in which the toner includes a large amount of fine toner particles. In contrast, when the volume average particle diameter of the toner is greater than 7 μm, it is hard to produce high resolution and high quality images and in addition the particle diameter of the toner largely changes if a cyclic operation of consumption and replenishment is repeatedly performed. The same is true for the case in which the ratio Dv/Dn is greater than 1.25. It is preferable that the ratio Dv/Dn approaches 1.00, because the resultant toner particles have uniform performance and the charge quantity thereof is uniform, and thereby high quality images can be stably produced. In addition, there is preferred stabilization of behavior of toner and uniformity of electrostatic charge amount when a volume average particle/number average particle is smaller than 1.03. However, it became clear that there was a point where the electrostatic charge of the toner was not enough and was found and to deteriorate cleaning property. The toner of the present invention preferably has a controlled spherical degree and spherical degree distribution. When the toner has an average spherical degree less than 0.94, i.e., the toner has a form largely different from a spherical form, and high quality images cannot be produced (for example, transferability deteriorates and the resultant images have background fogging). In the present invention, the spherical degree of the toner is preferably measured as follows: the particles are optically observed by a CCD camera to analyze the shapes thereof, and the spherical degree of a particle is determined by the following equation: spherical degree= Cs/Cp wherein Cp represents the length of the circumference of the projected image of a particle and Cs represents the length of the circumference of a circle having the same area as that of the projected image of the particle. When the average spherical degree is from 0.94 to 0.99, the resultant toner can stably produce high quality images having a proper image density and a high resolution. It is more preferable for the toner of the present invention to have an average spherical degree of from 0.975 to 0.990. In addition, in the toner of the present invention the content of the toner particles having a spherical degree less than 0.94 is preferably not greater-than 10%. In the present invention, the spherical degree and average spherical degree are measured by a flow-type particle image analyzer FPIA-2100 manufactured by Toa Medical Electronics Co., Ltd. Modified Polyester Resin Reactive with Active Hydrogen Suitable reactive modified polyester resins (RMPE) for use in the toner of the present-invention, which can react with an active hydrogen, include polyester prepolymers having a functional group, which can react with an active hydrogen, such as an isocyanate group. Suitable polyester prepolymers for use in the toner of the present invention include polyester prepolymer (A) having an isocyanate group. The polyester prepolymer (A) having an isocyanate group can be prepared by reacting an isocyanate compound (PIC) with a polyester which is a polycondensation product of a polyol (PO) and a polycarboxylic acid (PC) and which has a group having an active hydrogen. Suitable groups having an active hydrogen include a hydroxyl group (an alcoholic hydroxyl group and a phenolic hydroxyl group), an amino group, a carboxyl group, a mercapto group, etc. Among these groups, the alcoholic hydroxyl group is preferable. Suitable polyols (1) include diols (1-1) and polyols (1-2) having three or more hydroxyl groups. It is preferable to use a (1-1) alone or mixtures in which a small amount of a (1-2) is mixed with a (1-2). Specific examples of the diols (1-1) include alkylene glycol (e.g., ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butanediol and 1,6-hexanediol); alkylene ether glycols (e.g., diethylene glycol, triethylene glycol, dipropylene glycol, polyethylene glycol, polypropylene glycol and polytetramethylene ether glycol; alicyclic diols (e.g., 1,4-cyclohexane dimethanol and hydrogenated bisphenol A); bisphenols (e.g., bisphenol A, bisphenol F and bisphenol S); adducts of the alicyclic diols mentioned above with an alkylene oxide (e.g., ethylene oxide, propylene oxide and butylene oxide); adducts of the bisphenols mentioned above with an alkylene oxide (e.g., ethylene oxide, propylene oxide and butylene oxide); etc. Among these compounds, alkylene glycols having from 2 to 12 carbon atoms and adducts of a bisphenol with an alkylene oxide are preferable. More preferably, adducts of a bisphenol with an alkylene oxide, or mixtures of an adduct of a bisphenol with an alkylene oxide and an alkylene glycol having from 2 to 12 carbon atoms are used. Specific examples of the polyols (1-2) include aliphatic alcohols having three or more hydroxyl groups (e.g., glycerin, trimethylol ethane, trimethylol propane, pentaerythritol and sorbitol); polyphenols having three or more hydroxyl groups (trisphenol PA, phenol novolak and cresol novolak); adducts of the polyphenols mentioned above with an alkylene oxide; etc. Suitable polycarboxylic acids (2) include dicarboxylic acids (2-1) and polycarboxylic acids (2-2) having three or more carboxyl groups. It is preferable to use dicarboxylic acids (2-1) alone or mixtures in which a small amount of a (2-2) is mixed with a (2-1). Specific examples of the dicarboxylic acids (2-1) include alkylene dicarboxylic acids (e.g., succinic acid, adipic acid and sebacic acid); alkenylene dicarboxylic acids (e.g., maleic acid and fumaric acid); aromatic dicarboxylic acids (e.g., phthalic acid, isophthalic acid, terephthalic acid and naphthalene dicarboxylic acids; etc. Among these compounds, alkenylene dicarboxylic acids having from 4 to 20 carbon atoms and aromatic dicarboxylic acids having from 8 to 20 carbon atoms are preferably used. Specific examples of the polycarboxylic acids (2-2) having three or more hydroxyl groups include aromatic polycarboxylic acids having from 9 to 20 carbon atoms (e.g., trimellitic acid and pyromellitic acid). As the polycarboxylic acid (2), anhydrides or lower alkyl esters (e.g., methyl esters, ethyl esters or isopropyl esters) of the polycarboxylic acids mentioned above can be used for the reaction with a polyol(1). preferred mixing ratios (i.e., an equivalence ratio [OH]/[COOH]) of a polyol (1) to a polycarboxylic acid (2) is from 2/1 to 1/1, more preferably from 1.5/1 to 1/1 and even more preferably from 1.3/1 to 1.02/1. Specific examples of useful polyisocyanates (3) include aliphatic polyisocyanates (e.g., tetramethylene diisocyanate, hexamethylene diisocyanate and 2,6-diisocyanate methylcaproate); alicyclic polyisocyanates (e.g., isophorone diisocyanate and cyclohexylmethane diisocyanate); aromatic didicosycantes (e.g., tolylene diisocyanate and diphenylmethane diisocyanate); aromatic aliphatic diisocyanates (e.g., α, α, α′, α′-tetramethyl xylylene diisocyanate); isocyanurates; blocked polyisocyanates in which the polyisocyanates mentioned above are blocked with phenol derivatives, oximes or caprolactams; etc. These compounds can be used alone or in combination. Preferred mixing ratios (i.e., [NCO]/[OH]) of a polyisocyanate (3) to a polyester having a hydroxyl group is from 5/1 to 1/1, more preferably from 4/1 to 1.2/1 and even more preferably from 2.5/1 to 1.5/1. When the [NCO]/[OH] ratio is too large, the low temperature fixability of the toner deteriorates. In contrast, when the ratio is too small, the content of the urea group in the modified polyesters decreases and thereby the hot offset resistance of the toner deteriorates. The content of the constitutional component of a polyisocyanate (3) in the polyester prepolymer (A) having a polyisocyanate group at its end portion is from 0.5% to 40% by weight, preferably from 1% to 30% by weight and more preferably from 2% to 20% by weight. When the content is too low, the hot offset resistance of the toner deteriorates and in addition the heat resistance and low temperature fixability of the toner also deteriorate. In contrast, when the content is too high, the low temperature fixability of the toner deteriorates. The number of the isocyanate groups included in a molecule of the polyester prepolymer (A) is at least 1, preferably from 1.5 to 3 on average, and more preferably from 1.8 to 2.5 on average. When the number of the isocyanate group is too small (less than 1 per 1 molecule), the molecular weight of the resultant modified polyester decreases and thereby the hot offset resistance deteriorates. The reactive modified polyester resins may be reacted with a crosslinking agent and/or an elongation agent. As the crosslinking agent and elongation agent, amines including an amino group are preferably used. Specific examples of the amines (B) include diamines (B1) polyamines (B2) having three or more amino groups, amino alcohols (B3), amino mercaptans (B4), amino acids (B5) and blocked amines (B6) in which the amines (B1–B5) mentioned above are blocked. Specific examples of the diamines (B1) include aromatic diamines (e.g., phenylene diamine, diethyltoluene diamine and 4,4′-diaminodiphenyl methane); alicyclic diamines (e.g., 4,4′-diamino-3,3′-dimethyldicyclohexy-1 methane, diaminocyclohexane and isophoron diamine); aliphatic diamines (e.g., ethylene diamine, tetramethylene diamine and hexamethylene diamine); etc. Specific examples of the polyamines (B2) having three or more amino groups include diethylene triamine, triethylene tetramine. Specific examples of the amino alcohols (B3) include ethanol amine and hydroxyethyl aniline. Specific examples of the amino mercaptan (B4) include aminoethyl mercaptan and aminopropyl mercaptan. Specific examples of the amino acids (B5) include amino propionic acid and amino caproic acid. Specific examples of the blocked amines (B6) include ketimine compounds which are prepared by reacting one of the amines B1–B5 mentioned above with a ketone such as acetone, methyl ethyl ketone and methyl isobutyl ketone; oxazoline compounds, etc. Among these compounds, diamines (B1) and mixtures in which a diamine (B1) is mixed with a small amount of a polyamine (B2) are preferable. The molecular weight of the modified polyesters can be controlled using an elongation anticatalyst, if desired. Specific examples of the elongation anticatalyst include monoamines (e.g., diethyle amine, dibutyl amine, butyl amine and lauryl amine), and blocked amines (i.e., ketimine compounds) prepared by blocking the monoamines mentioned above. The mixing ratio (i.e., a ratio [NCO]/[NHx]) of the prepolymer (A) having an isocyanate group to the amine (B) is preferably from 1/2 to 2/1, more preferably from 1.5/1 to 1/1.5 and even more preferably from 1.2/1 to 1/1.2. When the mixing ratio is too low or too high, the molecular weight of the resultant urea-modified polyester decreases, resulting in deterioration of the hot offset resistance of the resultant toner. In the toner of the present invention, the modified polyester resins (A) can be used alone or in combination with unmodified polyester resins (C) as the binder resin of the toner. By using a combination of a modified polyester resin (A) with an unmodified polyester resin (C), the low temperature fixability of the toner can be improved and in addition the toner can produce color images having a high gloss. Suitable unmodified polyester resins (C) include polycondensation products of a polyol with a polycarboxylic acid. Specific examples of the polyol and polycarboxylic acid are mentioned above for use in the modified polyester resins. In addition, specific examples of the suitable polyol(1) and polycarboxylic acid(2) are also mentioned above. In addition, as the unmodified polyester resins, polyester resins modified by a bonding (such as urethane bonding) other than a urea bonding, can also be used as well as the unmodified polyester resins mentioned above. When a mixture of a modified polyester resin (A) with an unmodified polyester resin (C) is used as the binder resin, it is preferable that the modified polyester resin (A) at least partially mixes with the unmodified polyester resin (C) to improve the low temperature fixability and hot offset resistance of the toner. Namely, it is preferable that the modified polyester resin (A) has a structure similar to that of the unmodified polyester resin (C). The mixing ratio (A/C) of a modified polyester resin (A) to an unmodified polyester resin (C) is preferably from 5/95 to 75/25, more preferably from 10/90 to 25/85, even more preferably from 12/88 to 25/75, and most preferably from 12/88 to 22/78. When the addition amount of the modified polyester resin (A) is too small, the hot offset resistance of the toner deteriorates and in addition, it is impossible to achieve a good combination of high temperature preservability and low temperature fixability. The peak molecular weight of the unmodified polyester resins (A) is preferably from 1,000 to 30,000, more preferably from 1,500 to 10,000 and most preferably from 2,000 to 8,000. When the peak molecular weight is too low, the heat resistance decreases. When the peak molecular weight is too high, low-temperature fixing property decreases. In the present invention, the binder resin preferably has a glass transition temperature (Tg) of from 50° C. to 70° C., and preferably from 55° C. to 65° C. When the glass transition temperature is too low, the high temperature preservability of the toner deteriorates. In contrast, when the glass transition temperature is too high, the low temperature fixability deteriorates. When a cured and/or elongated polyester resin is used in combination with an unmodified polyester resin as the binder resin, the resultant toner has better high temperature preservability than conventional toners including a polyester resin as a binder resin even if the urea-modified polyester resin has a relatively low glass transition temperature compared to the polyester resin included in conventional toners. With respect to the storage modulus of the toner binder for use in the toner of the present invention, the temperature (TG′) at which the storage modulus is 10,000 dyne/cm 2 when measured at a frequency of 20 Hz is not lower than 100° C., and preferably from 110° C. to 200° C. With respect to the viscosity of the toner binder, the temperature (Tη) at which the viscosity is 1,000 poise when measured at a frequency of 20 Hz is not higher than 180° C., and preferably from 90° C. to 160° C. When the temperature (Tη) is too high, the low temperature fixability of the toner deteriorates. In order to achieve a good combination of low temperature fixability and hot offset resistance, it is preferable that the TG′ is higher than the Tη. Specifically, the difference (TG′−Tη) is preferably not less than 0° C., preferably not less than 10° C. and more preferably not less than 20° C. The difference particularly has an upper limit. In order to achieve a good combination of high temperature preservability and low temperature fixability, the difference (TG′−Tη) is preferably from 0° C. to 100° C., more preferably from 10° C. to 90° C. and even more preferably from 20° C. to 80° C. The flow beginning temperature Tfb of the toner for electrostatic image development is preferably 80° C. to 170° C. In the present invention, to provide toner particles of good charging ability and uniform particle distribution, toner formation using minute particles dispersed in an aqueous solvent may be used. Ther minute particle may be slightly soluble in the aqueous medium. Preferably, the average particle diameter of the minute particles has range of from 0.01 μm to 1 μm. Specific examples of such inorganic particulate materials include silica, alumina, titanium oxide, barium titanate, magnesium titanate, calcium titanate, strontium titanate, zinc oxide, tin oxide, quartz sand, clay, mica, sand-lime, diatom earth, chromium oxide, cerium oxide, red iron oxide, antimony trioxide, magnesium oxide, zirconium oxide, barium sulfate, barium carbonate, calcium carbonate, silicon carbide, silicon nitride, hydroxyapatite (preferably made by reacting sodium phosphate and calcium chloride), etc. In addition, crystallites of low molecular organic chemicals may be used as fine particles of organic substance. Preferably, the size of the minute particle (Rs)/the size of toner particle(R) satisfies 5≦R/Rs≦2000. It is more preferable that 20≦R/Rs≦200. When these relations are not satisfied, particle control decreases. In addition, the amount of an anchoring minute particle on the particle surface has range of from 0.1 wt % to 20 wt % by weight of resin particles. More preferably, form 1 wt % to 10 wt % by weight of resin particles. From the view point of particle size control, the resin minute particle diameter preferably satisfies 5≦Dv≦500, more preferably satisfies 50≦Dv≦200. (volume average particle diameter: Dv [nm]) Preferably, particle size distribution has a Dv/Dn of resin fine particle smaller than 1.25. For particle size control, particles having a narrow distribution of particle size are preferable. A resin fine particle may be provided by means of soap-free emulsified polymerization, suspension polymerization, dispersion polymerization, etc. Thermosetting resins and thermoplastic resins are preferable. Specific examples of the resins for use as resin particles include vinyl resin, polyurethane resin, epoxide resin, polyester resin, polyamide resin, polyimide resin, silicon type resin, phenol resin, melamine resin, urea resin, aniline resin, ionomer resin, polycarbonate resin, silicone resin, benzguanamine resin, and nylon resin. These resins are used alone or in combination. Of these, vinyl resin, polyurethane resin, epoxide resin, polyester resin and combinations thereof are desirable. Preferred are vinyl resin, polystyrene, methacrylate or acrylate. In addition, in terms of emulsification property, it is preferable to use surfactant having radical polymerization property as reaction initiator. The glass transition point (Tg) of the resin particle preferably is from 40 to 100° C., and the weight average molecular weight thereof preferably is 9,000 to 200,000. When the glass transition point of the resin is too low, the preservability of the toner deteriorates. In contrast, when the glass transition point is too high, the stability of the toner worsens. It is preferable for the residue rate in the toner particle to be controlled in range from 0.5 wt % to 5.0 wt %. When residue rate in the toner particle is less than 0.5 wt %, the toner decrease preservative property, therefore toner blocking occurs in safekeeping and developing machine. In addition, when residue rate in the toner particle is more than 5.0 wt %, resin minute particle obstructs sweating of wax and the effect of releasability of wax is not provided, and printing offset occurs. The residue rate in the resin minute particle is analyzed with thermal decomposition gas chromatograph mass spectrometer. The material which residue rate of resin minute particle is due to not toner particle, and it is due to the resin fine particle. The residue rate in the toner particle is calculated from the peak area of the analyzed result. Mass spectrometer is preferable as detecting element. However, there is no limit in particular. In the present invention toner, a content of THF soluble resin in the toner, which has molecular weight peak of from 1,000 to 30,000, is preferably from 1% by weight or more. And, a number average molecular weight range is 2,000 to 15,000. Such a condition is believed to make the low-temperature fixability and the offset resistance property compatible. The reason why content of high molecular weight component is comparatively small amount preferable modified group in modified polyester (portion of bonding group except for ester bond) has strong cohesion of hydrogen bond. By cohesion of modified group, the resin characteristic that cannot control can be controlled with molecular weight or degree of cross-linking. A content of the THF soluble resin having a molecular weight of from 2,500 to 10,000 is preferably from 0.1 to 5.0% by weight. In addition, the molecular weight distribution of THF soluble component of any polyester type resin contained in the toner is such that from 0.1 to 5.0 wt % has a molecular weight less than 1000. When said component is more than 5.0 wt %, it is unfavorable for pair offset property. When said component is less than 0.1 wt %, it is increasing of raw materials and problem of manufacturing process, cost becomes high. Generally, THF insoluble components of the polyester type contained in toner is preferably in the range from 1 to 15% by weight. When an aqueous dispersion or emulsion is prepared, a solvent which can dissolve the toner composition is preferably used because the resultant particles have a sharp particle diameter distribution. The solvent is preferably volatile and has a boiling point lower than 150° C. due to ease in being removed from the dispersion after the particles are formed. Specific examples of such a solvent include toluene, xylene, benzene, carbon tetrachloride, methylene chloride, 1,2-dichloroethane, 1,1,2-trichloroethane, trichloroethylene, chloroform, monochlorobenzene, dichloroethylidene, methyl acetate, ethyl acetate, methyl ethyl ketone, methyl isobutyl ketone, etc. These solvents can be used alone or in combination. Among these solvents, aromatic solvents such as toluene and xylene; and halogenated hydrocarbons such as methylene chloride, 1,2-dichloroethane, chloroform, and carbon tetrachloride are preferably used. The addition quantity of such a solvent may be, for example, from 40 to 300 parts by weight, preferably from 60 to 140, and more preferably from 80 to 120 parts by weight, per 100 parts by weight of the toner composition used. Suitable colorants for use in the toner of the present invention include known dyes and pigments. Specific examples of the colorants include carbon black, Nigrosine dyes, black iron oxide, Naphthol Yellow S, Hansa Yellow (10G, 5G and G), Cadmium Yellow, yellow iron oxide, loess, chrome yellow, Titan Yellow, polyazo yellow, Oil Yellow, Hansa Yellow (GR, A, RN and R), Pigment Yellow L, Benzidine Yellow (G and GR), Permanent Yellow (NCG), Vulcan Fast Yellow (5G and R), Tartrazine Lake, Quinoline Yellow Lake, Anthrazane Yellow BGL, isoindolinone yellow, red iron oxide, red lead, orange lead, cadmium red, cadmium mercury red, antimony orange, Permanent Red 4R, Para Red, Fire Red, p-chloro-o-nitroaniline red, Lithol Fast Scarlet G, Brilliant Fast Scarlet, Brilliant Carmine BS, Permanent Red (F2R, F4R, FRL, FRLL and F4RH), Fast Scarlet VD, Vulcan Fast Rubine B, Brilliant Scarlet G, Lithol Rubine GX, Permanent Red F5R, Brilliant Carmine 6B, Pigment Scarlet 3B, Bordeaux 5B, Toluidine Maroon, Permanent Bordeaux F2K, Helio Bordeaux BL, Bordeaux 10B, BON Maroon Light, BON Maroon Medium, Eosin Lake, Rhodamine Lake B, Rhodamine Lake Y, Alizarine Lake, Thioindigo Red B, Thioindigo Maroon, Oil Red, Quinacridone Red, Pyrazolone Red, polyazo red, Chrome Vermilion, Benzidine Orange, perynone orange, Oil Orange, cobaltblue, ceruleanblue, Alkali Blue Lake, Peacock Blue Lake, Victoria Blue Lake, metal-free Phthalocyanine Blue, Phthalocyanine Blue, Fast Sky Blue, Indanthrene Blue (RS and BC), Indigo, ultramarine, Prussian blue, Anthraquinone Blue, Fast Violet B, Methyl Violet Lake, cobalt violet, manganese violet, dioxane violet, Anthraquinone Violet, Chrome Green, zinc green, chromium oxide, viridian, emerald green, Pigment Green B, Naphthol Green B, Green Gold, Acid Green Lake, Malachite Green Lake, Phthalocyanine Green, Anthraquinone Green, titanium oxide, zinc oxide, lithopone and the like. These materials are used alone or in combination. The content of the colorant in the toner is preferably from 1% to 15% by weight, and more preferably from 3% to 10% by weight, based on total weight of the toner. Master batch pigments, which are prepared by combining a colorant with a resin, can be used as the colorant of the toner composition of the present invention. Specific examples of the resins for use in the master batch pigments or for use in combination with master batch pigments include the modified and unmodified polyester resins mentioned above; styrene polymers and substituted styrene polymers such as polystyrene, poly-p-chlorostyrene and polyvinyltoluene; styrene copolymers such as styrene-p-chlorostyrene copolymers, styrene-propylene copolymers, styrene-vinyltoluene copolymers, styrene-vinylnaphthalene copolymers, styrene-methyl acrylate copolymers, styrene-ethyl acrylate copolymers, styrene-butyl acrylate copolymers, styrene-octyl acrylate copolymers, styrene-methyl methacrylate copolymers, styrene-ethyl methacrylate copolymers, styrene-butyl methacrylate copolymers, styrene-methyl.alpha.-chloromethacrylate copolymers, styrene-acrylonitrile copolymers, styrene-vinyl methyl ketone copolymers, styrene-butadiene copolymers, styrene-isoprene copolymers, styrene-acrylonitrile-indene copolymers, styrene-maleic acid copolymers and styrene-maleic acid ester copolymers; and other resins such as polymethyl methacrylate, polybutyl methacrylate, polyvinyl chloride, polyvinyl acetate, polyethylene, polypropylene, polyesters, epoxy resins, epoxy polyol resins, polyurethane resins, polyamide resins, polyvinyl butyral resins, acrylic resins, rosin, modified rosins, terpene resins, aliphatic or alicyclic hydrocarbon resins, aromatic petroleum resins, chlorinated paraffin, paraffin waxes, etc. These resins are used alone or in combination. The master batch for use in the toner of the present invention is typically prepared by mixing and kneading a resin and a colorant upon application of high shear stress thereto. In this case, an organic solvent can be used to heighten the interaction of the colorant with the resin. In addition, flushing methods in which an aqueous paste including a colorant is mixed with a resin solution of an organic solvent to transfer the colorant to the resin solution and then the aqueous liquid and organic solvent are separated to be removed can be preferably used because the resultant wet cake of the colorant can be used as it is. In this case, three-roll mills can be preferably used for kneading the mixture upon application of high shear stress thereto. A release agent may be included in the toner of the present invention. Suitable release agents include known waxes. Specific examples of the release agent include polyolefin waxes such as polyethylene waxes and polypropylene waxes; long chain hydrocarbons such as paraffin waxes and SAZOL waxes; waxes including a carbonyl group, etc. Among these waxes, the waxes including a carbonyl group are preferably used. Specific examples of the waxes including a carbonyl group include polyalkane acid esters such as carnauba wax, montan waxes, trimethylolpropane tribehenate, pentaerythritol tetrabehenate, pentaerythritol diacetate dibehenate, glycerin tribehenate, and 1,18-octadecanediol distearate; polyalkanol esters such as trimellitic acid tristearyl, and distearyl maleate; polyalkylamide such as trimellitic acid tristearylamide; dialkyl ketone such as distearyl ketone, etc. Among these materials, polyalkane acid esters are preferable. The waxes for use in the toner of the present invention preferably have a melting point of from 40° C. to 160° C., more preferably from 50° C. to 120° C., and even more preferably from 60° C. to 90° C. When the melting point of the wax included in the toner is too low, the high temperature preservability of the toner deteriorates. In contrast, when the melting point is too high, a cold offset problem in that an offset phenomenon occurs at a low fixing temperature tends to occur. The wax used in the toner of the present invention preferably has a melt viscosity of from 5 to 1000 cps and more preferably from 10 to 100 cps at a temperature 20° C. higher than the melting point of the wax. When the melt viscosity is too high, the effect of improving the hot offset resistance and low temperature fixability is lessened. The content of the wax in the toner is from 0% to 40% by weight and preferably from 3% to 30% by weight based on total weight of the toner. A charge controlling agent may be included in the toner of the present invention. Specific examples of the charge controlling agent include known charge controlling agents such as Nigrosine dyes, triphenylmethane dyes, metal complex dyes including chromium, chelate compounds of molybdic acid, Rhodamine dyes, alkoxyamines, quaternary ammonium salts (including fluorine-modified quaternary ammonium salts), alkylamides, phosphor and compounds including phosphor, tungsten and compounds including tungsten, fluorine-containing activators, metal salts of salicylic acid, metal salts of salicylic acid derivatives, etc. Specific examples of the marketed products of the charge controlling agents include BONTRON 03 (Nigrosine dyes), BONTRON P-51 (quaternary ammonium salt), BONTRON S-34 (metal-containing azo dye), E-82 (metal complex of oxynaphthoic acid) E-84 (metal complex of salicylic acid), and E-89 (phenolic condensation product), which are manufactured by Orient Chemical Industries Co., Ltd.; TP-302 and TP-415 (molybdenum complex of quaternary ammonium salt), which are manufactured by Hodogaya Chemical Co., Ltd.; COPY CHARGE PSY VP2038 (quaternary ammonium salt), COPY BLUE (triphenyl methane derivative), COPY CHARGE NEG VP2036 and NX VP434 (quaternary ammonium salt), which are manufactured by Hoechst AG; LRA-901, and LR-147 (boron complex), which are manufactured by Japan Carlit Co., Ltd.; copper phthalocyanine, perylene, quinacridone, azo pigments and polymers having a functional group such as a sulfonate group, a carboxyl group, a quaternary ammonium group, etc. The content of the charge controlling agent is determined depending on the species of the binder resin used, whether or not an additive is added and toner manufacturing method (such as dispersion method) used, and is not particularly limited. However, the content of the charge controlling agent is typically from 0.1 to 10 parts by weight, and preferably from 0.2 to 5 parts by weight, per 100 parts by weight of the binder resin included in the toner. When the content is too high, the toner has too large charge quantity, and thereby the electrostatic force of a developing roller attracting the toner increases, resulting in deterioration of the fluidity of the toner and decrease of the image density of toner images. The charge controlling agent can be dissolved or dispersed in an organic solvent after kneaded together with a master batch pigment and resin. In addition, the charge controlling agent can be directly dissolved or dispersed in an organic solvent when the toner constituents are dissolved or dispersed in an organic solvent. Alternatively, the charge controlling agent may be fixed on the surface of the toner particles after the toner particles are prepared. Preferably, the charge controlling resin particle, for example polymer type particle is produced by soap-free emulsified polymerization, suspension polymerization, dispersion polymerization. Especially, polycondensation system of silicone, benzoguanamine or nylon, polystyrene provide by monomer which polymer fine particle by thermosetting resin which copolymer was able to put polystyrene turned monomer and copolymerization having carboxyl group of methacrylic acid in particular into, fluorine type methacrylate and fluorine type acrylate in case of emulsion polymerization, dispersion polymerization are made. The thus prepared toner particles may be mixed with an external additive to assist in improving the fluidity, developing property and charging ability of the toner particles. Suitable external additives include particulate inorganic materials. It is preferable for the particulate inorganic materials to have a primary particle diameter of from 5 mμ to 2 μm, and more preferably from 5 mμ to 500 mμ. In addition, it is preferable that the specific surface area of such particulate inorganic materials measured by a BET method is from 20 m 2 /g to 500 m 2 /g. The content of the external additive is preferably from 0.01% to 5% by weight, and more preferably from 0.01% to 2.0% by weight, based on total weight of the toner. Specific examples of such inorganic particulate materials include silica, alumina, titanium oxide, barium titanate, magnesium titanate, calcium titanate, strontium titanate, zinc oxide, tin oxide, quartz sand, clay, mica, sand-lime, diatom earth, chromium oxide, cerium oxide, red iron oxide, antimony trioxide, magnesium oxide, zirconium oxide, barium sulfate, barium carbonate, calcium carbonate, silicon carbide, silicon nitride, etc. In addition, particles of polymers such as polymers and copolymers of styrene, methacrylates, acrylates or the like; polymers prepared by polycondensation polymerization, such as silicone resins, benzoguanamine resins and nylon resins; and thermosetting resins, which can be prepared by a soap-free emulsion polymerization method, a suspension polymerization method or a dispersion method, can also be used as the external additive. These materials for use as the external additive can be subjected to a surface treatment to be hydrophobized, thereby preventing the fluidity and charge properties of the toner even under high humidity conditions. Specific examples of the hydrophobizing agents include silane coupling agents, silylation agents, silane coupling agents including a fluoroalkyl group, organic titanate coupling agents, aluminum coupling agents, silicone oils, modified silicone oils, etc. The toner of the present invention may include a cleanability improving agent to improve the cleaning ability thereof such that the toner remaining on an image bearing member such as photoreceptors and intermediate transfer belts can be easily removed therefrom. Specific examples of the cleanability improving agents include fatty acids and metal salts thereof such as zinc stearate, calcium stearate and stearic acid; polymer particles which are prepared by a soap-free emulsion polymerization method or the like, such as polymethyl methacrylate particles and polystyrene particles; etc. The polymer particles preferably have a narrow particle diameter distribution and the volume average particle diameter thereof is preferably from 0.01 μm to 1 μm. The binder resins (e.g., modified polyester resins and unmodified polyester resins) for use in the toner of the present invention may typically be prepared by the following method. A polyol and a polycarboxylic acid are heated to a temperature of from 150° C. to 280° C. in the presence of a known esterification catalyst such as tetrabutoxy titanate and dibutyltinoxide. Then water generated is removed, under a reduced pressure if desired, to prepare a polyester resin having a hydroxyl group. Then the polyester resin is reacted with a polyisocyanate at a temperature of from 40° C. to 140° C. to prepare a prepolymer (A) having an isocyanate group. The toner of the present invention can be manufactured by the following method, but the manufacturing method is not limited thereto. Suitable aqueous media for use in the toner manufacturing method of the present invention include water and mixtures of water with a solvent which can be mixed with water. Specific examples of such a solvent include alcohols (e.g., methanol, isopropanol and ethylene glycol), dimethylformamide, tetrahydrofuran, cellosolves (e.g., methyl cellosolve), lower ketones (e.g., acetone and methyl ethyl ketone), etc. In addition, there is when adding fine particle of resin fine particle in aqueous solvent phase beforehand. Toner particles can be prepared by reacting a dispersion, in which a prepolymer (A) having an isocyanate group is dispersed in an aqueous medium, with an amine (B). In order to prepare a dispersion in which a urea-modified polyester resin or a prepolymer (A) is stably dispersed in an aqueous medium, a method, in which toner constituents including a urea-modified polyester or a prepolymer (A) are added into an aqueous medium and then dispersed upon application of shear stress, is preferably used. A prepolymer (A) and other toner constituents such as colorants, master batch pigments, release agents, charge controlling agents, unmodified polyester resins, etc. may be added into an aqueous medium at the same time when the dispersion is prepared. However, it is preferable that the toner constituents are previously mixed and then the mixed toner constituents are added to the aqueous liquid at the same time to be dispersed. In addition, toner constituents such as colorants, release agents and charge controlling agents are not necessarily added to the aqueous dispersion before particles are formed, and may be added thereto after particles are prepared in the aqueous medium. For example, a method in which particles, which are previously formed without a colorant, are dyed by a known dying method can also be used. The dispersion method is not particularly limited, and low speed shearing methods, high speed shearing methods, friction methods, high pressure jet methods, ultrasonic methods, etc. can be used. Among these methods, high speed shearing methods are preferable because particles having a particle diameter of from 2 μm to 20 μm can be easily prepared. When a high speed shearing type dispersion machine is used, the rotation speed is not particularly limited, but the rotation speed is typically from 1,000 rpm to 30,000 rpm, and preferably from 5,000 rpm to 20,000 rpm. The dispersion time is not also particularly limited, but is typically from 0.1 to 5 minutes. The temperature in the dispersion process is typically from 0° C. to 150° C. (under pressure), and preferably from 40° C. to 98° C. When the temperature is relatively high, a urea-modified polyester or a prepolymer (A) can be easily dispersed because the dispersion has a low viscosity. The weight ratio (T/M) of the toner constituents (T) (including a prepolymer (A)) to the aqueous medium (M) is typically from 100/50 to 100/2,000, and preferably from 100/100 to 100/1,000. When the ratio is too large (i.e., the quantity of the aqueous medium is small), the dispersion of the toner constituents in the aqueous medium is not satisfactory, and thereby the resultant toner particles do not have a desired particle diameter. In contrast, when the ratio is too small, the manufacturing costs increase. Specific examples of the dispersants which are used for dispersing or emulsifying an oil phase, in which toner constituents are dissolved or dispersed, in an aqueous liquid, include anionic surfactants such as alkylbenzene sulfonic acid salts, .alpha.-olefin sulfonic acid salts, and phosphoric acid salts; cationic surfactants such as amine salts (e.g., alkyl amine salts, aminoalcohol fatty acid derivatives, polyamine fatty acid derivatives and imidazoline), and quaternary ammonium salts (e.g., alkyltrimethyl ammonium salts, dialkyldimethyl ammonium salts, alkyldimethyl benzyl ammonium salts, pyridinium salts, alkyl isoquinolinium salts and benzethonium chloride); nonionic surfactants such as fatty acid amide derivatives, polyhydric alcohol derivatives; and ampholytic surfactants such as alanine, dodecyldi(aminoethyl)glycin, di)octylaminoethyle)glycin, and N-alkyl-N,N-dimethylammonium betaine. By using a surfactant having a fluoroalkyl group, a dispersion having good dispersibility can be prepared even when a small amount of the surfactant is used. Specific examples of anionic surfactants having a fluoroalkyl group include fluoroalkyl carboxylic acids having from 2 to 10 carbon atoms and their metal salts, disodium perfluorooctanesulfonylgl-utamate, sodium 3-{omega-fluoroalkanoyl(C6–C11)oxy}-1-alkyl(C3–C4) sulfonate, sodium 3-{omega-fluoroalkanoyl(C6–C8)-N-ethylamino}-1-propanes-ulfonate, fluoroalkyl(C11–C20) carboxylic acids and their metal salts, perfluoroalkylcarboxylic acids and their metal salts, perfluoroalkyl(C4–C12)sulfonate and their metal salts, perfluorooctanesulfonic acid diethanol amides, N-propyl-N-(2-hydroxyethyl-)perfluorooctanesulfone amide, perfluoroalkyl(C6–C10)sulfoneamidepropyltri-methylammonium salts, salts of perfluoroalkyl (C6–C10)-N-ethylsulfonyl glycin, monoperfluoroalkyl(C6–C16)ethylphosphates, etc. Specific examples of the marketed products of such surfactants having a fluoroalkyl group include SURFLON S-111, S-112 and S-113, which are manufactured by Asahi Glass Co., Ltd.; FRORARD FC-93, FC-95, FC-98 and FC-129, which are manufactured by Sumitomo 3M Ltd.; UNTDYNE DS-101 and DS-102, which are manufactured by Daikin Industries, Ltd.; MEGAFACE F-110, F-120, F-113, F-191, F-812 and F-833 which are manufactured by Dainippon Ink and Chemicals, Inc.; ECTOP EF-102, 103, 104, 105, 112, 123A,306A, 501, 201 and 204, which are manufactured by Tohchem Products Co., Ltd.; FUTARGENT F-100 and F150 manufactured by Neos; etc. Specific examples of the cationic surfactants, which can be used for dispersing an oil phase including toner constituents in water, include primary, secondary and tertiary aliphatic amines having a fluoroalkyl group, aliphatic quaternary ammonium salts such as perfluoroalkyl(C6–C10)sulfoneamidepropyltrimethylammonium salts, benzalkonium salts, benzetonium chloride, pyridinium salts, imidazolinium salts, etc. Specific examples of the marketed products thereof include SURFLON S-121 (from Asahi Glass Co., Ltd.); FRORARD FC-135 (from Sumitomo 3M Ltd.); UNIDYNE DS-202 (from Daikin Industries, Ltd.); MEGAFACE F-150 and F-824 (from Dainippon Ink and Chemicals, Inc.); ECTOP EF-132 (from Tohchem Products Co., Ltd.); FUTARGENT F-300 (from Neos); etc. An inorganic compound which is hardly soluble in water, such as calcium phosphate, titanium oxide, colloidal silica, and hydroxyapatite can also be used as the dispersant. Further, it is possible to stably disperse toner constituents in water using a polymeric protection colloid. Specific examples of such protection colloids include polymers and copolymers prepared using monomers such as acids (e.g., acrylic acid, methacrylic acid, .alpha.-cyanoacrylic acid, .alpha.-cyanomethacrylic acid, itaconic acid, crotonic acid, fumaric acid, maleic acid and maleic anhydride), acrylic monomers having a hydroxyl group (e.g., .beta.-hydroxyethyl acrylate, .beta.-hydroxypropyl methacrylate, .beta.-hydroxypropyl acrylate, .beta.-hydroxypropyl methacrylate, .gamma.-hydroxypropyl acrylate, .gamma.-hydroxypropyl methacrylate, 3-chloro-2-hydroxypropyl acrylate, 3-chloro-2-hydroxypropyl methacrylate, diethyleneglycolmonoacrylic acid esters, diethyleneglycolmonomethacrylic acid esters, glycerinmonoacrylic acid esters, N-methylolacrylamide and N-methylolmethacrylamide), vinyl alcohol and its ethers (e.g., vinyl methyl ether, vinyl ethyl ether and vinyl propyl ether), esters of vinyl alcohol with a compound having a carboxyl group (i.e., vinyl acetate, vinyl propionate and vinyl butyrate); acrylic amides (e.g, acrylamide, methacrylamide and diacetoneacrylamide) and their methylol compounds; acid chlorides (e.g., acrylic acid chloride and methacrylic acid chloride); and monomers having a nitrogen atom or an alicyclic ring having a nitrogen atom (e.g., vinyl pyridine, vinyl pyrrolidone, vinyl imidazole and ethylene imine). Polymers such as polyoxyethylene compounds (e.g., polyoxyethylene, polyoxypropylene, polyoxyethylenealkyl amines, polyoxypropylenealkyl amines, polyoxyethylenealkyl amides, polyoxypropylenealkyl amides, polyoxyethylene nonylphenyl ethers, polyoxyethylene laurylphenyl ethers, polyoxyethylene stearylphenyl esters, and polyoxyethylene nonylphenyl esters); and cellulose compounds such as methyl cellulose, hydroxyethyl cellulose and hydroxypropyl cellulose, can also be used as the polymeric protective colloid. When compounds such as calcium phosphate which are soluble in an acid or alkali are used as a dispersion stabilizer, it is preferable to dissolve calcium phosphate by adding an acid such as hydrochloric acid and to wash the resultant particles with water to remove calcium phosphate therefrom. In addition, such a dispersion stabilizer can be removed using a decomposition method using an enzyme. When a dispersant is used, the resultant particles are preferably washed after the particles are subjected to an elongation and/or a crosslinking reaction to impart good charge ability to the resultant toner particles. When a modified polyester resin reactive with an active hydrogen is reacted with an amine (B) serving as a crosslinking agent and/or an elongation agent, the crosslinking time and/or the elongation time is determined depending on the reactivity of the isocyanate group of the prepolymer (A) with the amine (B) used, but in general the time is from 10 minutes to 40 hours, and preferably from 2 to 24 hours. The reaction temperature is generally from 0° C. to 150° C., and preferably from 40° C. to 98° C. In addition, a catalyst such as dibutyltin laurate and dioctyltin laurate can be optionally used for the reaction. In order to remove the organic solvent from the thus prepared emulsion (dispersion), a drying method in which the temperature of the emulsion is gradually increased to evaporate the organic solvent from the drops dispersed in the emulsion can be used. Alternatively, a drying method in which the emulsion is sprayed in a dry atmosphere to dry not only the organic solvent in the drops in the emulsion but also the remaining aqueous medium. The dry atmosphere can be prepared by heating gases such as air, nitrogen, carbon dioxide and combustion gases. The temperature of the heated gases is preferably higher than the boiling point of the solvent having the highest boiling point among the solvents used in the emulsion. By using spray dryers, belt dryers, rotary kilns, etc., as a drying apparatus, the drying treatment can be completed in a short period of time. When particle size distribution in emulsification dispersion keeps the particle size distribution broadly, and cleaning and desiccation treatment did, classifying is done, and desired particle size distribution can fix particle size distribution. When the thus prepared toner particles have a wide particle diameter distribution even after the particles are subjected to a washing treatment and a drying treatment, the toner particles are preferably subjected to a classification treatment so that the toner particles have a desired particle diameter distribution. The classification operation can be performed on a dispersion liquid using a cyclone, a decanter or a method utilizing centrifuge to remove fine particles therefrom. Of course, it is possible to classify the dried toner particles. However, it is preferable to subject the liquid including the particles to the classification treatment in view of efficiency. The toner particles having an undesired particle diameter can be reused as the raw materials for the kneading process. Such toner particles for reuse may be in a dry condition or a wet condition. The dispersant used is preferably removed from the particle dispersion. The dispersant is preferably removed from the dispersion when the classification treatment is performed. The thus prepared toner particles can be mixed with other particles such as release agents, charge controlling agents, fluidizing agents and colorants. Such particles can be fixed on the toner particles by applying mechanical impact thereto while the particles and toner particle can be integrated. Thus the particles can be prevented from being released from the toner particles. Specific examples of such mechanical impact application methods include methods in which a mixture is mixed with a highly rotated blade and methods in which a mixture is put into a jet air to collide the particles against each other or a collision plate. Specific examples of such mechanical impact applicators include ONG MILL (manufactured by Hosokawa Micron Co., Ltd.), modified I TYPE MILL in which the pressure of air used for pulverizing is reduced (manufactured by Nippon Pneumatic Mfg. Co., Ltd.), HYBRIDIZATION SYSTEM (manufactured by Nara Machine Co., Ltd.), KRYPTRON SYSTEM (manufactured by Kawasaki Heavy Industries, Ltd.), automatic mortars, etc. The toner of the present invention can be used for a two-component developer in which the toner is mixed with a magnetic carrier. The weight ratio (T/C) of the toner (T) to the carrier (C) is preferably from 1/100 to 10/100. Suitable carriers for use in the two component developer include known carrier materials such as iron powders, ferrite powders, magnetite powders, magnetic resin carriers, which have a particle diameter of from about 20 μm to about 200 μm. The surface of the carriers may be coated by a resin. Specific examples of such resins to be coated on the carriers include amino resins such as urea-formaldehyde resins, melamine resins, benzoguanamine resins, urea resins, and polyamide resins, and epoxy resins. In addition, vinyl or vinylidene resins such as acrylic resins, polymethylmethacrylate resins, polyacrylonitirile resins, polyvinyl acetate resins, polyvinyl alcohol resins, polyvinyl butyral resins, polystyrene resins, styrene-acrylic copolymers, halogenated olefin resins such as polyvinyl chloride resins, polyester resins such as polyethyleneterephthalate resins and polybutyleneterephthalate resins, polycarbonate resins, polyethylene resins, polyvinyl fluoride resins, polyvinylidene fluoride resins, polytrifluoroethylene resins, polyhexafluoropropylene resins, vinylidenefluoride-acrylate copolymers, vinylidenefluoride-vinylfluoride copolymers, copolymers of tetrafluoroethylene, vinylidenefluoride and other monomers including no fluorine atom, and silicone resins. If desired, an electroconductive powder may be included in the toner. Specific examples of such electroconductive powders include metal powders, carbon blacks, titanium oxide, tin oxide, and zinc oxide. The average particle diameter of such electroconductive powders is preferably not greater than 1 μm. When the particle diameter is too large, it is hard to control the resistance of the resultant toner. The toner of the present invention can also be used as a one-component magnetic developer or a one-component non-magnetic developer. Having generally described this invention, further understanding can be obtained by reference to certain specific examples which are provided herein for the purpose of illustration only and are not intended to be limiting. In the descriptions in the following examples, the numbers represent weight ratios in parts, unless otherwise specified. Synthesis of Low Molecular Weight Polyester Manufacturing Example 1-1 In a reaction container equipped with a condenser, a stirrer and a pipe from which a nitrogen gas was supplied to the container, 229 parts of an adduct of bisphenol A with 2 moles of ethyleneoxide, 529 parts of an adduct of bisphenol A with 3 moles of propyleneoxide, 208 parts of terephthalic acid, 46 parts of adipic acid, and 2 parts of dibutyl tin oxide were mixed. Then the mixture was reacted for 8 hours at 230° C. under a normal pressure. Then the reaction was further performed for 5 hours under a reduced pressure of from 10 mmHg to 15 mmHg. In addition, 44 parts of trimellitic anhydride were added thereto and the mixture was reacted for 2 hours at 180° C. under a normal pressure. Thus, a low molecular weight polyester 1 was prepared. The low molecular weight polyester 1 had a number average molecular weight of 2500, a weight average molecular weight of 6700, a glass transition temperature of 43° C. and an acid value of 25. Preparation of Prepolymer Manufacturing Example 2 In a reaction container equipped with a condenser, a stirrer and a pipe from which a nitrogen gas was supplied to the container, 682 parts of an adduct of bisphenol A with 2 moles of ethyleneoxide, 81 parts of an adduct of bisphenol A with 2 moles of propyleneoxide, 283 parts of terephthalic acid, 22 parts of trimellitic anhydride, and 2 parts of dibutyl tin oxide were mixed. Then the mixture was reacted for 8 hours at 230° C. under a normal pressure. Then the reaction was further performed for 5 hours under a reduced pressure of from 10 to 15 mmHg. Thus, an intermediate polyester 1 was prepared. The intermediate polyester 1 had a number average molecular weight of 2100, a weight average molecular weight of 9500, a glass transition temperature of 55° C. acid value of 0.5 and a hydroxyl value of 51. In a reaction container equipped with a condenser, a stirrer and a pipe from which a nitrogen gas was supplied to the container, 411 parts of the intermediate polyester 1, 89 parts of isophorondiisocyanate and 500 parts of ethyl acetate were added. The mixture was reacted for 5 hours at 100° C. Thus, a prepolymer 1 was prepared. The prepolymer included a free isocyanate group in an amount of 1.53% by weight. The solid content of the prepolymer was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Synthesis of Ketimine Manufacturing Example 3 In a reaction container equipped with a stirrer and a thermometer, 170 parts of isophoronediamine and 75 parts of methyl ethyl ketone were mixed. The mixture was reacted for 5 hours at 50° C. Thus, a ketimine compound 1 was prepared. The ketimine compound had an amine value of 418. (Preparation of MB) Manufacturing Example 4-1 1200 parts of water, 800 parts of carbon black, and 800 parts of polyester resin were mixed in a Henshel mixer (made in MITSUI MINING COMPANY, LTD.). This mixture was kneaded for 30 minutes at 130° C. using a two-roll mill. After rolling cooled, the kneaded mixture was pulverized. Thus, a[master batch 1] was prepared. Manufacturing Example 4-2 1200 parts of water, 800 parts of C.I. Pigment yellow 180, and 800 parts of polyester resin were mixed in a Henshel mixer (made in MITSUI MINING COMPANY, LTD.). This mixture was kneaded for 30 minutes at 150° C. using a two-roll mill. After the mixture was rolling and cooled, the kneaded mixture was pulverized. Thus, a[master batch 2] was prepared. Manufacturing Example 4-3 1200 parts of water, 3800 parts of Cu-phthalocyanine 5, and 800 parts of polyester resin were mixed in a Henshel mixer. This mixture was kneaded for 30 minutes at 150° C. using a two-roll mill. After the mixture was rolling and cooled, the kneaded mixture was pulverized. Thus, a[master batch 3] was prepared. Manufacturing Example 4-4 1200 parts of water, 800 parts of C.I. Pigment red 122, and 800 parts of polyester resin were mixed in a Henshel mixer. This mixture was kneaded for 30 minutes at 150° C. using a two-roll mill. After the mixture was rolling and cooled, the kneaded mixture was pulverized. Thus, a[master batch 4] was prepared. Preparation of Oil Phase Manufacturing Example 5-1 In a reaction container equipped with a stirrer and a thermometer, 100 parts of synthetic ester wax low molecular weight polyester 1, 20 parts of a metal complex of salicylic acid serving as a charge controlling agent (E-84 from Orient Chemical Industries Co., Ltd.) and 880 parts of ethyl acetate were mixed. The mixture was heated at 80° C. for 5 hours while agitated and then cooled to 30° C. while taking one hour. Then 400 parts of the master batch 1 and 600 parts of ethyl acetate were added thereto to be mixed for 1 hour. Thus, a toner constituent solution 1 was prepared. Then 600 parts of the toner constituent solution 1 were contained in a container, and then dispersed using a bead mill (ULTRAVISCOMILL from AIMEX) under the following conditions: Liquid feeding speed: 1 kg/hr, Disc rotation speed: 6 m/sec, Diameter of beads: 0.5 mm, Filling factor: 80% by volume, and Repeat number of dispersion treatment: 3 times. Thus, the pigment and wax were dispersed. Then 2024 parts of a 65% ethyl acetate solution of the low molecular weight polyester 1 were added thereto, and the mixture was dispersed under the conditions mentioned above except that the repeat number of the dispersion treatment was changed to 1 time. Thus, a pigment/wax dispersion 1 was prepared. The solid content of the pigment/wax dispersion 1 was 49% when measured by heating the dispersion at 130° C. for 30 minutes. Manufacturing Example 5-2 The procedure for preparation of the pigment/wax dispersion 1 was repeated except that the master batch 1 was replaced with the master batch 2. Thus, pigment/wax dispersion 2 was prepared. The solid content of the pigment/wax dispersion 2 was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Manufacturing Example 5-3 The procedure for preparation of the pigment/wax dispersion 1 was repeated except that the master batch 1 was replaced with the master batch 3. Thus, pigment/wax dispersion 3 was prepared. The solid content of the pigment/wax dispersion 2 was 49% when measured by heating the dispersion at 130° C. for 30 minutes. Manufacturing Example 5-4 The procedure for preparation of the pigment/wax dispersion 1 was repeated except that the master batch 1 was replaced with the master batch 4. Thus, pigment/wax dispersion 4 was prepared. The solid content of the pigment/wax dispersion 4 was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Preparation of Aqueous Phase Manufacturing Example 6-1 In a container, 990 parts of water, 80 parts of the particle dispersion 1, 35 parts of a 49.3% aqueous solution of sodium dodecyldiphenylether disulfonate (EREMINOR MON-7 manufactured by Sanyo Chemical Industries, Ltd.) and 90 parts of ethyl acetate were mixed. As a result, an aqueous phase 1 was prepared. Preparation of Fluorine Type Activator Aqueous Solution Manufacturing Example 7-1 In container, 10 parts of N,N,N-trimethly-[3-(4-perfluorononenyloxy banzamide)propyl]ammonium iodide(Ftergent 310 manufactured by Neos Company), 297 parts of methanol s were mixed. The mixture was heated at 50° C. while agitated and the mixture become transparent. Then the fluorine type activator methanol solution was provided. 693 parts of ion exchanged water agitating drop wised to the fluorine active agent methyl alcohol solution. After a drop wise was finished, it was agitated in 50° C. for 30 minutes. Fluorine active agent water solution 1 was thus prepared. Emulsification and Solvent Removal EXAMPLE 1 The following components were contained in a contained to be mixed for 1 minute using a TK HOMOMIXER (manufactured by Tokushu Kika Kogyo Co., Ltd.) at a revolution of 5,000 rpm. 1. Pigment/wax dispersion 1 806 parts 2. Prepolymer 1 154 parts 3. Ketimine compound 10.7 parts  Then, 1960 parts of the aqueous phase 1 were added thereto and the mixture was dispersed for 20 minute using a TK HOMOMIXER at a revolution of 13,000 rpm. Thus, an emulsion slurry 1 was prepared. In a container equipped with a stirrer and a thermometer, the emulsion slurry 1 was added and then was heated at 30° C. for 8 hour to remove the solvents therefrom. Then the slurry was aged at 50° C. for 8 hours to prepare a dispersion slurry 1. Washing and Drying 100 parts of the emulsion slurry 1 were filtered by filtering under a reduced pressure. Then the following operations were performed. (1) 100 parts of deionized water were added to the thus prepared cake and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; (2) 100 parts of a 10% aqueous solution of sodium hydroxide were added to the cake prepared in (1) and the mixture was mixed for 30 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm while applying supersonic vibration thereto, and then filtered under a reduced pressure, wherein this washing using an alkali was repeated twice; (3) 100 parts of a 10% hydrochloric acid were added to the cake prepared in (2) and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; and (4) 300 parts of deionized water were added to the cake prepared in (3) and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; wherein this washing was repeated twice to prepare a filtered cake 1. Fluorine Type Activator Treatment In container, 630 parts of filtered cake 1, 2928 parts of ion-exchange water were agitated for 5 minutes by three one motor (manufactured by Shinto Science Corp.) at revolution of 4,000 rpm. The mixture composition was heated for 30° C. The fluorine active agent water solution 1 drop wised to the mixture composition under maintaining at revolution and temperature. After drop wised, the mixture composition was agitated for 60 minutes, wherein this filtered to prepare a Fluorine type activator treatment filtered cake 1. The filtered cake 1 was dried for 48 hours at 45° C. using a circulating drier. The dried cake was sieved using a screen having openings of 75 μm. Thus a toner 1 was prepared. EXAMPLE 2 The procedure for preparation of the toner 1 was repeated except that the pigment/wax dispersion 1 was replaced with the pigment/wax dispersion 2. Thus, a toner 2 was prepared. EXAMPLE 3 The procedure for preparation of the toner 1 was repeated except that the pigment/wax dispersion 1 was replaced with the pigment/wax dispersion 3. Thus, a toner 3 was prepared. EXAMPLE 4 The procedure for preparation of the toner 1 was repeated except that the pigment/wax dispersion 1 was replaced with the pigment/wax dispersion 4. Thus, a toner 4 was prepared. Then 600 parts of the toner constituent solution 1 were contained in a container, and then dispersed using a bead mill (ULTRAVISCOMILL from AIMEX) under the following conditions: Liquid feeding speed: 1 kg/hr, Disc rotation speed: 6 m/sec, Diameter of beads: 0.5 mm, Filling factor: 80% by volume, and Repeat number of dispersion treatment: 3 to 12 times. Thus, the pigment and wax were dispersed. Then 588 parts of a 65% ethyl acetate solution of the low molecular weight polyester 1 were added thereto, and the mixture was dispersed under the conditions mentioned above except that the repeat number of the dispersion treatment was changed to 1 time. Thus, a pigment/wax dispersion 1 was prepared. The solid content of the pigment/wax dispersion 1 was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Manufacturing Example 5-6 The procedure for preparation of the pigment/wax dispersion 1 was repeated except that the master batch 1 was replaced with the master batch 2. Thus, pigment/wax dispersion 6 was prepared. The solid content of the pigment/wax dispersion 6 was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Manufacturing Example 5-7 The procedure for preparation of the pigment/wax dispersion 1 was repeated except that the master batch 1 was replaced with the master batch 3. Thus, pigment/wax dispersion 7 was prepared. The solid content of the pigment/wax dispersion 7 was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Manufacturing Example 5-8 The procedure for preparation of the pigment/wax dispersion 1 was repeated except that the master batch 1 was replaced with the master batch 4. Thus, pigment/wax dispersion 8 was prepared. The solid content of the pigment/wax dispersion 8 was 50% when measured by heating the dispersion at 130° C. for 30 minutes. Emulsification and Solvent Removal EXAMPLE 5 The following components were contained in a contained to be mixed for 1 minute using a TK HOMOMIXER at a revolution of 5,000 rpm. 1. Pigment/wax dispersion 5  888 parts 2. Prepolymer 1 1464 parts 3. Ketimine compound   6.2 parts Then, 1960 parts of the aqueous phase 1 were added thereto and the mixture was dispersed for 20 minute using a TK HOMOMIXER at a revolution of 13,000 rpm. Thus, an emulsion slurry 2 was prepared. In a container equipped with a stirrer and a thermometer, the emulsion slurry 2 was added and then was heated at 30° C. for 8 hour to remove the solvents therefrom. Then the slurry was aged at 50° C. for 8 hours to prepare a dispersion slurry 2. Washing and Drying 100 parts of the emulsion slurry 1 were filtered by filtering under a reduced pressure. Then the following operations were performed. (1) 100 parts of deionized water were added to the thus prepared cake and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; (2) 100 parts of a 10% aqueous solution of sodium hydroxide were added to the cake prepared in (1) and the mixture was mixed for 30 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm while applying supersonic vibration thereto, and then filtered under a reduced pressure, wherein this washing using an alkali was repeated twice; (3) 100 parts of a 10% hydrochloric acid were added to the cake prepared in (2) and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; and (4) 300 parts of deionized water were added to the cake prepared in (3) and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered, wherein this washing was repeated twice to prepare a filtered cake 1. Fluorine Type Activator Treatment In container, 630 parts of filtered cake 2, 2928 parts of ion-exchange water were agitated for 5 minutes by three one motor (manufactured by Shinto Science Corp.) at revolution of 4,000rpm. The mixture composition was heated for 30° C. The fluorine active agent water solution 1 drop wised to the mixture composition under maintaining at revolution and temperature. After drop wised, the mixture composition was agitated for 60 minutes, wherein this filtered to prepare a Fluorine type activator treatment filtered cake 2. (Desiccation/Air Elutriation) The filtered cake 2 was dried for 48 hours at 45° C. using a circulating drier. The dried cake was sieved using a screen having openings of 75 μm. Thus a toner 5 was prepared. EXAMPLE 6 The procedure for preparation of the toner 6 was repeated except that the pigment/wax dispersion 5 was replaced with the pigment/wax dispersion 6. Thus, a toner 6 was prepared. EXAMPLE 7 The procedure for preparation of the toner 7 was repeated except that the pigment/wax dispersion 5 was replaced with the pigment/wax dispersion 7. Thus, a toner 7 was prepared. EXAMPLE 8 The procedure for preparation of the toner 8 was repeated except that the pigment/wax dispersion 5 was replaced with the pigment/wax dispersion 8. Thus, a toner 8 was prepared. Synthesis of Emulsion of Resin Particles Manufacturing Example 8-1 In a reaction container equipped with a stirrer and a thermometer, 683 parts of water, 11 parts of a sodium salt of sulfate of an adduct of methacrylic acid with ethyleneoxide (EREMINOR RS-30 from Sanyo Chemical Industries Ltd.), 83 parts of styrene, 83 parts of methacrylic acid, 111 parts of butyl acrylate, and 1 part of ammonium persulfate were added and the mixture was agitated for 15 minutes at a revolution of 400 rpm. As a result, a white emulsion was obtained. Then the emulsion was heated to 75° C. to perform a reaction for 5 hours. Then 30 parts of a 1% aqueous solution of ammonium persulfate were added to the emulsion and the mixture was further aged for 5 hours at 75° C. Thus, an aqueous dispersion (particle dispersion 1) of a vinyl resin (i.e., a copolymer of styrene-methacrylic acid-methacrylate-a sodium salt of a sulfate of an adduct of methacrylic acid with ethyleneoxide) was prepared. The volume average particle diameter of the particle dispersion 1 was 0.10 μm when measured with an instrument LA-920. A part of the particle dispersion 1 was dried to prepare a particulate resin. The glass transition temperature of the particulate resin was 60° C. Preparation of Aqueous Phase Manufacturing Example 6-2 83 parts of the particle dispersion 1 were mixed with 990 parts of water, 40 parts of a 48.5% aqueous solution of sodium dodecyl diphenyl ether disulfonate (EREMINOR MON-7 from Sanyo Chemical Industries, Ltd.), and 90 parts of ethyl acetate. Thus, an aqueous phase 2 was prepared. EXAMPLE 9 The procedure for preparation of the toner 9 was repeated except that the aqueous phase 1 was replaced with the aqueous phase 2. Thus, a toner 9 was prepared. EXAMPLE 10 The procedure for preparation of the toner 10 was repeated except that the aqueous phase 1 was replaced with the aqueous phase 2. Thus, a toner 10 was prepared. EXAMPLE 11 The procedure for preparation of the toner 11 was repeated except that the aqueous phase 1 was replaced with the aqueous phase 2. Thus, a toner 11 was prepared. EXAMPLE 12 The procedure for preparation of the toner 12 was repeated except that the aqueous phase 1 was replaced with the aqueous phase 2. Thus, a toner 12 was prepared. Emulsification and Solvent Removal EXAMPLE 13 The following components were contained in a contained to be mixed for 1 minute using a TK HOMOMIXER (manufactured by Tokushu Kika Kogyo Co., Ltd.) at a revolution of 5,000 rpm. 1. Pigment/wax dispersion 1 888 parts 2. Prepolymer 1 146 parts 3. Ketimine compound  6.2 parts Then, 1960 parts of the aqueous phase 2 were added thereto and the mixture was dispersed for 20 minute using a TK HOMOMIXER at a revolution of 13,000 rpm. Thus, an emulsion slurry 3 was prepared. In a container equipped with a stirrer and a thermometer, the emulsion slurry 1 was added and then was heated at 30° C. for 8 hour to remove the solvents therefrom. Then the slurry was aged at 50° C. for 8 hours to prepare a dispersion slurry 3. Using a procedure as in example 5, a toner 13 was prepared. Preparation of Fluorine Type Activator Aqueous Solution Manufacturing Example 7-2 In container, 10 parts of MEGAFACE F-120 manufactured by DAINIPPON INK AND CHEMICALS INC.), 297 parts of methanol s were mixed. The mixture was heated at 50° C. while agitated and the mixture become transparent. Then the fluorine type activator methanol solution was provided. 693 parts of ion exchanged water agitating drop wised to the fluorine active agent methyl alcohol solution. After a drop wise was finished, it was sagitated in 50° C. for 30 minutes. That result fluorine active agent water solution 2 was prepared. EXAMPLE 14 Washing and Drying 100 parts of the emulsion slurry 3 were filtered by filtering under a reduced pressure. Then the following operations were performed. (1) 100 parts of deionized water were added to the thus prepared cake and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; (2) 100 parts of a 10% aqueous solution of sodium hydroxide were added to the cake prepared in (1) and the mixture was mixed for 30 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm while applying supersonic vibration thereto, and then filtered under a reduced pressure, wherein this washing using an alkali was repeated twice; (3) 100 parts of a 10% hydrochloric acid were added to the cake prepared in (2) and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered; and (4) 300 parts of deionized water were added to the cake prepared in (3) and the mixture was mixed for 10 minutes by a TK HOMOMIXER at a revolution of 12,000 rpm and then filtered, wherein this washing was repeated twice to prepare a filtered cake 2. Fluorine Type Activator Treatment In container, 630 parts of filtered cake 2, 2928 parts of ion-exchange water were agitated for 5 minutes by three one motor (manufactured by Shinto Science Corp.) at revolution of 4,000 rpm. The mixture composition was heated for 30° C. The fluorine active agent water solution 1 drop wised to the mixture composition under maintaining at revolution and temperature. After drop wised, the mixture composition was agitated for 60 minutes, wherein this filtered to prepare a Fluorine type activator treatment filtered cake 3. (Desiccation/Air Elutriation) The fluorine type activator treatment filtered cake 3 was dried for 48 hours at 45° C. using a circulating drier. The dried cake was sieved using a screen having openings of 75 μm. Thus a toner 14 was prepared. EXAMPLE 15 The procedure for preparation of the toner 15 was repeated except that the pigment/wax dispersion 5 was replaced with the pigment/wax dispersion 8. Thus, a toner 15 was prepared. Preparation of Organic Particle Emulsion Manufacturing Example 8-2 In a reaction vessel equipped with an agitator and a thermometer, 683 parts of water, 11 parts of a sodium salt of sulfate of an adduct of methacrylic acid with ethylene oxide (EREMINOR RS-30 from Sanyo Chemical Industries, Ltd.), 111 parts of styrene, 83 parts of methacrylic acid, 55 parts of butyl acrylate, 28 parts of perpenthafluoroacrylate, dibvinylbenzene and 1 part of ammonium persulfate were contained and agitated for 15 minutes at a revolution of 400 rpm. As a result, a white emulsion was prepared. The emulsion was heated to 75° C. to perform a reaction for 5 hours. In addition, 30 parts of a 1% aqueous solution of ammonium persulfate were added thereto and aged for 5 hours at 75° C. Thus, an aqueous dispersion (particle dispersion 2) was prepared. The volume average particle diameter of the particle dispersion 2 was 0.16 μm when measured with an instrument LA-920. By drying a part of the particle dispersion 2, resin particles were prepared. The glass transition temperature of the resin particles was 128° C. (Preparation of Aqueous Phase) Manufacturing Example 2-3 The manufacturing method 8-2 was repeated except that the fine particle dispersion liquid 2 was replaced with the fine particle dispersion liquid 1. Thus, a aqueous phase 3 was prepared. Emulsification and Solvent Removal EXAMPLE 16 The following components were contained in a contained to be mixed for 1 minute using a TK HOMOMIXER (manufactured by Tokushu Kika Kogyo Co., Ltd.) at a revolution of 5,000 rpm. 1. Pigment/wax dispersion 1 888 parts 2. Prepolymer 1 146 parts 3. Ketimine compound  6.2 parts Then, 1960 parts of the aqueous phase 3 were added thereto and the mixture was dispersed for 20 minute using a TK HOMOMIXER at a revolution of 13,000 rpm. Thus, an emulsion slurry 4 was prepared. In a container equipped with a stirrer and a thermometer, the emulsion slurry 4 was added and then was heated at 30° C. for 8 hour to remove the solvents therefrom. Then the slurry was aged at 50° C. for 8 hours to prepare a dispersion slurry 4. EXAMPLE 17 The procedure for preparation of the toner 17 was repeated except that the pigment/wax dispersion 5 was replaced with the pigment/wax dispersion 8. Thus, a toner 17 was prepared. Comparative Example 1 In a container, 709 parts of deionized water and 451 parts of a 0.1 mole aqueous solution of Na 3 PO 4 were mixed. After the mixture was heated to 60° C., the mixture was agitated with a TK HOMOMIXER at a revolution of 12,000 rpm. Then 68 parts of a 1.0 mole aqueous solution of CaCl 2 were gradually added thereto to prepare an aqueous medium including Ca 3 (PO 4 ) 2 . Then 170 parts of styrene, 30 parts of 2-ethylhexyl acrylate, 10 parts of a carbon black (REGAL400R from Cabot Corp.), 60 parts of paraffin wax having a softening point of 70° C., 5 parts of a metal compound of di-tert-butyl salicylate and 10 parts of a styrene-methacrylic acid copolymer having a weight average molecular weight of 50,000 and an acid value of 20 mgKOH/g were mixed in a container and the mixture was heated to 60° C. Then the mixture was agitated with a TK HOMOMIXER at a revolution of 12,000 rpm to be uniformly dissolved and dispersed. Then 10 parts of a polymerization initiator, 2,2′-azobis(2,4-dimethylvaleronitrile) were dissolved therein. Thus, a polymerizable liquid was prepared. This polymerizable liquid was added to the above-prepared aqueous medium and the mixture was agitated for 20 minutes at 60° C. using a TK HOMOMIXER at a revolution of 10,000 rpm under a nitrogen atmosphere. The thus prepared polymerizable monomer particles dispersion was reacted for 3 hours at 60° C. while agitated with a paddle agitator. Then the liquid was heated to 80° C. and further reacted for 10 hours. After completion of the reaction, the liquid was cooled and hydrochloric acid was added thereto-to dissolve calcium phosphate. Then the liquid was filtered and the cake was washed and dried. Thus, a toner 18 was prepared. Comparative Example 2 It was provided with example 1 except fluorine type activator treatment, then following treatment. (Cleaning 2 and Air Elutriation) Fluorine Type Activator Treatment In container, 630 parts of filtered cake 2, 2928 parts of ion-exchange water were agitated for 5 minutes by three one motor (manufactured by Shinto Science Corp.) at revolution of 4,000rpm. The mixture composition was heated for 30° C. at 60° C. The mixture was filtered, and was dried for 48 hours at 45° C. using a circulating drier. The dried cake was sieved using a screen having openings of 75 μm. Thus a toner 20 was prepared. Comparative Example 3 The procedure for preparation of the toner 20 was repeated except that the filtered cake 1 was replaced with the filtered cake 2 which providing Example 5. Thus, a toner 20 was prepared. 100 parts of provided toner, 1.0 parts of hydrophobic silica and 0.7 parts of hydrophobing titania were mixed in a Henshel mixer. Provided toner physical property was shown in table 1. 5% by weight of toner which treated external additive, and the silicone resin coated copper-zinc ferrite carrier which has 35 μm. were mixed, then the developer was prepared. Each toner was used with IPSIOcolor8000 remodeling machine made by Ricoh, and 50000 sheets of image area rate 5% chart continuity horsepower endurance test was executed. The results are shown in table 2. The evaluation items are as follows. (1) Particle Diameter (Dv, Dn) The particle diameter (i.e., volume average particle diameter and number average particle diameter) of a toner was measured with a particle diameter measuring instrument, COULTER COUNTER TAII, manufactured by Coulter Electronics, Inc., which was equipped with an aperture having a diameter of 100 μm. (2) Spherical Degree (S.D.) The spherical degree can be measured by a flow type particle image analyzer FPIA-2100 manufactured by Toa Medical Electronics Co., Ltd. The average spherical degree of each toner was determined. The specific procedure is as follows: 1) a surfactant serving as a dispersant, preferably 0.1 ml to 5 ml of an alkylbenzenesulfonic acid salt, is added to 100 ml to 150 ml of water from which solid impurities had been removed; 2) 0.1 g to 0.5 g of a sample to be measured is added into the mixture prepared in (1); 3) the mixture prepared in (2) is subjected to an ultrasonic dispersion treatment for about 1 to 3 minutes such that the concentration of the particles is 3,000 to 10,000 particles per microlitter; and 4) the shape and average particle diameter distribution of the sample are determined using the instrument mentioned above. (3) XPS An amount of fluorine and carbon of toner particle surface in the present invention can measure by the following technique. The apparatus used XPS (X-ray photoelectron spectroscopy) method. The way of measuring it that the same result can provide, a device kind and a condition are not particularly limited. It is the following condition preferably. Apparatus: X-ray photoelectron spectrometry (Type 1600S manufactured by ULVAC-PHI Inc.) X-ray source: Mg K α (400W) Analysis region: 0.8 mm×2.0 mm Preparation and Measured; A sample is crammed in aluminum plate. A sample was glued to the sample holder by carbon seat after that. Then, a sample was measured. Face Atom Density Calculation; Relative sensitivity factor of PHI's factor was used. A measurement area is specially a territory on the surface of the toner of about the some nm. In addition, as a result of being provided, it is atomic % (atom number %). (4) Charge Quantity (Q/M) 6 grams of a developer were contained in a closed metal cylinder and subjected to a blow-off treatment to determine the charge quantity of the toner. In this case, the toner concentration of the developer was adjusted so as to range from 4.5% to 5.5% by weight. (5) Background Fouling When a white image was developed with each toner, the operations of the copier were stopped. The toner particles present on the surface of the photoreceptor was transferred to an adhesive tape. The reflection densities of the adhesive tapes with or without toner particles were measured with a spectrodensitometer 938 manufactured by X-Rite to determine the difference in reflection density between the adhesive tape with toner particles and the adhesive tape without toner particles. (6) Cleanability The toner particles remaining on the photoreceptor were transferred on a SCOTCH adhesive tape manufactured by Sumitomo 3M Limited. The adhesive tape with the toner particles was adhered to a white paper to measure the reflection density thereof. The cleanability was evaluated by classifying as follows: o: the difference in reflection density is not greater than 0.01. x: the difference in reflection density is greater than 0.01 TABLE 1 particle size distribution of Toner volume weight particle particle diameter diameter Toner shape Dv Dn Dv/Dn spherical XPS Toner No. [μm] [μm] [—] degree F C F/C Ex. 1 Toner 1 5.26 3.89 1.35 0.97 2.24 74.56 0.03 Ex. 2 Toner 2 5.92 4.13 1.42 0.96 3.20 72.37 0.04 Ex. 3 Toner 3 5.40 4.01 1.35 0.97 3.17 78.30 0.04 Ex. 4 Toner 4 5.76 4.23 1.36 0.95 4.38 76.91 0.06 Ex. 5 Toner 5 5.16 3.87 1.33 0.97 1.18 80.15 0.01 Ex. 6 Toner 6 5.83 4.20 1.39 0.97 3.46 75.88 0.05 Ex. 7 Toner 7 5.55 4.36 1.27 0.96 3.09 79.22 0.04 Ex. 8 Toner 8 5.49 4.34 1.26 0.95 3.87 76.37 0.05 Ex. 9 Toner 9 5.08 4.48 1.13 0.96 8.45 74.56 0.11 Ex. 10 Toner 10 5.47 4.77 1.15 0.96 9.68 72.02 0.13 Ex. 11 Toner 11 5.65 4.92 1.15 0.97 10.22 73.94 0.14 Ex. 12 Toner 12 5.33 4.68 1.14 0.97 9.91 78.20 0.13 Ex. 13 Toner 13 5.13 4.45 1.15 0.96 6.41 74.81 0.09 Ex. 14 Toner 14 5.01 4.40 1.14 0.97 28.18 75.02 0.38 Ex. 15 Toner 15 5.29 4.59 1.15 0.96 19.60 71.71 0.27 Ex. 16 Toner 16 5.11 4.34 1.18 0.96 36.29 75.69 0.48 Ex. 17 Toner 17 5.44 4.81 1.13 0.97 24.37 76.74 0.32 Co-Ex. 1 Toner 18 6.28 5.60 1.12 0.98 — — — Co-Ex. 2 Toner 19 5.26 3.92 1.34 0.97 — — — Co-Ex. 3 Toner 20 5.18 3.88 1.34 0.97 — — — TABLE 2 Charge Quantity (Q/M) Background Fouling Cleanability Toner 10,000 th 100,000 th 10,000 th 100,000 th 10,000 th 100,000 th No. Initial image image Initial image image Initial image image Ex. 1 Toner 1 28.7 29.6 27.1 0.02 0.03 0.08 ∘ ∘ ∘ Ex. 2 Toner 2 29.4 32.8 33.1 0.01 0.03 0.06 ∘ ∘ ∘ Ex. 3 Toner 3 25.0 26.9 24.5 0.02 0.03 0.07 ∘ ∘ ∘ Ex. 4 Toner 4 32.0 31.9 33.8 0.01 0.04 0.06 ∘ ∘ ∘ Ex. 5 Toner 5 26.4 27.1 27.7 0.01 0.03 0.09 ∘ ∘ ∘ Ex. 6 Toner 6 30.3 28.0 29.6 0.02 0.02 0.05 ∘ ∘ ∘ Ex. 7 Toner 7 27.2 28.6 27.3 0.02 0.01 0.07 ∘ ∘ ∘ Ex. 8 Toner 8 28.6 28.5 29.1 0.01 0.02 0.06 ∘ ∘ ∘ Ex. 9 Toner 9 29.8 28.6 28.3 0.02 0.03 0.04 ∘ ∘ ∘ Ex. 10 Toner 27.9 26.5 26.4 0.02 0.03 0.03 ∘ ∘ ∘ 10 Ex. 11 Toner 28.9 27.3 27.1 0.02 0.04 0.04 ∘ ∘ ∘ 11 Ex. 12 Toner 26.8 28.6 28.0 0.03 0.03 0.03 ∘ ∘ ∘ 12 Ex. 13 Toner 29.5 29.3 26.9 0.03 0.05 0.06 ∘ ∘ ∘ 13 Ex. 14 Toner 27.9 27.4 27.7 0.01 0.02 0.02 ∘ ∘ ∘ 14 Ex. 15 Toner 28.1 28.0 28.4 0.02 0.02 0.02 ∘ ∘ ∘ 15 Ex. 16 Toner 36.3 36.9 36.7 0.02 0.01 0.02 ∘ ∘ ∘ 16 Ex. 17 Toner 38.9 38.1 38.8 0.01 0.02 0.02 ∘ ∘ ∘ 17 Co-Ex. 1 Toner 30.6 — 0.05 — — ∘ — — 18 Co-Ex. 2 Toner 28.3 26.4 0.12 0.24 — x x — 19 Co-Ex. 3 Toner 37.2 42.3 0.10 0.46 — x x — 20 The above written description of the invention provides a manner and process of making and using it such that any person skilled in this art is enabled to make and use the same, this enablement being provided in particular for the subject matter of the appended claims, which make up a part of the original description. All references, patents, applications, tests, standards, documents, publications, brochures, texts, articles, etc. mentioned herein are incorporated herein by reference. Also incorporated herein by reference is Japanese priority application No.2003-75828, filed on Mar. 19, 2003, to which priority is hereby claimed. Where a numerical limit or range is stated, the endpoints are included. Also, all values and subranges within a numerical limit or range are specifically included as if explicitly written out. The above description is presented to enable a person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, this invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
The present invention relates to a toner useful, for example, for visualizing an electrostatic latent image formed on an image bearing member by a method such as electrophotography and electrostatic recording methods.
6
This application is a continuation of Ser. No. 07/517,231 filed 05/01/90. FIELD OF THE INVENTION This invention relates to techniques for using decoys. More particularly, this invention relates to use of decoys for hunting. Even more particularly, this invention relates to techniques for supporting bird decoys while hunting. BACKGROUND OF THE INVENTION The use of decoys to attract game birds while hunting has been commonplace for many, many years. Various types of decoys have been used, both on land and on water. Decoys used on land are typically rested directly on the ground and remain in a stationary position. Sometimes such decoys are held in place by a stake driven into the ground to prevent them from being tipped over or moved by the wind. Unfortunately, it has been found that decoys which are stationary are not as effective as desired for attracting live birds and enticing such birds to approach the decoys. There has not heretofore been provided a decoy stand which is effective in supporting a bird decoy on the ground in a manner which enables the decoy to exhibit natural or desirable movement. Although there has been proposed an air sock decoy which can be pivotably supported on a stake, such type of decoy is not realistic in appearance or movement and accordingly has not been very successful. SUMMARY OF THE INVENTION In accordance with the present invention there is provided a portable decoy stand which is especially useful for supporting a bird decoy (e.g., a goose or duck decoy) on the ground in a manner such that the decoy appears life-like and is able to move slightly in response to moving air currents. In one embodiment the invention comprises a base means and attachment means for attaching the decoy to the base. The base means enables the decoy to bob or wobble slightly relative to the base. This bobbing action or movement makes the decoy appear to be a live bird. This is very desirable and it makes the decoy much more effective than stationary decoys in terms of the ability to attract live birds. The portable decoy stand of this invention is intended primarily for use on land to support game bird decoys (e.g., goose, duck, turkey, quail, pigeons, doves, etc.). The base can be secured to the ground, if desired, by means of stakes, pins, nails, anchors, etc. The portable stand can also be collapsed for easy and convenient transport and storage. This makes it easier and more convenient to use the decoy stand in the field. Other advantages of the invention will be apparent from the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS The invention is described in more detail hereinafter with reference to the accompanying drawings, wherein like reference characters refer to the same parts throughout the several views and in which: FIG. 1 is a perspective view illustrating the use of a decoy stand of the invention to support a bird decoy; FIG. 2 is a top view of the decoy stand of FIG. 1; FIG. 3 is a side elevational view of the decoy stand of FIG. 1; and FIG. 4 is a side elevational view illustrating another embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION In the drawings there is illustrated a portable decoy stand 10 of the invention for supporting a game bird decoy 100 on the ground in the field The decoy stand includes a base 12 to which a plurality of leg members 14 have been attached. One end of each leg may be attached to the base by means of a bolt 16 having a wing nut 17 thereon. This enables the bolts to be tightened or loosened without the need for tools. Thus, the decoy stand can be carried to the field in a collapsed position and then the legs can be pivoted outwardly to a desired position where the bolts can be readily tightened to hold the legs in that desired position. Attached to base 12 there is an upstanding support member 20 including post member 22 and elongated mounting bar 24. The lower end of post member 22 is rotatably mounted to housing 22A by means of a castor 22B (e.g., a conventional mop bucket castor). This type of castor has sufficient play in it to allow post 22 to tilt slightly in every direction without binding. For example, post 22 should be able to tilt at least 3° from vertical in every direction and it may tilt as much as 5° in every direction. This tilting or bobbing feature is illustrated in FIG. 3 where the dotted lines illustrate permissible tilting movement of the post 22 and the mounting bar 24. The bird decoy 100 is attached or fastened to mounting bar 24 by means of bars 26 and bolts 27. Bar 24 includes elongated apertures 24A so that the position of the decoy on the stand may be adjusted forwardly or rearwardly, as desired. Other types of decoys may require different types or styles of mounting brackets in order to enable such decoys to be mounted or supported on post 22. The particular type or style of mounting brackets used is not critical for the purpose of this invention. It is important, however, for the decoy to be mounted in such a manner that it is balanced or nearly balanced on post 22. This enables the decoy to tilt or bob easily with the slightest amount of air movement past the decoy. This tilting or bobbing action or movement simulates a live bird and makes the decoy much more effective in attracting live birds to the vicinity of the decoy. The size and style of the base 12 may vary. It is shown in the drawings as a rectangular plate but it could be round, oval, square, triangular, etc. If desired, it could be disk-shaped and could include a concave bottom surface. It may be composed of metal, plastic, or composite materials. Preferably it is weather-proof. The presence of legs 14 is preferred. These legs are preferably pivotably or detachably attached to the base 12 so that they can be pivoted to an inward position for transport and storage of the stand, or they may be removed entirely. The length of the leg members may vary, e.g., from about 8 inches to 16 inches. When leg members are used, there should be at least three of them (and preferably four). Although additional leg members could be used, if desired, they are not necessary. The leg members preferably have appropriate bends in them which enable them to support the base 12 above the ground a few inches. If desired, the outer end of each leg member may include an eyelet 14A to enable a stake, spike, or pin to be driven therethrough into the ground to hold the stand steady against high winds, for example. The leg members may be composed of metal, for example. They may be made of round, square or flat bar stock, if desired, and they may be bent slightly in the field, if necessary, to enable the stand to be firmly supported evenly on all legs regardless of the type of terrain in the field. Another variation of the invention is illustrated in FIG. 4. In this embodiment a planar deflector 30 is shown attached to bird decoy 100. Each end of the deflector includes means for attaching the deflector to a bird decoy in a manner such that the deflector is in a vertical plane and will present a large surface against which air currents can act to cause the decoy to turn or move as it is supported on the stand. The decoy stand of the invention can be made in any size desired for accommodating a bird decoy of any size or style. As described herein, the decoy stand is light-weight and portable to facilitate convenience of handling, carrying and storage thereof. Because of the ability of the post member to rock or tilt relative to a vertical axis, the decoy supported on the stand appears more life-like and is therefore more effective in attracting live birds. The decoy stand of the invention is useful even in conditions of high wind. Whenever the decoy on the stand moves too much or too rapidly to simulate a live bird, it is possible to retard or slow the movement of the decoy by simply tilting the stand to one side. This can be done, for example, by bending one of the leg members so that the stand leans to one side. Another manner of slowing the action of the decoy is by adjusting the position of the decoy on the stand so that it is off-balance to some extent. Another manner of changing the balance of the decoy on the stand is by adding weights to the front or the rear of the decoy. As described above, the preferred decoy stand of the invention includes a mounting post secured to the base by means of a castor mounting which allows the post to tilt at least 3° in every direction. It also allows the post to rotate freely. Other mounting systems for supporting the decoy may also be used so long as it enables the decoy to tilt or rock in a similar manner. For example, the mounting could include a tubular member having an open lower end and a closed upper end. The tubular member could be supported on an upright post of smaller diameter having a pointed or rounded upper end. This enables the tubular member to rock or tilt relative to the upright post. Other variants are possible without departing from the scope of this invention. The type and size of decoy supported on the stand may vary, as desired. The decoy may also be changed, as desired.
A portable decoy stand is described which is especially useful for supporting a bird decoy. The stand includes a base and attachment mechanism which supports the decoy and allows it to bob or tilt relative to a vertical axis. Air movement past the decoy causes it to move, giving the impression that the decoy is alive. The decoy is very effective in attracting live birds.
0
BACKGROUND OF THE INVENTION [0001] This invention relates, in general, to an collapsible, wheeled cart, and, in particular, to a two wheeled cart take can be collapsed for transport and storage, and used to transport decoys, rifles, game and other items related to hunting. [0002] Field or shore hunting for waterfowl requires a large number of decoys and associated equipment. Decoys are bulky. Transporting a large number of decoys and associated hunting equipment a significant distance to and from the hunting field is very difficult. Furthermore, today's waterfowl are more conditioned and wary then previous generations. In many cases, to successfully hunt today's waterfowl requires not only a great number of decoys, but a great number of ultra-realistic full-body decoys. These full-body decoys are very voluminous and therefore transportation of a number of these bulky decoys poses an even a greater difficulty than encountered in the past with more compact silhouette and shell decoys. The problems associated with waterfowl hunting and the need to transport decoys and associated gear are old and well known. As a result, there have been a number decoy carts of designed and a variety of utility, hunting, and game carts employed for decoy transportation with mixed success. [0003] Previously hunters have used a wide variety of vehicles such as deer carts, wheel barrows, trash cans, 3-wheel running carts, “flat bed” carts, folding garden carts, children's wagons and various homemade carts. A whole host of wheeled contrivances have been used, mostly with unsatisfactory results. Blog sites commenting on the topic of decoy carts illustrate the frustration that exists with existing carts, and a search for a satisfactory solution to the need for transporting bulking decoys and waterfowl gear over rough terrain. DESCRIPTION OF THE PRIOR ART [0004] In the prior art various types of collapsible carts for transporting game and similar items have been proposed. The following prior art describes previous devices related to the instant invention. [0005] U.S. Pat. No. 3,222,100 issued Dec. 7, 1965, to Lindzy for a Personnel or Game Carrier. Lindzy shows a game cart frame that disconnects at the middle of the cart to allow the frame to be longitudinally folded via the pivoted wheel supports, and has detachable wheels. This allows the cart to be reduced to a low profile configuration for transport and storage. [0006] U.S. Pat. No. 3,860,254 issued Jan. 14, 1975, to Wegener for a Foldable Packer. Wegener shows a cart which folds in the longitudinal direction. The frame is pivoted at the axle, and has upper braces to hold it in the unfolded position. The upper braces are pivoted in the middle to allow folding, and are locked in the unfolded position by a sliding sleeve which covers the pivot joints. This sliding sleeve is much different than the slider in the instant invention. [0007] U.S. Pat. No. 5,785,334 issued Jul. 28, 1998, to Robinson for a Bicycle Towable Collapsible Cart. Robinson shows a folding cart with a frame mounted flexible container that is similar to the flexible container of the instant invention. [0008] U.S. Pat. No. 7,032,921 issued Apr. 25, 2006, to Swanner for a Cart to Transport Equipment or the Like. Swanner shows a cart which partially folds in the longitudinal direction and has detachable wheels. [0009] U.S. Pat. No. 7,172,207 issued Feb. 6, 2007, to Henry for a Collapsible Cart. Henry shows a cart that folds in the transverse direction. This is accomplished by the use of telescoping uprights on both sides of the frame. SUMMARY OF THE INVENTION [0010] The instant invention is directed to the need for an improved economic, stable, lightweight, two-wheeled hand cart for the transportation of a large number of bulky waterfowl decoys and associated hunting gear into the field over rough terrain. The cart is easily foldable for compact storage, portability, field concealment, and shipping. The cart also functions in stretcher fashion to carry the load, with or without the wheels, when terrain conditions render wheels ineffective, or for when the loaded cart needs to be lifted over obstacles en route, or into or out of a vehicle or storage area. [0011] It is an object of the present invention to provide a new and improved folding hand cart for transporting large numbers of bulky decoys and game across rough terrain by two people. [0012] It is an object of the present invention to provide a new and improved cart with removable wheels which can be easily and quickly folded to a smaller profile for transport and storage. [0013] It is an object of the present invention to provide a new and improved cart with a flexible container to hold the decoys during transport, and to prevent them from spilling out. [0014] It is an object of the present invention to provide a new and improved cart with multiple gun scabbards for hands free transport of guns. [0015] It is an object of the present invention to provide a new and improved cart with pockets to contain ammunition and other equipment for transport. [0016] It is, an object of the present invention to provide a new and improved cart with load stability provided by a low cart height to wheel base width ratio and a low loaded center of gravity. [0017] It is an object of the present invention to provide a new and improved cart having ease of rollability by the use of large diameter tires. [0018] It is an object of the present invention to provide a new and improved cart that is lightweight by the use of a minimal structure, efficient truss frame design, and construction with lightweight tubular members. [0019] It is an object of the present invention to provide a new and improved cart having economic construction by efficient design, ready availability of materials, and with minimum artisan technical skill. [0020] It is an object of the present invention to provide a new and improved cart having ease of extension or folding by manual insertion or removal of a few self securing fasteners without requiring the use of tools. [0021] It is an object of the present invention to provide a new and improved cart which is readily broken down into its component members for compact shipping. [0022] It is an object of the present invention to provide a new and improved cart with increased strength provided by the overall design arrangement, a central frame that bears all the cart forces and moments, and the strength of materials utilized. [0023] It is an object of the present invention to provide a new and improved cart which can used to carry a load stretcher fashion. [0024] These and other objects and advantages of the present invention will be fully apparent from the following description, when taken in connection with the annexed drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0025] FIG. 1 is an overall view of the decoy cart. [0026] FIG. 2 is a view of the central frame. [0027] FIG. 3 a - 3 h show alternative central frame geometries. [0028] FIG. 4 is a view of the slider. [0029] FIG. 5 is a view of the frame. [0030] FIG. 6 a - 6 f are views of alternative frame geometries. [0031] FIG. 7 is a view of the flexible container. [0032] FIG. 8 is a view of an alternate flexible container. DESCRIPTION OF THE PREFERRED EMBODIMENT [0033] The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to best explain the invention so that others, skilled in the art to which the invention pertains, might utilize its teachings. [0034] Referring now to the drawings in greater detail, FIG. 1 shows an overall view of the cart 1 . A central frame 2 is located in the center of the cart 1 . Extending fore and aft of the central frame 2 are two identical frame sections 3 . Each frame section 3 is pivotally mounted to the lower end of the central frame 2 , and also pivotally mounted to a slider 4 , which is slidably mounted near the upper end of the central frame 2 . When the slider 4 is fixed in the upper position, the frame sections 3 are extended into their operational configuration. When the slider 4 is lowered to a low position on the central frame 2 , the frame sections 3 fold into a storage position. Wheels 5 are rotatably and removably mounted to the lower end of the central frame 2 . Utility straps 6 are mounted to the top end of the central frame 2 . A flexible container 7 is mounted on the frame sections 3 . [0035] FIG. 2 shows the details of the central frame 2 . In the preferred embodiment, the central frame 2 is a square U-shaped tubular frame 8 . The tubular frame 8 has a transverse lower horizontal member 9 . Parallel gusset plates 10 are rigidly attached to each end of the lower horizontal frame member 9 by welding, fasteners, or other known connection means. Parallel upright frame members 11 are rigidly attached to the transverse lower horizontal member 9 by welding, fasteners, or other known connection means. An axle 12 is mounted on the central frame 2 by passing through the center of the parallel upright frame members 11 . The axle 12 bears on the holes in parallel upright frame members 11 . The axle 12 might also take the form of two stub axles (not shown) which extend only part way into the transverse lower horizontal member 9 . A pair of wheels 13 are pivotally and removably mounted to the opposite ends of the axle 12 . The ends of the axles 12 are provided with holes 14 , through which fasteners 15 are connected to keep the wheels 13 on the axle 12 . The fasteners 15 are removed from the holes 14 when the wheels are removed for storage or transport. A plurality of adjustable utility straps 6 are mounted to the tops of the upright members 11 and are used to secure a variety of loads (not shown) to the cart 1 . The utility straps 6 can be provided with couplers 16 for quick connection and disconnection. The utility straps 6 may also be provided with hook and loop type fasteners (not shown) such as Velcro™ hook and loop fasteners. [0036] FIGS. 3 a - 3 h show alternative geometries for constructing the central frame 2 . FIG. 3 a shows the central frame with a square U-shaped geometry, which is described above. FIG. 3 b shows a central frame with an inverted square U-shaped geometry. In this variant, the lower horizontal frame member 9 has been relocated to the top of the upright members 11 . FIG. 3 c shows a central frame with a bent U-shaped geometry. In this variant the transverse lower horizontal member 9 and the upright members 11 are constructed from a single tubular member 17 which has been bent into a U-shape. FIG. 3 d shows a central frame with an inverted bent U-shaped geometry. FIG. 3 e shows a central frame with a truss geometry. In this variant, the transverse lower horizontal member 9 has been replaced with two truss members 18 . FIG. 3 f shows a central frame with a half-truss geometry. In this variant, two half truss members 19 have been connected between the transverse lower horizontal member 9 and the upright members 11 . FIG. 3 g shows a central frame with a solid geometry. In this variant, the transverse lower horizontal member 9 and the upright members 11 have been replaced with a solid sheet of material 20 . FIG. 3 h shows a central frame with an H-shaped geometry. In this variant, the transverse lower horizontal member 9 has been relocated to the center of the upright members 11 . [0037] FIG. 4 shows one of the sliders 4 . Each slider 4 is comprised of two parallel plates 21 . Each of the plates 21 has several openings. The central openings are provided for fasteners 22 which connects the sliders 4 to the uptight members 11 . Keepers 22 a are provided on the end of each fastener 22 which loops around the upright members and connects to the opposite end of fastener 22 to holder the fastener 22 in place. The end openings are provided for fasteners 23 which pivotally connect the slider 4 to the frame sections 3 . The upper intermediate openings are provided for bolts 24 , which extend through one plate 21 , through spacers 25 , and then the second plate 21 , the whole of which being secured with nuts 26 . Other types of fasteners may be used instead of bolts 24 and nuts 26 . The lower intermediate openings are provided for bolts 27 , which extend through plates 21 and on which rollers 27 a are mounted. When the sliders 4 are mounted on the upright members, the rollers 27 a provide for smooth movement between the operational and storage positions of the frame sections 3 . [0038] FIG. 5 shows details of the frame sections 3 . The frame sections 3 are symmetrically mounted fore and aft of the central frame 2 . The components of the frame sections 3 are preferably made of light weight tubular material, such as aluminum tubing. The upper frame members 28 are pivotally connected to the sliders 4 by fasteners 23 . The lower frame members 29 are pivotally connected to the gusset plates 10 by fasteners 30 . The opposite end of the lower frame members 29 are pivotally connected to brackets 31 by fasteners 32 . The brackets 31 are connected to the upper frame members 28 by fasteners 33 . Cross members 34 extend transversely between the brackets 31 , and are connected to either the brackets 31 or the upper frame members 28 by fasteners 35 . Alternatively, the lower frame members 29 and the cross member 34 may be constructed as a single U-shaped frame member (not shown). The end of the upper frame members 28 opposite the connection to the sliders 4 extend beyond the connection with the lower frame members 29 to form handles 36 . The cross members 34 may extend beyond the upper frame members 28 to provide additional handles 37 . The flexible container 7 is supported by upper frame members 28 , cross members 34 and the transverse lower horizontal member 9 . [0039] FIGS. 6 a - 6 z show frame geometry variations. FIG. 6 a shows the truss geometry of the preferred embodiment described previously. FIG. 6 b shows a King Post truss geometry in which the lower frame members 29 are positioned above the upper frame members 28 . FIG. 6 c shows a cabled stayed truss geometry in which the lower frame members 29 are removed and replace with cable stays 40 . FIG. 6 d shows a cantilevered truss geometry in which the lower frame members 29 are removed, and the upper frame members 28 are made thicker near the central frame 2 . FIG. 6 e shows an alternative truss geometry in which the upper frame members 28 end at their connection with the lower frame members 29 , and the lower frame members 29 extend beyond their connection with the upper frame members 28 to form handles 41 . FIG. 6 f shows a scissors truss geometry in which upper frame members 28 angle downward to cross lower frame members 29 . The upper frame members 28 and the lower frame members 29 are pivotally connected at their center points. The ends of the upper frame members 28 and the lower frame members 29 are pivotally connected to end uprights 42 . [0040] FIG. 7 shows the construction of the flexible container 7 . The flexible container 7 is suspended from upper frame members 28 and cross members 34 , and rests on the transverse lower horizontal member 9 . The body 43 of the flexible container 7 is constructed of a strong and light material such as nylon, and may be a solid or a net-like fabric. The body 43 is provided with six suspension tubes 44 through which the upper frame members 28 and cross members 34 are inserted. Four external tubes 38 are provided on the bottom of the bag 7 . Tube inserts 39 are inserted into the external tubes 38 to provide support for the load. Tube inserts 39 are made of a light weight material such as PVC pipe or aluminum tubing. The external tubes 38 may extend across the width of the bag or may be formed as short sections on each side of the bag. More than four external tubes 38 and tube inserts 39 may be used if desired. A wear liner 49 is attached to the bottom of the body 43 to resist wear from the transverse lower horizontal member 9 . Grommets 50 are provided at the ends of the wear liner 49 for the purpose of fastening the body 43 to the transverse lower horizontal member 9 . A cord (not shown) or other fastening means can be passed through the grommets 50 to attach the body 43 to the transverse lower horizontal member 9 . End pockets 51 are attached to the ends of the body 43 by sewing or other suitable fasteners. The top openings of the pockets 51 are sealed with hook and loop type fasteners (not shown) such as Velcro™ hook and loop fasteners, or other suitable fasteners. Scabbards 52 are suspended from the longitudinal suspension tubes 44 . The scabbards 52 are used for carrying guns and other hunting equipment. The openings of the scabbard may be sealed with hook and loop type fasteners (not shown) such as Velcro™ hook and loop fasteners, or other suitable fasteners. [0041] FIG. 8 shows a second embodiment of the flexible bag 7 . Extending downward from the suspension tubes 44 are twelve support straps 45 , six on each side. The support straps 45 may be sewn or otherwise fastened to the body 43 . The lower ends of the support straps 45 are connected to cross supports 46 by fasteners 47 . The cross supports 46 pass through grommets 48 in the bottom of the body 43 and serve to support the weight of the decoys, game and other items carried in the flexible container 7 . A third embodiment of the flexible bag 7 uses an internal frame (not shown) that lays inside on the bottom the flexible bag 7 . The internal frame is made of a light weight material such as PVC pipe or aluminum tubing. [0042] Although the Decoy Cart and the method of using the same according to the present invention has been described in the foregoing specification with considerable details, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention done by others skilled in the art to which the invention pertains will be considered infringements of this invention when those modified forms fall within the claimed scope of this invention.
The Decoy Cart is an improved economic, stable, lightweight, two-wheeled hand cart for the transportation of a large number of bulky waterfowl decoys and associated hunting gear into the field over rough terrain. The cart is easily foldable for compact storage, portability, field concealment, and shipping. The cart also functions in stretcher fashion to carry the load, with or without the wheels, when terrain conditions render wheels ineffective, or for when the loaded cart needs to be lifted over obstacles en route, or into or out of a vehicle or storage area.
1
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0001] (Not applicable.) FIELD OF THE INVENTION [0002] The present invention relates to a sewing machine, a bobbin to supply thread in the sewing machine, a bobbin case for the bobbin and a method of winding thread on the bobbin. The invention relates particularly, but not exclusively, to sewing machines intended for domestic or household use, and can be applied to industrial and other sewing machines, if desired. In general, the invention provides a novel and improved bobbin, bobbin case and bobbin winding method useful with sewing machines employing a loop-making hook rotating about a vertical axis, and other types of sewing machine. BACKGROUND OF THE INVENTION [0003] Sewing machines which employ an upper and lower thread to form a seam or other sewn element employing lockstitches or other suitable stitches are sometimes subject to stitching problems which yield poor seams or other stitchwork. [0004] Beitzel U.S. Pat. No. 699,067 discloses a sewing machine of this type which employs a spool of thread supported in spool house mounted for rotation beneath a work bed to supply a lower thread to the needle. [0005] Johnson U.S. Pat. No. 4,182, 250 and Rodda et al. U.S. Pat. No. 4,487,142 both disclose sewing machine employing a rotating hook which functions as a loop taker. As disclosed in these patents a bobbin case, bearing a bobbin wound with thread, can be located beneath the sewing machine work bed, directly under the needle which is threaded with the upper thread. A hook travels around the bobbin case, rotating about a vertical axis, takes a loop from the upper thread and pulls it around the bobbin. The loop extends around the lower thread which runs from the bobbin to the fabric. As it advances, the hook sheds the loop and the sewing machine's take-up lever tightens the threads into a lockstitch or the like. [0006] The above patents do not address the problem of poor stitch formation which may occur in a lockstitch or similar sewing machine which draws a lower thread from a bobbin contained in a bobbin case. [0007] The foregoing description of background art may include insights, discoveries, understandings or disclosures, or associations together of disclosures, that were not known to the relevant art prior to the present invention but which were provided by the invention. Some such contributions of the invention may have been specifically pointed out herein, whereas other such contributions of the invention will be apparent from their context. Merely because a document may have been cited here, no admission is made that the field of the document, which may be quite different from that of the invention, is analogous to the field or fields of the present invention. SUMMARY OF THE INVENTION [0008] It is an object of the invention to provide a sewing machine which addresses the problem of poor stitch formation which may occur in forming lockstitches or the like when drawing a lower thread from a bobbin contained in a bobbin case. Other objects of the invention lie in providing a bobbin, bobbin case and threading method useful in addressing this problem. [0009] In one aspect, the invention provides a sewing machine which includes a needle mounted for reciprocal movement in opposed descending and ascending directions toward and away from a workpiece to sew the workpiece with an upper thread. In addition the machine includes a bobbin mounted to supply a lower thread to the needle. The bobbin can comprise a hub to support wound thread and respective first and second flanges located at opposed ends of the hub to retain the thread on the hub. Furthermore, the machine includes a bobbin case to support the bobbin for reciprocal movement beneath the workpiece, the bobbin case having a chamber to receive and seat the bobbin. In this novel sewing machine the bobbin and bobbin case are cooperably configured to seat the bobbin in the bobbin case chamber in a working orientation and to prevent seating of the bobbin in a nonworking orientation. [0010] To this end, the second bobbin flange can be larger than the first bobbin flange. The bobbin case chamber can have a mouth and a narrower portion inwardly of the chamber mouth. The mouth can be capable of receiving the second bobbin flange and the narrower portion can be capable of receiving the smaller, first bobbin flange. This structure enables proper seating of the bobbin in the bobbin case chamber, but the narrower portion of the chamber is incapable of receiving the larger, second bobbin flange being thereby preventing seating of the bobbin in a nonworking orientation. [0011] The bobbin hub can have an axial opening to receive a bobbin winder spindle in one axial direction. The hub opening may be at least partially obstructed to prevent insertion of the bobbin winder spindle into the hub opening in another axial direction opposed to the one axial direction. Embodiments of bobbin employing this construction fit the winder spindle in only one way. Employing a predetermined winder direction, incorrect winding can be avoided. [0012] Surprisingly, it has been found that some stitching problems in lockstitch sewing machines employing a lower thread drawn from a bobbin mounted in a bobbin case are attributable to user error in replacing and/or rewinding empty bobbins. The invention provides structural measures useful in overcoming or mitigating these problems. [0013] In another aspect, the invention provides a bobbin to supply thread in a sewing machine. The sewing machine can comprise a needle to sew the workpiece with an upper thread and a lower thread, the needle being mounted for reciprocal movement in opposed descending and ascending directions toward and away from the workpiece. The sewing machine can comprise a bobbin case to support the bobbin for reciprocal movement beneath the workpiece. The bobbin case can have a chamber to receive and seat the bobbin. The bobbin may comprise a hub to support wound thread and respective first and second flanges located at opposed ends of the hub to retain the thread on the hub. The bobbin and bobbin case can be cooperably configured to seat the bobbin in the bobbin case chamber in a working orientation and to prevent seating of the bobbin in a nonworking orientation. [0014] The invention also provides a bobbin case having the described cooperative structure and provides such a bobbin case with the bobbin seated therein. [0015] In a further aspect, the invention provides a method of winding thread on the bobbin of such a sewing machine which comprises a number of steps. The steps may comprise assembling the bobbin, when in need of thread, to the bobbin winder spindle by inserting the bobbin winder spindle into the bobbin hub in the one axial direction. Thread can then be wound on to the bobbin mounted on the bobbin winder spindle. In the event of an attempt to insert the bobbin winder spindle into the hub opening in the opposed axial direction, the method includes removing and reorienting the bobbin when the partial obstruction prevents the insertion attempt. Pursuant to the method, after removing and reorienting the incorrectly oriented bobbin, the bobbin winder spindle is now inserted into the bobbin and the bobbin is wound with thread. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING [0016] Some embodiments of the invention, and of making and using the invention, as well as the best mode contemplated of carrying out the invention, are described in detail below, by way of example, with reference to the accompanying drawings, in which like reference characters designate like elements throughout the several views, and in which: [0017] FIG. 1 is a front perspective view showing one embodiment of an error-resistant bobbin for a sewing machine, according to the invention; [0018] FIG. 2 is a front perspective view of a top portion of a sewing machine showing an embodiment of bobbin winder mechanism for winding the bobbin illustrated in FIG. 1 wherein the bobbin is mounted on a winder spindle; [0019] FIG. 3 is a view similar to FIG. 2 showing the bobbin detached from the winder spindle and having a desired orientation; [0020] FIG. 4 a is a view similar to FIG. 3 , showing a portion of the structure shown in FIG. 3 wherein the bobbin has an undesired orientation; [0021] FIG. 4 b is a view similar to FIG. 4 a, from a different angle, wherein the bobbin has the undesired orientation shown in FIG. 4 a; [0022] FIG. 5 is a front perspective view of the top portion of a sewing machine similar to that shown in FIG. 2 , showing one embodiment of a bobbin winding method according to the invention; [0023] FIG. 6 is a cross-sectional view of one embodiment of an error-resistant bobbin case according to the invention, within which the bobbin illustrated in FIG. 1 is accommodated with a desired orientation; [0024] FIG. 7 is a cross-sectional view of a rotating hook mechanism employing a bobbin case such as that shown in FIG. 6 in which a bobbin like that illustrated in FIG. 1 has been properly installed; [0025] FIG. 7 a is a view of the bobbin case shown in FIG. 6 , with a bobbin, such as that illustrated in FIG. 1 , properly installed; [0026] FIG. 8 is a top perspective view of the work bed of a sewing machine employing the rotating hook mechanism shown in FIG. 7 , with a cover retracted to reveal the bobbin and bobbin case; [0027] FIG. 9 is a view similar to FIG. 7 showing an attempt to improperly install the bobbin in the bobbin case shown in FIG. 6 ; and [0028] FIG. 9 a is a view similar to FIG. 7 a also showing an attempt to improperly install the bobbin in the bobbin case. DETAILED DESCRIPTION OF THE INVENTION [0029] It is an understanding of the invention that lockstitch or similar sewing machine which draw a lower thread from a bobbin contained in a bobbin case are likely to consume a large amount of the lower thread. This circumstance requires frequent manually effected replacements of the lower thread bobbin. Typically, to do this, the operator or user must stop the sewing machine, remove the bobbin from the bobbin case and rewind the bobbin with new thread. The rewound bobbin must then be reinstalled in the bobbin case. [0030] While removal and reinstallation of the bobbin may be a necessary procedure and may often be straightforward it is nevertheless a manual procedure which with known machines may be subject to one or more errors. It is an insight of this invention that such errors may lead to stitching problems and poor seams or other poor stitchwork. [0031] The invention provides a novel, error-resistant bobbin useful for supplying thread to the needle of a sewing machine. It also provides a novel bobbin case which is cooperative with the bobbin. [0032] In particular, but not exclusively, the novel bobbin is useful with sewing machines of the type comprising a needle mounted for reciprocal movement in opposed descending and ascending directions. Typically, in such machines, the needle is carried by a needle bar which moves toward and away from a workpiece to sew the workpiece, which may for example be one or more layers of fabric, with an upper thread threaded through the needle. For certain stitches, for example straight stitches and zig-zag stitches, a second lower thread may be supplied to the needle from beneath a work bed which supports the fabric. The novel bobbin can be used to supply this lower thread, for which purpose it may be mounted beneath the work bed. [0033] When the bobbin runs out of thread, it has to be rewound. This may be accomplished by manually removing the bobbin from the bobbin case and mounting it on a winder spindle on top of the sewing machine where it is rewound with thread from a stock source such as a spool or reel of thread using a rotary drive supplied by the sewing machine. While the bobbin winding process is essentially simple, known methods are prone to certain errors. For example, the bobbin may be wound upside down or in the wrong direction or may be inserted into the bobbin case the wrong way round. Also, the winding operation may in some cases become uncontrolled, tangling knotting or even breaking the thread as a result of improper mounting of the bobbin on the winder spindle, or other factors. The bobbin and bobbin case and associated bobbin winder mechanism illustrated in the drawings can alleviate one or more of these problems. [0034] The sewing machine can be a domestic sewing machine useful for sewing in a household or other domestic environment or other suitable location. However, the inventive bobbin may be employed with other sewing machines as will be apparent to those skilled in the art. Only portions of the complete sewing machine are shown. The structure not shown can take any suitable form, as is well known in the art and may for example comprise a portable unit or a table-mounted unit. While it is envisaged that the invention is particularly useful when embodied in a unit supported or mounted on a tabletop, bench or the like for operation by a seated user, it will be understood that the invention can be embodied in other sewing machines, as will be or may become apparent. Directional references such as “front”, “rear” or “behind”, “up”, “down”, “left” and “right”, as used herein are to be understood as being from the perspective of such a user [0035] As shown in FIG. 1 , a sewing machine bobbin 10 can comprise a hollow, approximately cylindrical, central hub 12 to support wound thread (not shown in this figure) which hub is with its axis vertically disposed in FIG. 1 . Bobbin 10 can have a first flange 14 at one end of central hub 12 and a second flange 16 located at the other end of central hub 12 , opposing flange 14 , to retain the thread on the hub 12 . As oriented in FIG. 1 , bobbin flanges 14 and 16 can be described as lower and upper flanges respectively. In the embodiment shown, they are disposed perpendicularly to the axis of central hub 12 . [0036] To help control user errors in handling bobbin 10 , as will be further explained herein, second flange 16 is distinctly larger in diameter than flange 14 . Flange 16 can, for example, be from about 2 to about 10 percent larger in diameter than flange 14 , although other proportions may be employed. As shown in FIG. 1 , flanges 14 and 16 are uniformly thin disks with circular peripheries which are formed integrally and monolithically with central hub 12 , for example as a one-piece molding. However, other shapes and configurations may be employed including, for example, a polygonal shape and a tapered cross-section in a radial plane. Also, while shown as being similar, one flange 14 or 16 may have a different geometry from the other. One or more intermediate flanges (not shown) could be provided, if desired, between flanges 14 and 16 , for example to permit bobbin 10 to carry multiple threads. Such intermediate flanges, if provided, desirably are smaller than flange 16 . [0037] The peripheries of flanges 14 and 16 , in the circular embodiment shown in FIG. 1 , lie on a conical or frusto-conical surface. [0038] Central hub 12 has an axial opening 18 to receive a bobbin winder spindle 30 ( FIG. 2 ) in one axial direction. In the embodiment shown, central hub 12 is thin walled and hub opening 18 is a sizeable volume occupying much of the volume of central hub 12 . Hub opening 18 is at least partially obstructed to prevent insertion of the bobbin winder spindle 30 into central hub 12 opening in the opposite axial direction so that bobbin 10 is a one-way fit on the winder spindle 30 and can only be assembled with the spindle in a properly oriented fashion. In the embodiment shown in FIG. 1 , hub opening 18 is obstructed by the second bobbin flange which extends continuously across the whole cross-section of hub opening 18 to close it. Other obstructions may be employed to provide bobbin 10 with a desirable one-way character, for example a constricted diameter to hub opening 18 at second flange 16 , a cross-member extending across hub opening 18 at or near second flange 16 or a tapering of hub opening 18 (and thence of the bobbin winder spindle 30 ) towards second flange 16 . [0039] Hub opening 18 is formed with a channel-like keyway 20 , which may be a groove or slot and which extends axially along part of hub opening 18 , and opens at one end into smaller, first flange 14 . The other end of keyway 20 is blind. Other suitable keying, or spindle-cooperative locking structure, will be apparent to those skilled in the art. Second bobbin flange 16 has a threading aperture 22 adjacent central hub 12 for receiving the end of a thread to be wound on bobbin 10 . [0040] An optional strengthening fillet 24 can be provided around the junction between second flange 16 and central hub 12 and also around the junction between first flange 14 and central hub 12 , which latter fillet is not shown. [0041] Bobbin 10 can be constructed in one monolithic piece, as noted above, or may be fabricated from multiple components welded, adhered, fastened with fasteners or otherwise assembled together. In one embodiment of the invention, bobbin 10 is molded from a durable, and optionally resilient, material, for example a suitable thermosetting synthetic polymeric resin, such as clear styrene acrylonitrile copolymer. [0042] Bobbin 10 can have any suitable size and may for example be of a size suitable to accommodate from about 5 to about 100 meters of wound cotton thread of a type commonly used for domestic sewing such as 100% mercerized cotton thread N o 50. One embodiment of the invention provides a bobbin 10 with a capacity for from about 25 to about 38 meters of such cotton thread. Such a bobbin could have dimensions of, for example, about 20 mm external diameter, 10 mm height and a central hub diameter of about 8.0 mm. Other bobbins may be in proportion or may have other suitable dimensions, as will be apparent to one skilled in the art. [0043] Bobbin 10 can have any desired appearance and finish and may for example be transparent or opaque, colored or achromatic. In one embodiment of the invention, bobbin 10 is supplied in a range of transparent colors including pastel blues, greens pinks, yellows, secondary colors and stronger tints of the pastel hues. [0044] Referring now to FIGS. 2-3 and 5 , a bobbin winder mechanism 26 can be located on the top or back of a sewing machine 28 , of which only a portion is shown in the drawings, or elsewhere on or off the sewing machine, as may be desired. It will be understood that those parts of the sewing machine that are neither illustrated nor described may have any suitable structure known or apparent to one skilled in the art in light of this disclosure, or as will become known or apparent as the art develops. [0045] The bobbin winder mechanism comprises a bobbin winder spindle 30 projecting upwardly from the top of sewing machine 28 and which can be rotatably driven by sewing machine 28 . Winder spindle 30 is receivable into hub opening 18 . Winder spindle 30 and hub opening 18 have cooperative locking structure, in the vicinity of first bobbin flange 14 , to lock bobbin 10 to the winder spindle 30 against rotation of bobbin 10 relatively to the winder spindle 30 . As may be seen from FIG. 1 , in the embodiment shown, the other end of bobbin 10 , in the vicinity of second flange 16 , lacks locking structure cooperative with the winder spindle 30 . [0046] Winder spindle 30 can be resiliently engageable in central hub opening 18 to grip central hub 12 for rotation therewith. Winder spindle 30 may be a close sliding fit in hub opening 18 . In one embodiment of the invention, the winder spindle 30 is formed of a resilient material, has a transverse dimension nominally larger than axial opening 18 and is resiliently compressible laterally to receivable in central hub 12 opening. Such compressibility can be provided by a transverse slot 32 opening at the free end 34 of winder spindle 30 . With this construction, winder spindle 30 has a diameter at its free end which is slightly larger than that of hub opening 18 . Free end 34 may be chamfered or otherwise shaped to guide it into hub opening 18 . [0047] The locking structure can comprise a key 36 rotatable with winder spindle 30 and which is configured to be accommodated in keyway 20 . Key 36 may be formed as an axial rib projecting from winder spindle 30 , or may have other suitable structure. [0048] Winder spindle 30 may be fabricated of any suitable material, for example a durable resilient plastic such as an acetal copolymer for example that supplied under the trademark HOSTAFORM® LW90 BSX (Hoechst A.G.). [0049] Multiple stops 38 can be disposed peripherally around the winder spindle 30 to position central hub 12 along the winder spindle 30 . In the embodiment illustrated, stops 38 have the form of longitudinal splines projecting radially from winder spindle 30 . The upper end of each stop 38 provides a seat to support bobbin 10 during winding. Together, stops 38 provide a ring of support for bobbin 10 around winder spindle 30 . [0050] Winder spindle 30 can be freely rotatable about its vertical axis with a resistance and/or inertia which can be predetermined to facilitate a smooth winding operation. Winder spindle 30 is shown in the drawings in a drive-engaging position where it receives rotary drive from sewing machine 28 . In the particular embodiment shown, rotary drive for bobbin 10 is provided by a drive boss 40 which receives rotational drive from sewing machine 28 . [0051] Drive boss 40 provides drive to bobbin 10 , when seated on winder spindle 30 , by frictional engagement therewith. For this purpose, drive boss 40 has a cylindrical shape with a cylindrical outer surface 42 , a flat or domed top surface 44 and a peripheral recess 46 around the upper circumference edge of drive boss 40 . Drive boss 40 is mounted on a drive shaft 48 which is drivingly connected, or connectable, with the sewing machine drive (not shown). Drive shaft 48 extends through an aperture 50 in the top housing of sewing machine 28 . Drive boss 40 may have either a solid or hollow structure and outer surface 42 usefully has a matt or textured finish to help provide good driving engagement with flanges 14 and 16 of bobbin 10 . If desired, transmission of drive to drive boss 40 may be controlled by a user actuated control means such as a switch (not shown). [0052] Outer surface 42 of drive boss 40 can radially engage the periphery of smaller, lower flange 14 of bobbin 10 when bobbin 10 is located in its drive-engaging position, to apply drive thereto. Also, in another useful but not essential feature of the invention, when bobbin 10 is properly seated on winder spindle 30 against stops 38 , larger, upper flange 16 of bobbin 10 engages in peripheral recess 46 . Such engagement of flange 16 in recess 46 assists in the transmission of drive to bobbin 10 and in maintaining alignment of bobbin 10 on winder spindle 30 during winding. The axial position of one or more stops 38 along winder spindle 30 may be adjusted to facilitate snug engagement of bobbin flange 16 in recess 46 in drive boss 40 . [0053] In many embodiments, but not all, it is desirable to provide the user the ability to move winder spindle 30 away from drive boss 40 to disengage bobbin 10 from drive boss 40 to facilitate mounting of bobbin 10 on winder spindle 30 and removal of the loaded bobbin. Desirably, such movement of winder spindle 30 can be effected by operation of a lever or dial or other mechanical device or by electronic or electrical means (not shown). For example, winder spindle 30 can be supported for arcuate lateral movement of its rotation axis toward and away from the drive position by means not shown. If desired, winder spindle 30 may latch into its out-of-engagement position. Furthermore, a drive switch or other drive engagement device (neither one is shown) can, if desired, be associated with the movement of bobbin winder spindle 30 to turn on the rotary drive to bobbin 10 as winder spindle 30 moves toward bobbin 10 and to disconnect or turn off the drive as winder spindle 30 moves away. [0054] Also, if desired, winder spindle 30 can be resiliently urged into its drive position thereby applying a resilient urging force to engage bobbin 10 with drive boss 40 . Such resilient urging engagement can promote consistent application of a drive force to bobbin 10 and reliable winding of thread on to bobbin 10 . Sewing machine 28 can have an arcuate slot 52 formed in its housing to accommodate this lateral movement. [0055] Other suitable drive means for applying a rotational drive to bobbin 10 will be apparent to one skilled in the art. For example winder spindle 30 may be rotated by sewing machine 28 and apply to bobbin 10 . In this case, drive boss 40 can be replaced by an idler or a fixed guide that helps to guide and position bobbin 10 on winder spindle 30 but does not apply drive to it. Usefully, the drive means can be user-actuatable enabling the user to rotate or cease rotation of bobbin 10 . [0056] As shown in FIG. 5 , a spool 54 loaded with thread can be mounted for rotation on a spool pin 56 to provide a source of supply of thread to bobbin 10 . Desirably spool pin 56 can provide limited resistance to rotation of the bobbin, to avoid overrun. A spool holder 58 can be used to retain bobbin 10 in position on spool pin 56 . Spool pin 56 can be disposed on sewing machine 28 conveniently adjacent winder spindle 30 and with any suitable orientation, for example with the longitudinal axis of spool pin 56 disposed approximately horizontally, or in another suitable location and orientation. [0057] To control the running thread 60 traveling from spool 54 to bobbin 10 , a thread guide 62 can be provided. Thread guide 62 can be spaced longitudinally away from spool pin 56 , along the top of sewing machine 28 , to receive thread 60 from spool 54 across spool holder 58 which guides thread leaving spool 54 . A winder pretensioner 64 can be disposed just downstream of thread guide 62 about which thread 60 turns into the final leg of its travel to bobbin 10 . This arrangement is intended to permit bobbin 10 to draw thread from spool 54 and to wind the thread neatly in continuous helical layers. Use of an appropriate pretensioner and one or more guides facilitates winding of bobbin 10 with a proper tension. Excess tension may lead to thread breakage, and undue slackness may cause surpluses, entanglement or knotting. [0058] In using the bobbin winder apparatus of the invention, before mounting a bobbin 10 on winder spindle 30 , the user ensures that a spool 54 of suitable thread is loaded on to spool pin 56 . The thread end is drawn from spool pin 56 , threaded over spool pin holder 58 and thread guide 62 , around pretensioner 64 to bobbin 10 . The thread end can be fed through threading aperture 22 and bobbin 10 can be given a turn or two to secure the thread end on bobbin 10 or it may be secured in another suitable manner. [0059] The user then mounts bobbin 10 on bobbin winder spindle 30 . The contrasting appearances provided by first flange 14 at one end of bobbin 10 with the large central aperture provided by hub opening 18 and the continuous surface of flange 16 which closes the other end of bobbin 10 makes it easy for the user to orient bobbin 10 correctly, with smaller flange 14 downward. With this orientation, bobbin 10 is pressed on to winder spindle 30 , compressing slotted end 34 of winder spindle 30 to fit within hub opening 18 . Winder spindle 30 can offer moderate resistance to the descent of bobbin 10 , providing a good tight feel to the user. Bobbin 10 is pushed down winder spindle 30 until it is securely seated on stops 38 . The combination of the resilient resistance provided by slotted spindle end 34 and the ability to positively seat the bobbin against stops 38 , will help most users position bobbin 10 on winder spindle 30 to be properly aligned with drive boss 40 for driving engagement therewith. [0060] In the event the user attempts to mount bobbin 10 on winder spindle 30 with larger flange 16 lowermost, such effort is rendered obviously impossible by engagement of the aperture-free flange with free end 34 of winder spindle 30 . This difficulty is graphically illustrated in FIGS. 4 a and 4 b. Accordingly, the user may be expected to quickly abort the attempt and to correctly reorient bobbin 10 with flange 14 downward and hub opening 18 addressing winder spindle 30 . [0061] The foregoing operations desirably are performed with winder spindle 30 latched into its out-of-drive position. Once bobbin 10 , with thread end attached, is properly mounted on winder spindle 30 , the user can operate the appropriate control device to move winder spindle 30 into its driven position. This movement can bring bobbin 10 into engagement with winder boss 40 and may activate the drive to winder boss 40 , if the drive is so switched. Smaller flange 14 of bobbin 10 is resiliently urged into engagement with outer surface of drive boss 40 and large flange 16 engages in peripheral recess 46 . [0062] Bobbin 10 is rotated by engagement with drive boss 40 , drawing thread from spool 54 and winding bobbin 10 . The cooperative locking action of key 36 on winder spindle 30 and keyway 20 in hub opening 10 of bobbin 10 ensures that there is no rotational slippage of bobbin 10 on winder spindle 30 ; which helps promote a smooth and effective winding action. The direction of winding is predetermined by the direction of rotation of drive boss 40 and the one way orientation of bobbin 10 . It is not subject to user selection; which avoids possible error in the direction of winding that could be problematic when the wound bobbin is utilized in the bobbin case. [0063] When bobbin 10 is adequately wound, or at another desired moment, the user can activate the winder spindle drive control to terminate the rotation of bobbin 10 , cut the thread and remove the wound bobbin from winder spindle 30 . Wound bobbin 10 is now ready for loading into a bobbin case to supply thread to a sewing machine needle. An example of one suitable bobbin case and related mechanism that may be employed will now be described. Others will be apparent to those skilled in the art. [0064] One bobbin case with which bobbin 10 is useful is a bobbin case such as is employed in a rotating hook sewing machine. In one known form of rotating hook machine, the bobbin case, bearing the bobbin is located beneath the sewing machine work bed, directly under the needle which is threaded with the upper thread. A hook travels around the bobbin case, rotating about a vertical axis, takes a loop from the upper thread and pulls it around the bobbin. The loop extends around the lower thread which runs from the bobbin to the fabric. As it advances, the hook sheds the loop and the sewing machine's take-up lever tightens the threads into a stitch. [0065] One form of rotating hook machine employing a bobbin case is disclosed in Rodda et al., U.S. Pat. No. 4,487,142 cited above. The hook rotating structure constituted by rotary loop taker 20 in Rodda et al., and its associated structure, which carries bobbin case 42 in Rodda et al., can be employed to support the novel bobbin case of the present invention for rotary movement beneath a sewing machine needle. The so-supported bobbin case of the invention can be employed to supply a lower thread to the needle for forming dual-thread stitches, for example lock stitches, employing a bobbin 10 supported in the inventive bobbin case. [0066] A bobbin case according to one embodiment of the invention can have an internal frustoconical configuration with a smaller diameter in its lower portion to properly accommodate bobbin 10 . Proper seating and alignment of a correctly wound bobbin in its bobbin case, as may be achieved with this embodiment of the invention can prevent variations in stitching, inconsistent sewing performance, tension variations, cording, and related problems that may otherwise occur. [0067] The bobbin case of the present invention can also be employed in a relatively simple style of machine such as that shown in Beitzel U.S. Pat. No. 699,067, which is incorporated by reference herein, where the instant bobbin case may replace cup-like spool holder c of Beitzel. [0068] In the embodiment illustrated in FIGS. 6-9 a, a bobbin case pursuant to the present invention, can accommodate bobbin 10 in only one orientation to reduce user error that may lead to thread-handling problems and/or poor stitching. This can be accomplished employing a bobbin such as bobbin 10 which has an end-for-end asymmetry arising from the differences in size of flanges 14 and 16 . In contrast, many known bobbins are reversible end-for-end and can be installed in a bobbin case in more than one way. Incorrect installation while apparently satisfactory to the user may adversely affect sewing quality. [0069] Referring now to FIGS. 6-9 a, the bobbin case there illustrated, referenced 70 , has a cup-like configuration with a sidewall 71 and a mouth 72 through which bobbin 10 may be received into an interior chamber 74 within bobbin case 70 . Bobbin case 70 has a bottom portion 75 structured to retain bobbin 10 in bobbin case 70 . The exterior of bobbin case 70 is structured to be supported in a suitable rotary mechanism such as Rodda et al.'s rotary loop taker 20 , for example by means of a peripheral lip 76 . Externally, bobbin case 70 can have any desired structure consistent with its bobbin-support and thread supply functions. [0070] Interior chamber 74 of bobbin case 70 is configured to closely fit bobbin 70 for which purpose it has, in its lower portion, a shape which, in the downward direction tapers or reduces in cross-section, being smaller at the bottom of chamber 74 . In height, chamber 74 may approximate the height of bobbin 10 from flange to flange, and desirably may be just sufficient for chamber 74 to completely accommodate bobbin 10 . The cross-sectional shape of bobbin case chamber 74 desirably may conform with the shape of bobbin flanges 14 and 16 and in one useful embodiment is circular. However, it will be understood that chamber 74 need not conform with the bobbin shape at all points of a given horizontal periphery and may so conform at multiple points or portions, or a single major portion of the periphery. [0071] In the illustrated embodiment of bobbin case 70 , interior chamber 74 has a middle diameter 78 and a bottom diameter 80 . Middle diameter 78 is somewhat larger than bottom diameter 80 . Thus, between middle diameter 78 and bottom diameter 80 , interior chamber 74 has a part-conical or frusto-conical shape. Above middle diameter 78 , the horizontal section of interior chamber 74 is at least as large as middle diameter 78 . Pursuant to the invention, the dimensions and configuration of interior chamber are selected so that bobbin 10 can be properly accommodated and seated in only one orientation. Usefully, the geometry can be such that attempts to seat bobbin 10 in other than the proper orientation result in misalignments or other problems such that it is clearly impossible to operate the sewing machine. [0072] For example, bottom diameter 80 may be selected to be approximately equal to the diameter of smaller flange 14 so that smaller flange 14 is a close fit into the bottom of chamber 74 . The dimensioning may provide a small clearance sufficient to prevent smaller flange 14 from being gripped by chamber 74 in a way that would interfere with removal of bobbin 10 . Middle diameter 78 may usefully be larger than bottom diameter 80 , and can be somewhat less than the diameter of larger flange 16 of bobbin 10 . The upper portion of interior chamber 74 can be sufficiently large to receive larger flange 16 of bobbin 10 with a small clearance. With these dimensions, bobbin 10 can be properly seated with smaller flange 14 downward. However, if larger flange 16 is downward, the flange will lodge near middle diameter 78 , leaving flange 14 projecting from bobbin case 70 . The projecting flange may render it impossible to assemble the bobbin case into the sewing machine. Nor can bobbin 10 be inserted into bobbin case chamber 74 with hub 12 horizontal and flanges 14 and 16 extending vertically. Thus, there is only one way in which bobbin 10 can be assembled with bobbin case 70 , as is shown. [0073] Bobbin case 70 as shown in FIG. 6 can be fabricated from a lightweight, durable wear-resistant synthetic plastic polymer, for example a phenolic resin such as a thermoset phenolic 525 or CB-7843. [0074] While the described and illustrated embodiment of bobbin case chamber 70 may have an interior chamber 74 which has horizontal cross-sectional surfaces which lie on circles to closely accommodate or fit circular flanges 14 and 16 of bobbin 10 , it will be understood that interior chamber 74 may have other cross-sectional shapes depending upon the shape of flanges 14 and 16 , or other bobbin structures. For example, the cross-sectional shape or shapes could be square, polygonal, or the like or irregular. [0075] As will be understood by one skilled in the art, the illustrated embodiment of bobbin case 70 of the invention can be employed in a sewing machine having a hook rotating structure and associated support mechanism such as is disclosed in Rodda et al., for lockstitch operation utilizing thread supplied by bobbin 10 from bobbin case 70 , and replacing bobbin case insert 38 described by Rodda et al. The present invention includes such a sewing machine. [0076] FIGS. 7-8 show bobbin case 70 supported in a rotating hook mechanism 81 of a sewing machine to supply thread (not shown) from bobbin 10 to the sewing machine's needle, as a lower thread. Conveniently, although not necessarily, the sewing machine of which portions are illustrated in FIGS. 7-9 may be the same machine as is partially illustrated in FIGS. 2-5 . [0077] The sewing machine shown in FIGS. 7-8 includes a spring guide 82 which cooperates with the bobbin case side wall 71 , over which the thread runs, to guide the lower thread and tension it during sewing. Rotating hook mechanism 81 is supported in a volume beneath the work bed 84 of the sewing machine which volume is closable by a slidable cover 86 . Cover 86 is closed in FIG. 7 and retracted, or open, in FIG. 8 to provide access to bobbin 10 , enabling it to be changed when exhausted of thread or when a different thread is required. Cover 86 has a downward retaining rib 88 . Desirably bobbin case 70 and other relevant components are dimensioned to provide a sufficient clearance 90 for the thread to pass as the hook rotates. Other elements of the rotating hook mechanism and the sewing machine can be as is known in the art. [0078] In use, a user retracts cover 86 , removes an existing bobbin 10 from bobbin case 70 , if present and manually inserts a wound bobbin 10 which has been prepared as shown in FIG. 5 . Properly oriented, for example as shown in FIG. 7 a, with smaller flange 14 downward, bobbin 10 readily drops into place in bobbin case 70 . Thread is drawn from bobbin 70 and positioned in the usual manner to supply lower thread to the needle. Cover 86 can be closed, ready for sewing. [0079] In the event the user inserts bobbin 10 with an incorrect orientation, for example with larger flange 16 downward, as shown in FIG. 9 and FIG. 9 a, flange 16 lodges near middle diameter and flange 14 projects above work bed 84 . Cover 86 cannot be closed, sewing is prevented and this state of affairs will usually prompt the user to remove, rotate and reinsert bobbin 10 in the correct orientation. Because the direction of winding of the thread on bobbin 10 has been predetermined in the winding operation, the user is assured of sewing with a properly installed and correctly wound bobbin. So long as other components of the sewing machine are functioning properly, the user may reasonably expect to be able to generate quality stitching until bobbin 10 is exhausted of thread and needs changing. [0080] Additional benefits obtainable with embodiments of novel bobbin case 70 are that it may easily be removed and reinstalled facilitating cleaning and lubricating of the rotating hook mechanism. [0081] In the above description, where structures are described as having, including, or comprising specific components, or where methods are described as having, including, or comprising specific steps, it is contemplated that structures and methods of the present invention may also consist essentially of, or consist only of, the particular components or steps recited. [0082] The foregoing detailed description is to be read in light of and in combination with the preceding background and invention summary descriptions wherein information regarding the best mode of practicing the invention may also be set forth and where modifications, alternative and useful embodiments of the invention may be suggested or set forth, as will be apparent to one skilled in the art. [0083] While illustrative embodiments of the invention have been described above, it is, of course, understood that many and various modifications will be apparent to those of ordinary skill in the relevant art, or may become apparent as the art develops. Such modifications are contemplated as being within the spirit and scope of the invention or inventions disclosed in this specification.
A sewing machine which may employ a loop-making hook rotating about a vertical axis employs a one-way bobbin and bobbin case. A bobbin can have a larger flange and a smaller flange so as to fit in a suitably configured bobbin case in only one way. The bobbin may have a blind axial opening with a guide groove to fit a winder spindle in only one way so that the bobbin can only be wound in one way. Attempts at incorrect orientations cause the bobbin to protrude from the bobbin case in an obviously incorrect manner. Inadvertent efforts to wind the bobbin incorrectly are likely to be fruitless. Thus, a user can readily install the bobbin in the bobbin case with a proper orientation and with the thread correctly wound. Surprisingly, stitching problems, such as poor seams or the like, can be reduced.
3
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] (Not applicable) STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH [0002] (Not applicable) BACKGROUND OF THE INVENTION [0003] 1. Field of the Invention [0004] The present invention is directed generally to a remote control device and, more specifically, to a remote control device with a directional mode indicator. [0005] 2. Description of the Background [0006] Virtually every consumer electronic (CE) device sold today comes with its own remote control. As a result, it is not uncommon for households to have as many as three different remote control devices to control separate CE devices on the living room coffee table, thus introducing clutter and confusion as to the remote control that controls each particular CE device. The home electronics industry has responded to consumer frustrations with the introduction of universal remote devices. A universal remote control can be “taught” to take the place of all of the individual remote controls, thus allowing reduction of the number of remote controls per household to one. [0007] Even though using a universal remote control has many advantages, it at the same time, introduces new problems. For one, it is difficult to determine the current mode of operation of the universal remote control merely by visual inspection. In addition, once the mode of operation is determined, a sequence of buttons must be pressed to change the mode of operation of the remote control to that of another CE device. Thus, there is a need for a remote control in which the mode of operation may be more easily changed. [0008] Another significant problem with universal remote controls is that no feedback is given to the user to identify the source of transmittal problems between the remote control and the CE device such as a weak remote control signal, low battery power, an incorrect mode of operation, a malfunctioning set-top box, and other such problems. Thus, there exists a need for a feedback device that indicates the mode of operation of the remote control whenever the buttons of the remote control are pressed to assist in diagnosing the source of transmittal problems. Further, there exits a need for a remote control having a feedback device that indicates weak signal strength and/or low battery power. [0009] In addition, many remote control users also find it frustrating to have to press a button or tap an LCD screen on the remote control that cannot be seen in a dark room in order to light the remote control's buttons. Further, pressing a random button or randomly tapping the LCD screen in the dark may trigger a remote control function that the user did not intend. Thus, there exists a need for a remote control having illumination whenever the remote control is moved or picked up. [0010] Advanced technophile users demand the functionality of universal remote control devices to become increasingly more sophisticated. For example, an experienced technical user may wish to do as much as the user can with a single remote control device, in addition, a home electronics maven might wish to be visually or audibly alerted to incoming telephone calls, or to a favorite television show starting, from the mobile remote control independent of the typically immobile set-top box or other CE device, which may be off when such an event occurs, thereby causing the user to miss that event. In addition, some advanced consumers may appreciate having the means to save and retrieve individualized settings of each CE device and/or their user profile from their remote control instead of having to use the set-top box to access these individualized settings and user profiles. SUMMARY OF THE INVENTION [0011] The present invention is directed to a remote control device including a processor and a motion detector in communication with the processor. The device also includes at least one input device in communication with the processor and a directional mode indicator in communication with the processor, the directional mode indicator for indicating the mode of operation of the device based on a signal generated by the motion detector. [0012] The present invention represents a substantial advance over prior remote control devices. The present invention has the advantage that the remote control device can indicate the mode of operation of the device based on tilting of the device. BRIEF DESCRIPTION OF THE DRAWINGS [0013] For the present invention to be clearly understood and readily practiced, the present invention will be described in conjunction with the following figures, wherein: [0014] FIG. 1 is a block diagram of a remote control device with motion-detected illumination according to one embodiment of the present invention; [0015] FIG. 2 is a block diagram of a remote control device with an automatic positional mode of operation changer according to another embodiment of the present invention; [0016] FIG. 3 is a block diagram of a remote control device with an automatic event notifier and a corresponding consumer electronic device that interacts with the remote control device according to another embodiment of the present invention; [0017] FIG. 4 is a block diagram of a remote control device with a smart card reader/writer and a corresponding consumer electronic device that interacts with the remote control device according to another embodiment of the present invention; and [0018] FIG. 5 is a block diagram of a universal remote feedback device according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0019] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements found in a typical device. Those of ordinary skill in the art will recognize that other elements are desirable and/or required to implement a device incorporating the present invention. However, because such elements are well known in the art and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein. [0020] FIG. 1 is a block diagram illustrating a remote control device 10 with motion-detected illumination according to one embodiment of the present invention. The device 10 includes a housing 12 that contains the circuitry of device 10 . Within the housing 12 are a microprocessor 14 , an input device 16 , a light source 18 , a motion detector 20 , and a data storage area 22 . [0021] According to one embodiment of the present invention, the housing 12 may be constructed of a durable material such as, for example, a lightweight metal such as, for example, aluminum, titanium or a long-lasting alloy. According to another embodiment, the housing 12 may be constructed of a heavy duty plastic such as, for example, PVC, ABS, or Fiber-reinforced plastic (FRP). According to still another embodiment, the housing 12 may be constructed of rubber or of any other material or any combination of materials than is capable of withstanding constant handling and use. [0022] The motion detector 20 can be any type of detector that senses when the device 10 is moved and can be of any type of mechanical switch such as, for example, a mercury switch or a gravity-based switch or of any type of electronic sensor. [0023] The microprocessor may be of any type of microprocessor appropriate such as, for example, AMD's K5, K6, or K7 series, Intel's Pentium series, Cyrix's 6×86 or Mxi series, IDT's WinChip series, or Rise's mP6 or any other suitable microprocessor. The data storage area 22 may be any data storage means that is utilized to store, retain and send computer readable instructions to the microprocessor such as; for example, the M-Systems flash memory chip; persistent data memory chips such as, for example, EEPROM, battery-backed SRAM or mask ROM; or temporary-data-storage memory chips, such as, for example, DRAM, SRAM or ferroelectric RAM (FRAM); or any combination of the above data-storage memory chips. According to another embodiment of the present invention, the microprocessor and the data storage area may be combined onto a single chip such as, for example, Atmel's 16-Mbit ConcurrentFlash dual-bank device or STMicroelectronics and Waferscale Integration's NOR-based Flash+ technology. [0024] The light source 18 may be, for example, an incandescent, fluorescent, electro-luminescent, or low-voltage light source, multicolored LEDs, or any lighting means that illuminates a portion or all of the input device 16 . The input device 16 may be an alphanumeric keyboard or buttons, arrowed buttons, plain buttons, an LCD screen, a touch screen, a joystick, a stylus, a mouse, a keypad, a modem jack or any means that can be utilized by the user to input information. [0025] When the motion detector 20 detects movement, the motion detector 20 transmits a signal to the microprocessor 14 indicating the movement. The motion detector 20 is connected to a microprocessor 14 and detects movement of the device 10 . The microprocessor 14 , in turn, after retrieving instructions from the data storage area 22 , sends a signal to the light source 18 . Upon receipt of the message, the light source 18 illuminates all or a portion of the input device 16 so that the input device 16 may be more readily seen in dark environments. According to one embodiment, a portion or all of the input device 16 may be backlit by the light source 18 . Alternatively, in another embodiment, the light source 18 may shine down upon the input device 16 from an extending projection or projections of the housing 12 to illuminate the input device 16 . The light sources 18 may thus be a single light that lights the input device 16 or may be, for example, a grid of lights, with each light corresponding to, for example, a button on the input device 16 . In another embodiment, a portion of the device 10 not used for input such as, for example, a border around the top side of the device 10 , may be backlit by the light source 18 , thus shedding light on the input device 16 . Optionally, after a pre-set period of time (e.g., five to ten seconds) without the remote control device 10 moving or without any input from the input device 16 , one embodiment of the present invention may have the microprocessor 14 send a signal to the light source 18 to cease the illumination of the input device 16 . In addition, according to another embodiment, the remote control device 10 may have a button or some other physical means of input that activates the illumination of the input device 16 so the user is not limited to moving the remote control device 10 to trigger illumination. Further, in another embodiment of the present invention, the automatic illumination due to movement feature of the remote control device 10 may be turned off with, for example, a user-controllable switch to save battery life. [0026] FIG. 2 is a block diagram of a remote control device 30 with an automatic positional mode of operation changer according to another embodiment of the present invention. The remote control device 30 is similar to the remote control device 10 described hereinbefore in conjunction with FIG. 1 with the exception that the remote device 30 in FIG. 2 also includes a motion detector 40 that detects a different type of motion than that of the motion detector 20 in FIG. 1 . The remote control device 30 also includes a directional mode indicator 44 . The motion detector 40 may be a gravity switch or any gyroscope-type device that can detect changes from horizontal in at least two degrees of freedom. [0027] The motion detector 40 detects the tilting or absence of tilting of the apparatus 30 and sends a signal to the microprocessor 34 indicating the direction of the tilt or lack thereof. After receiving the tilt directional information, the microprocessor 34 , acting on informational instructions retrieved from data storage area 42 , changes the mode of operation of the apparatus 30 to correspond to the appropriate consumer electronic device. The appropriate consumer electronic device may be, for example, a television, a VCR, a DVD, a DVR, a satellite, a cable or HDTV controller, home theater system components, or stereo system components, indicated by the tilt of the apparatus 30 . A number of different orientations of the remote device 30 may correspond to a separate operational mode. Therefore, when a particular orientation of the remote control device 30 is detected, the microprocessor 34 may then assume the appropriate operational mode. [0028] The microprocessor 34 may be programmed to detect the orientation of the device 30 based on feedback from the motion detector 40 and thus determine the mode of operation of the device 30 by any of a number passive programming techniques, such as, for example, numeric code programming, automatic programming, learned method programming, downloading from a personal computer, button presses or any of the typical means used to program remote controls to accept the codes recognized by consumer electronic devices. In addition to changing the mode of operation, in another embodiment of the present invention, the microprocessor 34 may transmit a message to the light source 38 to illuminate the corresponding directional mode indicator 44 so the user, at a glance, can determine the direction of the orientation of the device 30 and thus the mode of operation of the remote control device 30 . [0029] According to one embodiment of the present invention, the direction of the orientation and the corresponding mode of operation may be indicated by the directional mode indicator 44 which may consist of an arrangement of arrows corresponding to the different orientation directions. According to another embodiment of the present invention, the arrow corresponding to the direction of the orientation may light up when the remote control device 30 is tilted in that direction. The light source 38 may be any lighting means described hereinbefore in FIG. 1 that fully illuminates the direction mode indicator 44 . According to another embodiment, the directional mode indicator 44 is not limited to visual signals. Any means that adequately relays the tilt and mode of operation information of, for example, a television, a VCR, a DVD, a satellite, cable or HDTV controller, home theater system components, or stereo system components, may be used. [0030] FIG. 3 is a block diagram illustrating a remote control device 60 with an automatic event notifier and a corresponding consumer electronic device 100 that interacts with the remote control device 60 according to another embodiment of the present invention. The remote control device 60 is similar to the remote control device 10 described hereinbefore in FIG. 1 except that the remote control device 60 in this embodiment also incorporates a speaker 70 and a receiver 74 within the housing 62 . [0031] The consumer electronic device 100 has the capability to be programmed to keep track of scheduled events, such as television shows or sporting event starting times, through an electronic program guide 102 . The consumer electronic device 100 has a terminal connection 106 for receiving data via a telephone line. The consumer electronic device 100 may be, for example, a typical set-top box commonly used by HDTV, satellite or cable television companies or any consumer electronic device such as a television, a VCR, DVD, home theater system components, stereo system components, or a digital video recorder (DVR). Besides the electronic program guide 102 and the terminal connection 106 to a telephone line, the consumer electronic device 100 may additionally include a receiver 112 and at least one transmitter 110 to communicate with the remote control device 60 . The consumer electronic device 100 may also include a speakerphone 108 and/or a video conferencing system 104 . [0032] When a scheduled event occurs via the electronic program guide 102 or when a telephone call is received via the telephone terminal connection 106 , the consumer electronic device 100 may transmit a message via the consumer electronic device transmitter 110 to the receiver 74 of the remote control device 60 . Electromagnetic waves such as, for example, infrared (IR), radio frequency (RF), X-10, pulsed codes, sound waves, microwave, or any typical remote control signaling technique may be utilized to pass the message between the consumer electronic device transmitter 110 and the remote control device receiver 74 . [0033] When the receiver 74 receives the signal concerning an incoming event from the consumer electronic device 100 , the receiver 74 may transmit a signal to the microprocessor 64 . The microprocessor 64 may, in turn, retrieve informational instructions from the data storage area 72 , interpret the signal using the instructions, and provide an alert to a user that a scheduled event is about to occur or that there is an incoming telephone call by activating the speaker 70 and/or the light source 68 . The light source 68 may be any lighting means that can be fully customized to represent different scheduled events or incoming telephone calls. Additionally, the speaker 70 may emit brief “chirps” or “clicks” with varying pitches and tones programmed to represent different scheduled events or incoming telephone calls. However, the visual and audio alerts are not limited to these responses. According to other embodiments, other alerts may be used to allow the user to easily locate the remote control device 60 and recognize the event that is occurring. [0034] Both audio and visual responses may be customizable and programmed to be unique to the different incoming signals from the electronic program guide 102 , the video conferencing system 104 or the speakerphone 108 of the consumer electronic device 100 . For example, according to one embodiment of the present invention and in the case of an incoming telephone call, the input device 66 could have a caller id function so the user can determine who was calling before activating the speakerphone. In another embodiment and in the case of a scheduled event, the input device 66 could display what event is about to occur. According to one embodiment of the present invention, activating the input device 66 may turn off the audio and visual alerts by the speaker 70 and light source 68 and acknowledge the programmed event from the electronic program guide 102 or the incoming telephone or video conferencing call through the speakerphone 108 or video conferencing system 104 from the consumer electronic device 100 . [0035] According to one embodiment of the present invention, the consumer electronic device 100 does not need to be powered on when the event occurs or the telephone call is received. The remote control device 60 will still receive the notification from the consumer electronic device 100 and will alert the user to the event or call. Activating the input device 66 after an alert will power on the consumer electronic device 100 if selected by the user. [0036] FIG. 4 is a block diagram is a remote control device 80 with a smart card reader/writer and a corresponding consumer electronic device 140 that interacts with the remote control device 80 according to another embodiment of the present invention. The consumer electronic device 140 includes an electronic program guide 142 , a receiver 144 and at least one transmitter 146 to communication with the remote control device 80 . [0037] The remote control device 80 is similar to the remote control device 10 described herein before in conjunction with FIG. 1 . However, the remote control device 80 also incorporates within the housing 82 at least one transmitter 86 , a receiver 94 , and a smart card reader/writer 92 . The smart card reader/writer 92 is of a suitable type such as, for example, a manual insertion, manual swipe, motorized insertion, hybrid, TTL, RS232, proximity or any other appropriate variety of smart card reader/writer. However, the smart card reader/writer in the remote control device 80 is not limited to any particular type of smart card reader/writer listed above. The removable smart card 92 can be of any type of smart card including a contact, contactless, combi or hybrid type with either an embedded microprocessor or memory chip. [0038] A removable smart card 92 may be inserted by the user into the smart card reader/writer 90 of the remote control device 80 . The removable smart card 92 may contain information concerning user profiles, user history, favorite shows, favorite channels, favorite themes, channel order, reminders for favorite shows, parental controls, audio and visual settings, pay-for-view purchases and spending limits or any information that a user may want individualize for use with the consumer electronic devices. [0039] The information stored on the removable smart card 92 could also contain user Internet profiles and information including access to email, Internet browser bookmarks, account names, address lists, hosts, security features, and display formats pertaining to Internet browsing on a television monitor. According to one embodiment, the removable smart card 92 does not need to be remote control specific. The user may be able to take the removable smart card 92 anywhere there is a compatible remote control 80 to access personal information on the removable smart card 92 . In addition, the removable smart card 92 could store promotional information allowing the user to take the removable smart card 92 to other locations to receive coupons, discounts or special merchandise. [0040] The information stored on the smart card 92 may be read by the smart card reader/writer 90 and sent to the microprocessor 84 . The microprocessor 84 , after retrieving informational instructions from the data storage area 88 , transmits the information to the transmitter 86 . The transmitter 86 , in turn, transmits the information read from the removable smart card 92 to the receiver 144 of the consumer electronic device 140 . The transmitter 86 may transmit information via electromagnetic waves such as, for example, infrared (IR), radio frequency (RF), X-10, pulsed codes, sound waves, microwave or any type of remote control signal that can be interpreted easily by the receiver 144 . The receiver 144 then relays the information to the electronic program guide 142 , which then acts upon the information received. [0041] When information such as, for example, sound and video settings, is updated on the consumer electronic device 140 , the information may be sent to the transmitter 146 and then sent out to the receiver 94 of the remote control device 80 . The receiver 94 in turn may transmit the new information to the microprocessor 84 , which retrieves informational instructions from the data storage area 88 and relays the information to the smart card reader/writer 90 . Upon receipt of the information from the microprocessor 84 , the smart card reader/writer 90 writes the new information on the removable smart card 92 . Having the smart card reader/writer 90 in the remote control device 80 allows multiple users to move between several different removable smart cards 92 easily and quickly since the user no longer needs to have to walk over to the consumer electronic device 140 to swap out different smart cards, thus increasing convenience and productivity. [0042] FIG. 5 is a block diagram for a universal remote feedback device 120 according to another embodiment of the present invention. The universal remote feedback device 120 is programmed to respond to the signals sent by a consumer electronic (CE) device and its corresponding remote control device as a means of feedback to input entered into the remote control device. The universal remote feedback device 120 is similar to the remote control device 10 described hereinbefore in conjunction with FIG. 1 . The device 120 may also include a receiver 128 , a speaker 132 , and a display device 136 . [0043] The universal remote feedback device 120 may be programmed using any suitable programming techniques such as, for example, numeric code programming, automatic programming, learned method programming, downloading from a personal computer, and button presses or any of typical means being used to program universal remote controls to accept the codes needed to operate consumer electronic devices. According to one embodiment, the universal remote feedback device 120 may be attached to a CE device. In another embodiment, the universal remote feedback device 120 may be attached to the CE device's remote control. In yet another embodiment, the universal remote feedback device 120 may be attached to a commercially available universal remote control. In all embodiments, it is imperative that the device, either the CE device or the remote control device, to which the universal remote feedback device 120 is attached does not have its signal blocked and the universal remote feedback device 120 can receive the feedback signal the user wants. [0044] When the receiver 128 of the universal remote feedback device 120 receives a signal from a CE device or its remote control, the universal remote feedback device 120 transmits a message to the microprocessor 124 . The microprocessor 124 retrieves informational instructions from the data storage area 134 and activates the speaker 132 and light source 130 . The sound and light produced is customizable and can be unique to each device programmed into the universal remote feedback device 120 . The light source 130 may be, for example, multicolored LEDs or any lighting means that can be fully customized. The speaker 132 could emit brief “chirps” or “clicks” with varying pitches and tones programmed to represent different consumer electronic devices. [0045] According to one embodiment, the display device 136 may display multiple alphanumeric characters as an indication of what device sent the signal to the universal remote feedback device 120 . For example, if the universal remote control were in DVD mode, the display device 136 would show “DVD” each time input is received by the universal remote control device 120 . The user may select whether to have audio feedback, visual feedback, alphanumeric feedback, or any combination of feedback. However, other means of feedback are available to the user and should not be limited to those described. The display device 136 , speaker 132 and light source 130 as well as other means of feedback also may provide feedback when there is a weak signal, low battery power or other transmittal problems associated with either the remote control device and consumer electronic device. [0046] Although the present invention has been described herein with reference to certain embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
Methods, systems, and products disclose a remote control device that controls multiple consumer electronics devices based on orientation.
6
CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority of the U.S. Provisional Patent Application 61/769,023 filed on Mar. 4, 2013 entitled “Container with Removable Dividers,” the contents of which are hereby incorporated by reference. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not Applicable REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX Not Applicable BACKGROUND OF THE INVENTION The present invention relates to storage containers with lids. More particularly, the present invention relates to storage containers with removable partitions allowing compartmentalization. Traditional storage containers feature either a non-compartmentalized or compartmentalized interior enclosed by a lid for sealing and securing contents. Users often desire to store consumable and non-consumable goods in containers and are forced to use more than one container in order to avoid mixing contents or creating an undesired combination of certain types of contents as a result of having a non-compartmentalized container. Users may find compartmentalized containers are not always ideal, because the storage proportions in fixed-compartment containers do not match the user's requirements. As such, a container that allows users to reconfigure compartment sizes within the storage container is often useful, as it allows for separation of contents while allowing a level of customization not found in fixed compartment containers. Prior art teaches containers with removable partitions so users can customize compartment sizes. The problem with the containers found in the prior art that feature removable partitions is the partitions do not provide a liquid-proof seal, leading to unwanted transfers of consumables or non-consumables between partitions. The inventor performed a prior art search for storage containers of interest. The following U.S. patents of interest are: U.S. Pat. No.: Issue Date: Inventor: 4,360,105 Nov. 23, 1982 Williams 5,547,098 Aug. 20, 1996 Jordan 6,467,647 Oct. 22, 2002 Tucker D555,475 Nov. 20, 2007 Enriquez 8,322,530 Dec. 4, 2012 Furlong 8,328,034 Dec. 11, 2012 Miros SUMMARY OF THE INVENTION A storage container with a lid and an interior comprised of tracks and removable dividers that form a watertight seal between compartments so that contents are not inadvertently mixed. The container may be used for consumables and non-consumables in both solid and liquid states. The removable dividers may be arranged within the tracks to modify the sizes of the individual compartments. The lid of the container fits flush with the sides of the container and the seals on the removable dividers to form a leak-proof container. The removable dividers are inserted into tracks inside the storage container and allow the user to customize the storage configurations within the container. Rubberized edges surround the exterior dimensions of the removable dividers and provide for a leak-proof seal between compartments. The tracks that hold the removable dividers may be designed in such a way as to apply pressure to the removable dividers to seal and further prevent leakage between compartments. The configuration of the removable dividers and tracks may vary in quantity, dimensions, design and shape. The inventor believes the present invention is an improvement over prior art because it allows a level of customization not found in the prior art. By utilizing removable dividers with leak-proof seals, the present invention improves on prior art by stopping leakages between compartments in customizable storage containers. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the present invention showing the removable dividers and their insertion points in the tracks, according to the preferred embodiment of the present invention. FIG. 2 is a perspective view of the present invention with the removable dividers placed in the tracks according to the preferred embodiment of the present invention. FIG. 3 is the individual side view of the horizontal removable divider according to the preferred embodiment of the present invention. FIG. 4 is an individual top view of the horizontal removable divider according to the preferred embodiment of the present invention. FIG. 5 is an individual side view of the removable center vertical divider according to the preferred embodiment of the present invention. FIG. 6 is a side view of the container, demonstrating the orientation of the horizontal and vertical dividers, their insertion points within the tracks and the lid of the preferred embodiment of the present invention. FIG. 7 is an aerial view of an alternative embodiment of the present invention showing the removable dividers and their insertion points in the tracks. FIG. 8 is an aerial view of an alternative embodiment of the present invention with the removable dividers placed in the tracks. DETAILED DESCRIPTION OF THE INVENTION The system and methods described herein are provided for container assemblies for storing and transporting consumable and non-consumable products. The container assembly generally comprises one or more modifiable compartments and a lid for sealing the contents within the container. The container assembly may include two or more tracks for housing removable dividers with rubberized edges. One or more removable dividers may be used to configure storage compartments in the interior of the container assembly. Referring now to the preferred embodiment of the current invention as shown in FIG. 1 , there is shown the container 10 having removable horizontal divider 17 and removable vertical center divider 21 in disengaged mode. The preferred embodiment of the present invention consists of a container 10 with compartmentalization features. Side track channels 27 meet a bottom horizontal track channel 25 . A bottom center track channel 24 meets the bottom horizontal track channel 25 . A vertical center side track channel 26 meets the bottom center track channel 24 . The track channels 24 25 26 27 provide pressure to the removable horizontal divider 17 and removable center divider 21 when they are placed in the tracks to form a watertight seal between the storage chambers. Still referring to the preferred embodiment of the present invention as shown in FIG. 1 , the removable horizontal divider 17 features rubberized side edges 18 , a rubberized bottom edge 19 and a vertical track 20 , which is configured to join flush with the bottom center track channel 24 . The removable horizontal divider 17 slides within the container's vertical center side track channel 26 and horizontal track channel 25 when so desired by the user. The removable center divider 21 features rubberized side edges 22 and a rubberized bottom edge 23 . The removable center divider 21 slides within the container's vertical center side track channel 26 and the vertical track 20 of the removable horizontal divider 17 when further separation of compartments is desired. Still referring to FIG. 1 , the preferred order of compartmentalization is to engage the horizontal removable divider 17 prior to engaging the removable center divider 21 . FIG. 1 illustrates the fitting orientation of the horizontal removable divider 17 , wherein rubberized edges 18 19 slide into the horizontal track channels 25 27 . FIG. 1 . Illustrates the fitting orientation of the center vertical removable divider 21 , wherein the rubberized edges 22 slide into the vertical center side track channel 26 and the rubberized edge 23 slides into the bottom center track channel 24 . In the preferred embodiment of the present invention, the container 10 , and all tracks 24 25 26 27 are formed from a single piece of molded plastic. The preferred embodiment of the present invention calls for the horizontal removable divider 17 and center removable divider 21 to be formed of molded plastic as well, with the edges 18 19 22 23 formed from silicone, which is bonded to the dividers 17 21 . Alternative embodiments of the present invention allow for construction of different materials, such as glass, Pyrex or metal, and utilizing differing forming techniques. FIG. 2 shows how the different components of the container 10 and removable dividers 17 21 work together to provide sealed compartments when the removable dividers 17 21 are coupled into the tracks 24 25 26 27 . FIG. 2 shows the center vertical removable divider 21 perpendicular to the horizontal removable divider 17 , and between the vertical side track channel 26 and the vertical track 20 of the horizontal removable divider 17 . FIG. 3 shows the horizontal removable divider 17 apart from the preferred embodiment of the present invention. Seen in FIG. 3 are the horizontal removable divider 17 , rubberized edges 18 19 and vertical track 20 . FIG. 4 shows an alternative view of the horizontal removal divider 17 apart from the preferred embodiment of the present invention and from above and demonstrates the rubberized edges 18 and vertical track 20 . FIG. 5 shows the removable center vertical divider 21 with rubberized edges 22 and 23 . FIG. 6 is a side view of the container assembly 10 , showing the rubberized edges 18 19 and vertical track 20 of the horizontal removable divider 17 . FIG. 6 shows the position of the rubberized edges 18 19 of the horizontal removable divider 17 , in relation to the tracks of the container 25 27 . The lid 30 snaps securely in place onto the lip 11 of the container 10 . FIG. 6 shows the position of the rubberized edges 22 23 of the removable center vertical divider 21 as they fit within the container 10 . FIG. 6 depicts the orientation of one end of the horizontal removable divider 17 into the side track channel 27 and the orientation of the fitting of the perpendicular, vertical center removable divider 21 wherein the edges 22 fit respectively into the vertical center track channel 26 and into the center track 20 of the horizontal removable divider 17 . FIG. 6 further depicts lid 30 and its orientation with the lip 11 of the container 10 . FIG. 7 is an aerial view of an alternative embodiment of the present invention. FIG. 7 shows a circular container 10 , horizontal wall channel 27 , horizontal bottom channel 25 , bottom center channel 24 and a vertical center wall channel 26 . FIG. 7 also shows, in removed position, a removable divider 17 having rubberized edges 18 , and a center track 20 . FIG. 7 also shows, in removed position, a center vertical removable divider 21 having rubberized edges 22 . FIG. 7 illustrates the orientation of engagement of the components of this embodiment. FIG. 8 is an aerial view of the container according to the alternative embodiment of the present invention from FIG. 7 . FIG. 8 shows horizontal wall channels 27 , a horizontal bottom channel 25 , a vertical bottom channel 26 , and the center bottom channel 24 . The horizontal removable divider 17 with a center track 20 and corresponding rubberized edges 18 is shown inserted within the channels 24 25 26 27 . While particular embodiments have been shown and described, the above variations are for illustrative purposes. It will be apparent to those skilled in this art that a plurality of equivalent variations, changes, combinations to the idea of and without departing from the disclosing and explanation of this invention and its broader aspects shall also fall within the technical scope of the appended claims and encompass all such changes within the true spirit and scope of this invention. Therefore, it is to be understood that the invention is solely defined by the appended claims. It will be understood by those skilled in this art that, in general, terms used herein, particularly appended claims (e.g. bodies of the appended claims) are generally intended as “open” terms (e.g. the term “including” is to be interpreted as “including but not limited to”, the term “comprising” is not to be interpreted as limiting, the term ‘having” is not to be interpreted as “having only”. Any elements described herein as singular can be pluralized, and plural elements can be used in the singular. The above-described elements, assemblies and methods, elements for carrying out the invention, and variations of aspects of the invention can be modified such as dimensions, volumes, shapes, sizes, method of manufacturing, in a plurality of different ways and type of utility.
A storage system is provided comprising a container, lid and removable dividers with rubberized edges. The container features at least one track into which corresponding removable dividers with rubberized edges are inserted and held in place. The removable dividers of the system are inserted into the track(s) of the container and form a watertight seals and separate the container into two or more sections. The lid of the system is secured to the container with a threaded or pressure snap attachment mechanism and forms a watertight seal.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates in general to pickup arm driving apparatus and, more particularly, to a pickup arm driving control system in record disc players with repeat playback function. 2. Description of the Prior Art Auto-repeat record players which can automatically repeat the playback operation are known in the prior art. Conventionally, auto-repeat players repeatedly play back the full recorded surface on one side of a record disc. That is, it has been impossible in such record disc players to repeatedly play back an optionally selected part of the loaded record disc. While, there will be an occasion where an user requires to play back only a part of a loaded record disc recording some music or information to which he like to listen. Any heretofore known auto-repeat record disc player could not meet such user's requirement. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a novel pickup arm driving control system in record disc players capable of repeatedly playing back a part of a loaded record disc set or directed by an user without using recording-break portion detecting sensors or the like. In accordance with the above object, the present invention is addressed to a pickup arm driving control system which comprises means for producing an output signal at every predetermined step of the moving of a tone arm, means for calculating the moving distance of the tone arm from a reference position at every output signal by accumulating said output signals, means for generating a first setting signal in response to a manual operation conducted when the tone arm is just tracking the start position of a part of the loaded record disc where an user wants repeat playback operation and a second setting signal in response to another manual operation conducted when the tone arm is just tracking the end position of the above mentioned repeat playback part of the loaded record, a memory unit for successively storing the up-dated one of the calculated result of moving distance as a first memory value at a first address, the first memory value upon the generation of the first setting signal as a second memory value at a second address and the first memory value upon the generation of the second setting signal as a third memory value at a third address, means for generating a first coincidence signal when the first memory value coincides with the second memory value during the repeat playback operation mode and a second coincidence signal when the first memory value coincides with the third memory value while the repeat reproduction for the above mentioned part of the record disc is being executed, and means for in response to the first and second coincidence signals controlling the manipulation of the tone arm so that the repeat reproduction may begin from the start position determined by the generation of the first setting signal and terminate at the end position determined by the generation of the second setting signal. BRIEF DESCRIPTION OF THE DRAWINGS For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing wherein: FIG. 1 is a perspective view of a linear tracking arm assembly applicable to the present invention. FIG. 2 is a block diagram showing a pickup arm driving control system embodying the present invention. FIG. 3 consisting of FIG. 3A and FIG. 3B is a flow chart showing the logic operation sequence of the system of FIG. 2. DETAILED DESCRIPTION OF THE INVENTION There is shown in FIG. 1 of the drawings main part of a linear tracking pickup arm mechanical assembly which is applicable to a pickup arm driving control system according to the present invention. Worm gear 1 with a horizontal center axis is mounted across mounting plates 2 and 3 in such a manner as to freely rotate about the horizontal center axis. Reversible motor 4 drives worm gear 1 in a forward or reversal rotation through pulley 5 and belt 6. Sliding table 7 is engaged with worm gear 1 so as to slide along worm gear 1 rotates and disc-like rotator plate 8 is fixed to the end portion of worm gear 1 so as to rotate together with the rotation of worm gear 1. Tone arm 10 is pivotally mounted on arm holder 9, which is secured to sliding table 7, so as to be freely turned in vertical planes making a right angle with the horizontal center axis of worm gear 1. An arm lifter (not shown in the drawing) pivotally turns tone arm 10 by a predetermined angle in a clockwise or counterclockwise. On one end of tone arm 10 is provided pickup cartride 11 and on the other end of tone arm 10 balancing weight 12. Guide rails 13 crossing from plate 2 to plate 3 guide sliding table 7 through rollers 14 projecting out of table 7. And also, mounting plate 2 is provided with rest position detecting means (not shown in the drawings), for example limit switch, which detects that tone arm 10 reaches the arm rest position and in response to the detection produces an output signal. In rotator plate 8, a plurality of slits are radially formed. As a photocoupler a light emitting element and a photodetecting element are positioned at the opposite sides of rotator plate 8. Rotator plate 8 and photocoupler 15 constitute rotary encoder 16 which produces output pulses, the number of which is proportional to the number of rotations of rotator plate 8. The rotation of reversible motor 4 in a forward mode causes sliding table 7 and tone arm 10 to travel toward mounting plate 3 and the rotation of motor 4 in a reversal mode causes sliding table 7 and tone arm 10 to travel toward mounting plate 2, that is the arm rest position. When a positive polarity input signal is applied to the afore-mentioned arm lifter, tone arm 10 is driven to pivotally turn in a vertical plate to the position where the stylus point of cartridge 11 abuts with the surface of a loaded record disc. Reversely, the arm lifter in response to the receipt of a negative polarity input signal pivotally turns tone arm 10 to the position where the stylus point lies apart from the surface of the loaded record disc. System Architecture Description A pickup arm driving control system embodying the present invention is illustrated in a schematic block diagram of FIG. 2. The illustrated system is arranged to controllably drive the pickup assembly of FIG. 1. Central processor unit (hereinafter referred to as CPU) 21, read only memory (ROM) 22, read and write memory (RAM) 23, clock pulse oscillator 24, input/output interface unit (I/O adaptor) 25 and operation board 26 constitute a microcomputer system. It will be easily understood that CPU 21, ROM 22, RAM 23, oscillator 24 and I/O adaptor 25 can be realized by making use of corresponding parts of one chip microcomputer. ROM 22 previously stores a predetermined program which serves to control the sequence operation of CPU 21, ROM 22, RAM 23 and I/O adaptor 25. As required, CPU 21 fetches this program from ROM 22 and decodes it to generate control signals. ROM 22 also stores data for available record disc sizes, for 30 cm diameter record disc, count a 1 of output pulses produced in rotary encoder 16 when tone arm 10 travels from the arm rest position to the position where the stylus point of cartridge 11 lies right above the most outside sound groove of the loaded record disc during the forward driving mode of reversible motor 4 and count a 2 of output pulses produced in rotary encoder 16 when tone arm 10 travels from the arm rest position to the position where the stylus point lies right above the most inside sound groove of the disc. As further data of record disc size, counts b 1 and b 2 as defined in the above for 17 cm diameter record disc also are previously stored in ROM 22. Operation board 16 are provided with switch 26-1 for designating a record disc size in loading, switch 26-2 for directing the start of repeat operation and the end thereof, switch 26-3 directing play-cut operation and the like. When any one of switches on board 26 is depressed, an output signal associated with the depressed switch is transmitted through I/O adaptor 25 to CPU 21 and a processing directed by the depressed switch is executed. A control signal directing any one of forward rotation, stop or reverse rotation of reversible motor 4 is applied from CPU 21 through I/O adaptor 25 to motor driver 27. The rotation of motor 4 is driven by the output of driver 27 is a forward rotation mode, stop mode or reverse rotation mode. When tone arm 10 reaches the arm rest position, rest position arrival detector 28 produces an output signal which is in turn transmitted through I/O adaptor 25 to CPU 21. CPU 21 generates a signal for directing the turn of tone arm 10 in a vertical plane. This signal is applied through I/O adaptor 25 to the arm lifter. Reversible motor 4 rotates worm gear 1 through belt 6 and pulley 5. The rotation of worm gear 1 is accompanied with the rotation of rotator plate 8 of rotary encoder 16. Rotary encoder 16 produces output pulses the number of which is proportional to the number of rotations of rotator plate 8. These output pulses are transmitted through I/O adaptor 25 to CPU 21 and counted therein. The count V of these pulses is stored in RAM 23. The count V is up-dated at every output pulses produced by rotary encoder 16. During the interval while reversible motor 4 is rotating under the forward rotation driving signal, the pulses are up-counted. During the interval under the reverse rotation driving signal, the pulses are down-counted. And when tone arm 10 reaches the rest position, CPU 21 in response to the output issued from rest position arrival detector 28 clears count V. Accordingly, count V corresponds to the distance from the tone arm rest position to the existing position of tone arm 10. RAM 23 stores repeat operation start and end position data at predetermined addresses. When repeat switch 26-2 is depressed in such a manner as to direct the repeat operation start position, count V upon this depression of switch 26-2 (this count is hereinafter referred to as count C) is stored at an address in RAM 23. When repeat switch 26-2 depressed in such as amnner as to direct the repeat operation end position, count V upon this depression of switch 26-2 (this count is hereinafter referred to as count D) is stored at another address in RAM 23. CPU 21 makes a comparison between the current count V and the data count, that is count a 1 , a 2 , b 1 , b 2 , C or D, at a predetermined timing. According to the comparison resultant, CPU 21 provides moter driver 27, through I/O adapter 25, with a driving signal for directing forward rotation, stop or reverse rotation of reversible motor 4 and provides the arm lifter with a positive or negative polarity signal. System Operation Description A flow chart showing the logic sequence in the operation of the system arranged as shown in FIG. 2 is presented as FIG. 3. Steps in the sequence of the flow diagram are numbered 1-36 as shown in FIG. 3. The following description will be drawn along the flow in the diagram of FIG. 3. Steps 1-11 (Playback Start Operation Sequence) As a power switch is thrown, the microcomputer system enters on a running condition. It is examined as the first step whether or not tone arm 10 presently lies at the arm rest position. If yes, the system proceeds to a condition for waiting for a playback start signal originated by the depression of operation direction switch 26-3. If not, CPU 21 provides motor driver 27 with a reverse rotation driving signal so that the reverse rotation of motor 4 may move tone arm 10 to the arm rest position in a fast reversal driving mode. In response to the detection that tone arm 10 lies at the rest position, counts V, C and D in RAM 23 are cleared. As operation direction switch 26-3 generates the playback start signal, CPU 21 in response to the receipt of this signal provides motor driver 27 with a fast forward driving signal to drive motor 4 in a fast forward rotation mode so that tone arm 10 may move toward the center of a record disc (this moving direction is hereinafter referred to as forward direction) in a fast driving mode. Rotary encoder 16 generates output pulses as worm gear 1 rotates during the rotation of motor 4. These pulses are received by CPU 21 and counted therein. The count V is stored in RAM 23 and incrementedly up-dated at every pulse generated by rotary encoder 16. At every increment of count V, the current count V is compared with count a 1 or b 1 stored in ROM 22 according to the size of the loaded record disc. The record disc size has been designated by switch 26-1 before the user directs the start of playback. In the flow chart, the record disc size is designated as 30 cm diameter. Thus, CPU 21 can access an appropriate count data, in this case count a 1 , stored in ROM 22 according to the disc size designation. Disc size designation switch 26-1 can be replaced with for example an optical sensor mounted on tone arm 10 for detecting the outside peripheral edge of a loaded record disc. With this sensor, the size of a record disc loaded in the player can be determined by the count V at an instant when the optical sensor detects the outside peripheral edge of the record disc during the fast forward driving of tone arm 10. When count V coincides with count a 1 during the fast forward-driving of tone arm 10, CPU 21 learns it from this coincidence that tone arm 10 reaches the position right above the most outside sound groove of the loaded record disc. At this instant, CPU 21 generates a stop signal to be applied to motor driver 27 to transiently stop motor 4 and also a positive polarity signal to be applied to the arm lifter. Then CPU 21 provides motor driver 27 with a normal forward driving signal. Accordingly, tone arm 10 transiently stops at the position where count V=count a 1 . The arm lifter turns tone arm 10 so that the stylus point of cartridge 11 is put down on the record disc. After that, tone arm 10 is moved in the forward direction at a normal speed, with the stylus point of cartridge 11 abutting on the record disc. Now, the recorded information in the record disc is sequentially reproduced from the most outside sound groove. While tone arm 10 is being moved, rotary encoder 16 keeps generating output pulses. CPU 21 increments count V at every pulse. During the forward driving of tone arm 10, CPU 21 executes a comparison at every increment of count V to examine whether the current count V coincides with count a 2 stored in ROM 22 and with counts C and D stored in RAM 23. On the way of playback, when tone arm 10 reaches the start position of a part at which the user wants repeat playback, repeat switch 26-2 is depressed by the user. Steps 12-29 (Repeat Playback Operation Sequence) CPU 21 in response to an output signal produced by this first time depression stores at a predetermined address in RAM 23 count V upon the depression of repeat switch 26-2 as a start position data of repeat playback operation. As aforementioned, this count V is referred to as count C. Irrespective of the above repeat playback start position setting, the moving of tone arm 10 is kept and the reproduction continuously goes forward. Subsequently, when tone arm 10 reaches the end position at which the user requires to terminate the repeat playback operation, repeat switch 26-2 is depressed once again. CPU 21 in response to the second time depression on switch 26-2 stores at another address in RAM 23 count V upon the second time depression of switch 26-2, which is referred to as count D. At the same time of setting up the end position of repeat playback operation in the above manner, CPU 21 provides motor driver 27 with a stop signal to stop reversible motor 4. Successively, CPU 21 provides the arm lifter with a negative polarity signal to lift up tone arm 10 and also drives it at a fast speed through the fast reverse rotation of motor 4 so that tone arm 10 is moved toward the outside of the record disc (this direction is referred to as a reversal direction). CPU 21 decrements count V at every pulse generated from rotary encoder 16 during the reversal driving of tone arm 10. When tone arm 10 returns to the rest position, CPU 21 in response to the output signal produced by reset position arrival detector 28 rotates through motor driver 27 reversible motor 4 in the fast forward rotation mode. CPU 21 clears count V upon the situation of tone arm 10 at the rest position and in turn increments it at every pulse from rotary encoder 16 as tone arm 10 travels in the forward direction again. It will be understood that the above clearance of count V can be omitted from the operation sequence in case that count V decrements to zero when tone arm 10 arrives at the rest position. During the fast forward moving of tone arm 10, when the incremented count V coincides with count C stored in RAM 23 as the start position data of repeat playback operation, CPU 21 in response to this coincidence provides motor driver 27 with a stop signal and also the arm lifter with a positive polarity signal. Subsequently, CPU 21 provides motor driver 27 with a normal forward driving signal. As a result of the control by CPU 21, tone arm 10 transiently stops at the position where count V=count C, that is the start position of repeat playback operation, pivotally turns on arm holder 9 so that the stylus point of cartridge 11 may be put down on the record disc and then moves in the forward direction at the normal speed. Hereafter, the reproduction begins from the repeat playback start point set up through the first time depression of switch 26-2. On the way of this repeat playback, when count V coincides with count D stored in RAM 23 as the end position data of repeat playback operation, CPU 21 in response to this coincidence provides motor driver 27 with a stop signal to stop motor 4 at the end of repeat playback operation directed by the second time depression of repeat switch 26-2, the arm lifter with a negative polarity signal to lift up tone arm 10 so that the stylus point of cartridge 11 may lie apart from the record disc and then motor driver 27 with a fast reverse rotation signal to rotate motor 4 in a fast reversal mode so that tone arm 10 may be driven to the arm rest position. The next operation after tone arm 10 has arrived at the rest position returns to the starting step of repeat playback sequence. In this manner, the reproduction only for the selected part of a record disc is repeated. If the user want to stop the executing playback after step 28, he will depress operation direction switch 26-3 to generate an output signal which is interpreted as a cut signal in CPU 21 according to the program stored in ROM 22. In response to the cut signal, the operation sequence deviates from the repeat playback operation loop and goes to step 32 from step 29. Accordingly, tone arm 10 returns to the arm rest position. Provided that during the playback operation the second time depression of repeat switch 26-2 has not been made until tone arm 10 reaches the most inside sound groove of the loaded record disc, CPU 21 will detect the coincidence between count V and count a 2 . In this case, the operation sequence branches at step 14 and goes to step 17. CPU 21 stores count 92 at a predetermined address in RAM 23 as count D to set up D=a 2 . After that, the branch returns to the stem sequence at step 18. This operation is the same manner as a case where the second time depression of repeat switch 26-2 is made when count V reaches count a 2 . Accordingly, if the second time depression of repeat switch 26-2 is not made during the playback, the repeat playback operation will be executed in a range from the starting position directed by the first depression of repeat switch 26-2 to the end of recording in the loaded record disc. Steps 30-36 (Playback End Operation Sequence) After starting the playback operation, where the first time depression of repeat switch 26-2 is not made, tone arm 10 continues moving to the end position of the loaded record disc without any transient stop. CPU 21 will detect the coincidence between count V and count a 2 at the end position of the loaded record disc. CPU 21 in response to this detection stops reversible motor 4, lifts up tone arm 10 and return it to the arm rest position in a fast reversal driving. When motor 4 arrives at the arm rest position, count V is cleared. CPU 21 becomes a condition of waiting for a signal produced by operation direction switch 26-3. Thus, the repeat playback operation is not executed and the full one side of a record disc is reproduced. Cut Operation When a cut signal is originated by the depression of operation direction switch 26-3, CPU 21 in response to the receipt of the cut signal during the fast forward driving mode and the normal forward driving mode provides motor driver 27 with a stop signal, the arm lifter with a negative polarity signal and subsequently motor driver 27 with a fast reversal driving signal. Thus, tone arm 10 transiently stops, pivotally turns to the position where the stylus point of cartridge 11 can lie apart from the record disc and travels toward the arm rest position in the fast reversal driving mode. When tone arm 10 reaches the arm rest position, rest position detection device 28 generates an output signal. CPU 21 in response to the receipt of this signal stops motor 4 and becomes a condition of waiting for a signal from operation board 26. Whenever the cut signal is generated, CPU 21 accepts it except the operation stages where tone arm 10 is placed at the rest position or is moved toward the rest position in the fast reversal driving mode. The executing program is interrupted by the cut signal and the program following the interrupt is an instruction sequence which performs the return of tone arm 10 from the current position to the rest position. On the flow chart of FIG. 3, the cut signal acceptance is illustrated only at step 26. It, however, should be noted that the cut signal can be accepted as an interrupt signal with the first priority during any operation except the fast reversal driving of tone arm 10. In the foregoing repeat playback operation, it is required that tone arm 10 returns from the repeat playback end position to the arm rest position before the next repeat operation and then travels to the repeat playback start position. Instead of such a return manipulation of tone arm 10, CPU 21 can stop motor 4 when count V coincides with count C during the reverse driving of tone arm 10 toward the outside of the record disc. Subsequently, CPU 21 puts down cartridge 11 on the record disc at the stop position and starts the next repeat reproduction. Since count V decrements at every output pulses of rotary encoder 16 during the fast reverse driving of tone arm 10, tone arm 10 is correctly placed at the start position of repeat reproduction without returning arm 10 to the arm rest position. With the above mentioned pickup arm driving control system wherein tone arm positions corresponding to repeat playback start and end positions are memorized during the first time playback through manual operation by an user and then in the next time playback the current tone arm position is compared with the memorized tone arm position data to automatically determine the start and end positions of repeat playback, only the part of a loaded record disc where the user likes the listen is repeatedly reproduced. As one of the features, the system does not require recording-break portion detecting sensors or the like the execute the above repeat operation. As another of the features, an user can easily set up any position of a loaded record disc as the start and end positions of repeat playback while he is listening to the reproduced information like music, instead of previously giving a concrete data of repeat playback for the loaded record disc to the system. A program expressed in assembly language for MUCOM43 series by Nippon Electric Company Ltd., which serves to execute the operation sequence of FIG. 3, is shown in an attached Appendix. It will be easily understood for those skilled in the art that the present system is applicable the turning tracking arm assemblies as well as linear tracking arm assemblies. Since certain other changes also may be made in the above-described pickup arm driving control system without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description or shown in the acompanying drawings shall be interpreted as illustrative and not in a limiting sense. ##SPC1## ##SPC2## ##SPC3##
A pickup arm driving control system in record disc players with repeat playback function. The driving control system can drive the manipulation of a tone arm in such a manner that only an optionally selected portion is repeatedly reproduced. The system includes an encoder for producing an output pulse at every predetermined step of the moving of the tone arm, a circuit for calculating the moving distance of the tone arm from an arm rest position by accumulating the output pulses, an operation switch for generating setting signals in response to manual operations conducted when the tone arm is just tracking the starting and end positions of a repeat playback part of the loaded record disc, a memory for storing the up-dated one of the calculated result of moving distance as a first memory value, the first memory values upon the generation of the setting signals as a second and third memory values, and a circuit for in response to the coincidences between the first memory value and the second or third memory value controlling the manipulation of the tone arm.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a process for manufacturing crystallized glass substrates for magnetic disks. 2. Description of the Prior Art Main component elements of magnetic storages such as computers or the like are magnetic recording media and magnetic heads for reproducing magnetic records. As a material for hard disk substrates as the magnetic recording media, mainly aluminum alloys have been extensively employed. However, the flying height of the magnetic heads has been noticeably decreased with recent miniaturization of hard-disk drives. Consequently, a smoothness of extremely high precision has been required with respect to the surface of the magnetic disks. In general, the maximum height of the ruggedness on the surfaces of the magnetic disks should not exceed a half of the flying height of the magnetic disks. For example, in hard-disk drives with a flying height of 75 nm, the allowable maximum height of the ruggedness on the surfaces of the disks must be less than 38 nm. Particularly, recently, it has been required to restrict the Center-line Mean Roughness (Ra) defined in JIS B 0601, within 20 angstroms or less, in the read/write zone on the substrates of the magnetic disks. However, in the case of aluminum alloy substrates, their hardness is so low that ground surfaces are susceptible to plastic deformation, even when an abrasive finishing is conducted using abrasive grains and machine tools with a high precision. Therefore, it is difficult to produce flat surfaces with a precision higher than a certain level. Even if the surfaces of the aluminum alloy substrates are plated with nickel-phosphorus, flat surfaces on a level as mentioned above would not be able to be formed. Furthermore, with recent progress of the miniaturization and thickness-reduction of hard-disk drives, it has been strongly demanded to decrease the thickness of the substrates for magnetic disks. However, since aluminum alloys have low strength and stiffness, it is difficult to decrease the thickness of the disks while maintaining a predetermined strength which is required from the specification of the hard-disk drives. Particularly, when the substrates for magnetic disks are finished to be 0.5 mm thick or less, problems are posed such that the substrates may warp due to the deficiency of the strength thereof or the surfaces of the substrates vibrate during high speed revolving or at the start-up of the apparatus. In order to solve the above problems, substrates for magnetic disks, which are made of glass material, have been partly put to practical use. However, since the substrates for magnetic disks for HDD require particularly a high strength, it is necessary to use tempered glasses such as chemically tempered glasses, glass-ceramics or the like. By using these materials, magnetic recording surfaces having an extremely small Ra of 20 angstroms or less can be formed. Examples of the glasses for constituting the substrates for magnetic disks include chemically tempered glasses such as soda lime glasses or the like, crystallized glasses, non-alkali glasses and alumino-silicate glasses. Amongst the above, the chemically tempered glasses and crystallized glasses are preferred in view of the high strength thereof. Particularly, the crystallized glasses, since their hardness and bending strength are uniform, are more excellent in reliability in strength than the chemically tempered glasses. It is much preferred particularly when the thickness of the substrates for magnetic disks is reduced to 0.5 mm or less, as a desired strength is maintained. However, in mass-production of such substrates for magnetic disks made of a crystallized glass, the following problems have been realized. Namely, in conventional manufacturing processes, for example, when glass substrates having a diameter of 65 mm are produced, at first, a mass of molten glass is cast into a mold and pressed to provide an amorphous glass disk-shaped body about 1.2-1.5 mm thick. Alternatively, a columnar shaped body of amorphous glass is cut into disk-shaped plates of amorphous glass, and further, if required, the plates of amorphous glass are ground or abraded to provide a glass disk about 1.2-1.5 mm thick. These plates of amorphous glass are heated to crystallize and semi-finished products before abrasive finishing (the so-called "blanks") are produced. And then, both surfaces of the blanks are abrasive-finished, namely, both the top and bottom surfaces of the blanks are concurrently lapped and polished to provide finished crystallized glass substrates for magnetic disks, for example, 0.635 mm thick. Namely, in order that the semi-finished products (blanks) obtained by crystallizing an amorphous glass are finished into final products (crystallized glass substrates for magnetic disks), a half or more, indeed, of the thickness of the blanks must be removed by abrasion. Moreover, the hardness of the glasses after crystallization is appreciably higher than that before crystallization, so that it takes a long time to abrade the blanks. Consequently, a problem such as a remarkable increase in the cost of production has arisen. Naturally, in order to decrease this cost, it is preferred to finish glasses as thin as possible when they are in the amorphous state. However, in the case where the crystallization is merely conducted in this state, glass plates may warp on the stage of crystallization and it is almost impossible to rectify the warp by means of abrasion of both surfaces of the plates. Moreover, the thinner the blanks are made, the more difficult it is to rectify the warp. Therefore, in conventional processes, blanks have been produced necessarily by crystallizing an amorphous glass plate having a thickness of a certain extent (i.e. a thickness of about 1.2-1.5 mm). Additionally, the degree of flatness required for magnetic disk substrates, for example, having a diameter of 65 mm is generally 5 μm or less across the diameter. SUMMARY OF THE INVENTION The object of the present invention is to solve the above-mentioned problems by substantially decreasing abrasion losses of crystallized glass plates after crystallization and improving the cost of production of the crystallized glasses. The above object is achieved, according to the present invention, by a process for manufacturing crystallized glass substrates for magnetic disks, which process comprises the sequential steps of: holding an amorphous glass plate having substantially a uniform thickness and two principal surfaces thereof between a pair of pressing setters each having a flat surface, in a fashion that each of said principal surfaces of the amorphous glass plate is brought into contact with said flat surface of the pressing setter, said pressing setters being non-reactive with said amorphous glass and undeformable during crystallization by heading of said amorphous glass; softening said amorphous glass plate in the above state by heating at a temperature above an annealing point of a glass material of said amorphous glass, whereby said principal surfaces of the amorphous glass plate are firmly fitted onto said flat surfaces of said pressing setters, respectively, to rectify warping of said amorphous glass plate; then, increasing the temperature of said amorphous glass plate to a crystal growth temperature to grow crystals within said glass material, thereby to crystallize said amorphous glass plate as maintaining its warp-free state, followed by solidifying the crystallized glass plate. Namely, according to the present invention, the glass plate is abraded when the glass is in the amorphous state, that is, relatively low in hardness and so being readily abradable. This amorphous glass plate is then readily finished to have a uniform thickness close to an objective thickness of crystallized glass substrates for magnetic disks, i.e. final products, and the amorphous glass plate is crystallized simultaneously with improvement in flatness thereof, i.e., rectification of any warp present in the amorphous glass plate after abrasion. Thus, abrasion losses can be extremely decreased in processes of finishing the so-called blanks having an increased hardness after crystallization into the final products. Through the specification and appended claims of this invention, the phrase "substantially a uniform thickness" with respect to the amorphous glass plate, should be understood to mean the deviation of the thickness being within ±10 μm. BRIEF DESCRIPTION OF THE DRAWING The above and other objects, features and advantages of the present invention will become more apparent from reading the following description of the preferred embodiments taken in connection with the accompanying drawings, wherein: FIG. 1a is a slant view schematically showing a process for cutting out disk-shaped bodies having a predetermined thickness from a large-size columnar shaped body 1; FIG. 1b is a slant view schematically showing an operation of abrasion conducted with a jig held between a grinding wheel 4A on a top force 3A and a grinding wheel 4B on a bottom force 3B; FIG. 1c is a cross-sectional view schematically showing a grinding operation of the outer and inner circumferential portions of a shaped body after abrasion; FIG. 2 is a schematic view showing a heat treatment furnace which is suited for mass-production; FIG. 3a is a plan view showing an amorphous glass plate 12; FIG. 3b shows graphs each depicting a profile of an abraded surface of the amorphous glass plate 12; FIG. 3c shows graphs each depicting a profile of another abraded surface of the amorphous glass plate 12; FIG. 4a shows graphs each depicting a profile of an abraded surface of a substrate after crystallizing treatment; and FIG. 4b shows graphs each depicting a profile of another abraded surface of the substrate. DESCRIPTION OF THE PREFERRED EMBODIMENTS At first, molten glass is cast into a mold and cooled to produce a columnar shaped body. The shaped body is cut with a bandsaw, jig saw, inner diameter blade slicing machine, or the like, to produce disk-shaped amorphous glass plates. In FIG. 1a, a method for cutting with a bandsaw is schematically shown. A columnar large-size shaped body 1 has a pair of parallel end surfaces 1b and a cylindrical surface 1a. Cutter blades 2 are forced into the shaped body 1 from the cylindrical surface 1a along the direction parallel with each end surface 1b as shown by the arrow A, to cut out disk-shaped bodies having a predetermined thickness. A cutter device to be employed here is adequately selected from those described above. If the disk-shaped amorphous glass plates obtained by cutting have little deviation of thickness, the glass plates can be delivered directly to the crystallization step, without necessitating a subsequent step of grinding- or abrasive-finishing. Both the cut surfaces of the thus obtained disk-shaped amorphous glass plates are ground or abrasive-finished to remove the ruggedness formed on the cut surfaces when cutting, and thus amorphous glass plates of a uniform thickness having two principal surfaces are provided. The grinding- or abrasive-finishing method in this stage is not specifically restricted. However, in general, as shown in FIG. 1b, each of the amorphous glass plates 6 can be ground into a predetermined thickness, by holding a carrier 5 between a grinding wheel 4A on a top force 3A and a grinding wheel 4B on a bottom force 3B, fixing each of the cut amorphous glass plates 6 on the carrier 5 and revolving the carrier 5 in the direction shown by the arrow B. In the present invention, the crystallized glass substrates for magnetic disks are manufactured by crystallizing the amorphous glass plates which have been abrasive- or grinding-finished to have a predetermined thickness, and then subjecting the resulting crystallized glass plates to a final abrasive-processing (lapping or polishing). In order to decrease final abrasion losses as much as possible, it is preferred that the difference in thickness between the finished amorphous glass plate and the final product, i.e., a crystallized glass substrate for magnetic disks, is made to be 0.1 mm (100 μm) or less, more preferably, 0.05 mm (50 μm) or less. In other words, it is preferred to use an amorphous glass plate thick enough to allow an abrasion loss of thickness within 100 μm, preferably within 50 μm, in abrasive- or grinding-processing of the crystallized glass plate. For example, when the crystallized glass substrate for magnetic disks has a diameter of 65 mm, the thickness of the final products is typically 0.635 mm. In this instance, the thickness of the finished amorphous glass plate is preferred to be at most 0.735 mm, more preferably at most 0.685 mm. Furthermore, the thickness of the finished amorphous glass plates is preferred to be uniform, having a deviation within ±10 μm. Additionally, in this invention, since warp (i.e., unevenness) is rectified in the subsequent step (i.e., crystallization step), warping of the amorphous glass plate at this stage is not a concern. Next, the amorphous glass plate ground or abrasive-finished is held between a pair of pressing setters made of carbon, each having a flat surface of flatness of 10 μm or less (preferably, 5 μm or less) over its width of 65 mm, to form a sandwiched body. This sandwiched body is put into an oven with a nitrogen atmosphere inside and heated to a crystallization temperature so that the amorphous glass may be once softened and fitted firmly onto the flat surfaces of the carbon pressing setters, whereby warp is rectified, and then gradually crystallized as the rectified shape is maintained until solidification. In this instance, carbon is employed as a material for the pressing setters, so that when the amorphous glass plate is sandwiched with a pair of pressing setters and heated to soften in an inert atmosphere, the carbon pressing setters would not react with the amorphous glass plate, and moreover, since the carbon material has a low hardness, when the surface of the pressing setters is finished to be made flat, a high flatness can be readily obtained by abrasive-finishing. Furthermore, as the material for the pressing setters, use may be made of any materials other than carbon, as far as they neither react with nor bond to the glass and are chemically and mechanically stable at crystallization temperatures. Materials, such as carbon-coated ceramics, can preferably be used. Furthermore, in this instance, since nitrogen, i.e., an inert atmosphere, is used inside the oven, deterioration of the pressing setters induced by a reaction between the carbon and oxygen during heating is effectively prevented. From this viewpoint, the atmosphere also may be a reducing atmosphere. In addition, the practical substrates for magnetic disks require finishing for providing the outer diameter of the substrates with accuracy and boring a round aperture for setting in the center of the disks. Furthermore, it is necessary to chamfer the outer circumference of the disks and the inner circumference of the round aperture (not shown). Such processing can be conducted in either state of amorphous glass or crystallized glass. However, since amorphous glass is easier to process as compared with crystallized glass, it is preferred that the above processing is conducted in the state of amorphous glass. FIG. 1c is a cross-section schematically showing an operation of finishing the outer and inner circumferences of an amorphous glass plate before crystallization. The flat surface to be abraded of a shaped body 9 is made to face a processing tool 7. The processing tool 7 is attached with ring- or annular-shaped diamond wheel 8A and inner diamond wheel 8B. The surface to be abraded is brought into contact with the grinding wheels and the processing tool 7 is revolved, for example, in the direction shown by the arrow C. Thereby, an outer peripheral portion defined by the broken lines 10 of the shaped body 9 is removed and the outer peripheral dimension of the shaped body is controlled according to a predetermined specification. Simultaneously therewith, a central portion defined by the broken lines 11 is removed to form a round aperture having predetermined shape and dimension. Alternatively, in the case where the crystallization of the amorphous glass is conducted on a large scale, it is necessary to treat continuously a number of amorphous glass plates, as a whole, simultaneously. Accordingly, it is preferred that flat-shaped pressing setters are used, these pressing setters and amorphous glass plates are alternatively stacked to form a multi-layered body and a number of the multi-layered bodies are treated as a whole in the oven. Alternatively, it is also preferred that a tunnel furnace is used for continuously treating a number of the multi-layered bodies traveling therethrough. In FIG. 2, such a mass-productive process is schematically shown. In the heat treatment furnace shown in FIG. 2, an upper oven 15A is provided therein with a heater 16A and a lower oven B is provided therein with a heater 16B. Each multi-layered body, 18A, 18B, 18C or 18D, is composed of pressing setters 17 and amorphous glass plates 12 alternately stacked between the pressing setters. On the top and the bottom of the multi-layered body, the pressing setters 17 are arranged, respectively. The multi-layered bodies can travel towards the direction shown by the arrow E, by transfer means not shown, such as a conveyor or the like. The temperature inside the furnace is controlled according to each condition in the steps of heating up from room temperature, heating up to temperatures above an annealing point, and heating up to crystallization temperatures, of the multi-layered bodies. The obtained blanks made of crystallized glass are finished by conventional lapping and polishing to provide crystallized glass substrates for magnetic disks with predetermined thickness, flatness and surface roughness. Examples of the crystallized glass suited for manufacturing the substrates for magnetic disks according to the present invention include Li 2 O--Al 2 O 3 --SiO 2 --based crystallized glasses or the like, as shown hereinbelow. The present invention will be further explained in more detail by way of example hereinafter. However, it should be understood that these examples are not intended to limit the invention: EXAMPLE 1 Powders of various metal carbonates and the like were mixed together in such a proportion by weight of oxides as 76.1 weight % of SiO 2 , 11.8 weight % of Li 2 O, 7.1 weight % of Al 2 O 3 , 2.8% weight % of K 2 O, 2.0 weight % of P 2 O 5 and 0.2 weight % of Sb 2 O 3 . The mixture was melted by heat-treating at 1400° C. The resulting melt was cast into a cast-iron mold which was water-cooled, and a columnar shaped body having an outside diameter of 68 mm and a length of 150 mm was produced. This shaped body was released from the mold, gradually cooled to eliminate inner strain and provide a glass shaped body. This columnar glass shaped body was cut with an inner diameter blade slicing machine equipped with a #325 diamond wheel and disk-shaped bodies 0.7 mm thick were produced. These disk-shaped bodies 6 were ground with a cup-type grindstone and finished into annular amorphous glass plates 12 having an inside diameter of 20 mm and an outside diameter of 66 mm. The thus obtained amorphous glass plate 12 was held between a pair of pressing setters 17 having surfaces finished into a flatness of 5 μm over a width of 65 mm and thus a sandwiched body was produced. Both of the principal surfaces of the above amorphous glass plate were brought into contact with the flat surfaces, respectively, of the above pressing setters. In a successive sandwiching manner as above, an eight-layered stacked body with the pressing setters 17 on the topmost and bottommost layers was formed. The eight-layered stacked body was held horizontally within an atmospheric tubular furnace made of an alumina tube. In this state, the furnace was hermetically closed, an N 2 gas stream was flowed at a flow rate of 1 liter/min. in the furnace, wherein the temperature was kept at 550° C. for 2 hours, then increased at a rate of 125° C./hour until it reached 850° C., thereafter kept at 850° C. for 4 hours, and then cooled down to room temperature. The above process was conducted on 40 slices in total of the amorphous glass plates 12. As the result, though the amorphous glass plates 12 before crystallization had a flatness with a mean value of 7.1 μm and a standard deviation of 1.7 μm, across their diameter of 65 mm, blands after crystallization had a flatness with a mean value of 4.9 μm and a standard deviation of 1.1 μm, across their diameter of 65 mm. Thus, it was demonstrated that the flatness was appreciably improved. Furthermore, the flatnesses of the resulting crystallized glass substrates were not different between the uppermost substrate and lowermost substrate, in the stack. Thus, blanks with a high flatness were provided. These blanks were lapped with a #2000 GC abrasive grain, until their thickness was reduced to 0.66 mm, and further lapped with a #4000 GC abrasive grain to a thickness soft 0.64 mm. Thereafter, further polishing was conducted with cerium oxide to a thickness of 0.635 mm and magnetic disc substrates made of crystallized glass having a flatness of 4 μm across their diameter of 65 mm and an average surface roughness of 7 angstroms were obtained. EXAMPLE 2 A columnar amorphous glass shaped body having an outside diameter of 68 mm and a length of 150 mm which had been obtained in the same manner as EXAMPLE 1 above, was cut with a brade-saw using a 600 GC abrasive grain to produce shaped bodies 0.8 mm thick. Both principal surfaces of these shaped bodies were simultaneously ground with an #800 diamond abrasive grain to provide amorphous glass circular disks 0.7 mm thick. These amorphous glass disks were finished in the same manner as amorphous EXAMPLE 1 to produce doughnut- or annular-shaped amorphous glass plates 12 having an inside diameter of 20 mm and an outside diameter of 66 mm. The abraded surfaces of these amorphous glass plates 12 had a flatness of about 40 μm across the outside diameter. FIG. 3a is a plan view showing this amorphous glass plate 12. One principal surface of this amorphous glass plate 12 had a warp of 41.4 μm in the direction of a and a warp of 31.2 μm in the direction of b, as shown in FIG. 3b . The other principal surface of the amorphous glass plate 12 had a warp of 43.8 μm in the direction of a and a warp of 33.6 μm in the direction of b, as shown in FIG. 3c. Here, 24 is a standard line. The resulting amorphous glass plates 12 were heat-treated and crystallized in the same manner as EXAMPLE 1. As the result, the flatness of the blanks composed of crystallized glass was improved to 4.3 μm or less across the outside diameter. FIG. 4a is a graph showing a profile of one abraded principal surface of the blank, and FIG. 4b is a graph showing a profile of the other principal abraded surface of the blank, after crystallization treatment. As described and demonstrated by the EXAMPLES above, according to the process of the invention, glass plates are readily abraded because the abrasion is conducted when the glass material thereof is in an amorphous stage, that is, in a state of relatively low hardness and being liable to abrasion, and moreover, the amorphous glass plates are finished uniformly to have a thickness close to an objective thickness of finished final products, i.e., crystallized glass substrates for magnetic disks, simultaneously with correction of the flatness of the disks. Therefore, it has become possible to markedly reduce abrasion losses of crystallized blanks having a high hardness and thus produce magnetic disk substrates made of crystallized glass with easiness and a low cost.
A process for producing a crystallized glass substrate for magnetic disks, including the steps of: (a) holding an amorphous glass plate having a uniform thickness and two principal flat surfaces thereof between a pair of pressing setters in a sandwiched fashion, which pressing setters are non-reactive with the amorphous glass and undeformable during heating for crystallization of the amorphous glass; (b) softening the amorphous glass plate in a sandwiched stack form by heating at a temperature above an annealing point of the amorphous glass, whereby the principal surfaces are fitted onto the flat surfaces of the pressing setters to rectify warping to flatten the amorphous glass plate; and (c) then, increasing the temperature to a crystal growth temperature to grow crystals within the amorphous glass, whereby the amorphous glass plate is crystallized as maintaining its warp-free state, followed by solidifying.
2
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is the national stage of International Application No. PCT/ES2007/000053, filed Jan. 31, 2007, which claims priority under 35 U.S.C. §119(a) to Spanish Application No. P200600592 filed Mar. 9, 2006. FIELD OF THE INVENTION [0002] The present invention lies within the field of optical elements with refractive functions, and methods of manufacturing them. [0003] Optics elements are very important in all technological fields where it is necessary to modulate the spatial distribution of light. Bearing in mind this requirement, it is necessary to optimise techniques of manufacturing simple optical structures and producing optical structures with new functions. [0004] Most of the methods used to manufacture refractive optical elements on a medium-sized scale use repeated cutting and polishing processes, or heated moulding processes, prior to more complex subsequent treatments. Alternatively, different processes have been developed to manufacture elements on a small scale, based on complex multiple surface micromachining, or photolithography steps, and more recent methods that propose the ablation of plastic or glass surfaces, or the heat-assisted structural modification of semiconductor doped glass surfaces using lasers. Furthermore, methods of light-assisted deposits are used in planar technology production processes, the aim of which is to create a uniform layer of conductor, semiconductor or superconductor compounds on a substrate to form active and passive optical devices and/or planar electronic devices. SUMMARY OF THE INVENTION [0005] We present a simple, although not obvious, method for the light-assisted manufacturing of optical elements, various examples of which can take advantage of the following process considerations: [0006] 1. Structural fragments of the constituent elements of semiconductor compounds can be ejected from a solid when they are irradiated with light whose photon energy is comparable (in the order of magnitude) to its optical gap, with a high enough intensity. This intensify depends on the type of semiconductor material. [0007] 2. The vapour phase, or plasma plume, that is generated condenses on a substrate located in the proximity of the starting material, causing this material to be deposited on die substrate. [0008] 3. The morphology of the deposit is related to the characteristics of the plume or vapour phase, which depend on the spatial light intensity distribution on the target material, the spectral radiance of the light source, the distance between the target material and the substrate, the pressure and the atmosphere in the chamber, the temperature of the starting material, the temperature of the substrate, and the irradiation time. [0009] 4. Concurrent illumination of the deposit during its growth may affect the physicochemical properties of the material that forms said deposit, as a consequence of its effect on the structure being formed. [0010] In a preferred embodiment of the invention, which is not limiting in terms of the material used or the configuration of the manufacturing system, a continuous laser beam, with a wavelength of 532 nm and a Gaussian light intensity distribution, perpendicularly crosses a transparent substrate with planoparallel sides before reaching a target material situated a few millimetres from the substrate. Said target material is a disc (wafer) with a diameter of around 1 cm and a thickness of 2 mm, made from compacted powder of an amorphous V-VI semiconductor alloy (e.g. an alloy of As and S), which is sensitive to the photon energy of light radiation from a Nd:YAG laser (2.33 eV). The sides of the substrate and the wafer that face each other are parallel. [0011] The above-described configuration produces a deposit with an aspheric profile that generates an optical function as shown in FIG. 1 , which is characteristic of optical elements called axicons. Axicons, as shown in FIG. 2 , unlike lenses with conventional spherical profiles, are characterised in that they concentrate light energy along a focal segment that extends along the optical axis, and their lateral resolution remains constant to propagation on this focal segment. [0012] The transparency of V-VI semiconductors in the infrared (IR) spectral region guarantees the stability of the optical elements manufactured in this spectral window, therefore making it the preferred working spectral region. [0013] However, we have observed that the optical elements produced according to the above-described preferred embodiment present a greater optical transparency and a higher damage threshold to the laser radiation used in the manufacturing process compared to that of the starting material, possibly due to concurrent uniform illumination of the material being deposited. In experiments, an increase of more than one order of magnitude has been observed in the damage intensity in alloys with a composition of As 20 S 80 , in relation to the intensity supported by the starting material. [0014] Furthermore, it has been shown that coating an amorphous chalcogenide deposit with a layer of polymethyl methacrylate (PMMA) increases by several orders of magnitude the damage threshold to radiation for which the chalcogenide alloy would be sensitive without any coating. [0015] In view of such findings, both of our own and as reported in the literature, it can be inferred that although the IR region is the preferred window, it should not be considered the only one. [0016] The present invention discloses a simple method of manufacturing refractive optical elements, which is based on the light-assisted control of the profile of a semiconductor material that will be deposited on a substrate that is transparent to the working radiation, for which the optical element to be manufactured is designed. The method makes it possible to extend the functions of the optical elements that are manufactured so that they may be used at high light intensities. BRIEF DESCRIPTION OF THE FIGURES [0017] FIG. 1 illustrates light intensity distribution along the focal axis corresponding to an axicon, using an amorphous alloy with a composition of As 20 S 80 . The distances are measured in relation to the position of the axicon. A lateral resolution of about 60 μm is achieved at a distance of 35 mm from the axicon, and is maintained up to 45 mm, the position from which the energy begins to couple to higher modes than the zero order mode. The wavelength of the laser radiation used in these measurements was 532 mm. [0018] FIG. 2 is a diagram showing how an extended focal lens (axicon) works. This aspheric optical element presents a focal region on the optical axis with a high lateral resolution (of the order of microns) and a long depth of focus, Δf, from an initial focusing distance f 0 . The light intensity distribution at different distances along the optical axis is also shown. [0019] FIG. 3 is a cross-sectional diagram of a system for producing refractive optical elements, in a baste configuration wherein a light beam falls on the starting material at normal incidence, after crossing a transparent substrate. [0020] FIG. 4 is a cross-sectional diagram of a system for producing refractive optical elements. In a basic configuration wherein two light beams fall on the starting material, one with normal incidence to the starting material, which crosses the substrate, and a second light beam that falls obliquely on the material without crossing the substrate. DETAILED DESCRIPTION [0021] The following describes examples of methods for manufacturing refractive optical elements in a simple and economical way. The examples generally include the following steps: (a) situating a substrate close to a target material, both of which are situated inside a chamber, (b) using a light source to bring about the vaporisation or sublimation of the target material and (c) depositing this vapour phase on the substrate. The manufactured optical element presents a refractive optical function due to its composition and profile, as well as an increase in the damage threshold at high light intensities. [0022] FIG. 3 shows one example of a method for manufacturing optical elements with a refractive function. With reference to this figure, the system features a chamber 1 with transparent windows 2 and 3 , and a source of continuous or pulsed light radiation 10 , a starting material 5 , and a substrate 6 which is transparent to the radiation from light source 10 , and also transparent to the working radiation for which the optical element to be manufactured is designed. The light beam from source 10 enters the chamber through a transparent window 2 , and crosses the substrate 6 before tailing on the starting material 5 , causing its ejection. The generation of this plume can be assisted by heat from a heat source 9 . The deposition can also be thermally assisted by supplying heal to the substrate, in a similar way to heat source 9 (not shown in FIG. 3 ). The spatial intensity distribution on the starting material is controlled by a combination of optical (lenses, mirrors, filters, masks, spatial light, phase and amplitude modulators, etc.) and/or mechanical (linear positioning stages, angular positioning stages, mechanical spatial light modulators, etc.) elements 11 . The deposition is carried out at a controlled pressure and atmosphere. [0023] The starting material 5 , which is situated inside the chamber, can be an ingot of a semiconductor alloy, or a wafer made from the alloy to be deposited in powder form. The wafer can be a homogeneous or heterogeneous mixture of semiconductor alloys containing a chalcogen element (O, S, Se and/or Te) and other reactants (such as Ge, Ga, Si, P, As, Sb, I, Pm, Sm, Eu, Er, etc.), which act as both passive and active elements for a determined light radiation. Starting material 5 is an amorphous alloy with a composition of As 20 S 80 . This starting material is supported by a support system having a combination of mechanical elements that give the starting material freedom to move in the three Cartesian directions, x, y, z, and to rotate around an axis that is perpendicular to its surface, θ. [0024] The substrate 6 is also supported by a combination of mechanical elements in a manner that allows the substrate to move in the three Cartesian directions, x′, y′, z′, as well as to rotate around an axis that is perpendicular to its surface, θ′, and around an axis that is parallel to its surface, φ′, in a way that is not integral to the starting material. [0025] FIG. 4 shows another example of a method for manufacturing optical elements with a retractive function. With reference to this figure, and similarly to that described for FIG. 3 , the system consists of a chamber 1 with transparent windows 2 and 3 , two sources of continuous or pulsed light radiation 4 and 10 , a starting material 5 , and a substrate 6 which is transparent to the radiation from light source 10 , and also transparent to the working radiation for which the optical element to be manufactured is designed. The spatial intensity distribution, on the starting material is controlled by opto-mechanical control systems 7 , 11 , each of which includes a combination of optical (lenses, mirrors, filters, masks, spatial light, phase and amplitude modulators, etc.) and/or mechanical (linear positioning stages, angular positioning stages, mechanical spatial light modulators, etc) elements. The light beam from first light source 4 enters the chamber through window 3 , after falling on mirror 8 . The mirror 8 is mounted on translational and rotary positioning stages that give it degrees of freedom to control, in combination with control, system 7 , the light intensity distribution on the starting material. The light beam from second light source 10 enters the chamber through window 2 , and crosses the substrate 6 before falling on the starting material 5 . The beam from first light source 4 and the beam from second light source 10 do not necessarily fall on the same area of the starting material. The generation of the plume can be assisted by heat from a heat source 9 . The deposition can also be thermally assisted by supplying heat to the substrate, in a similar way to beat source 9 (not shown in FIG. 4 ). The deposition is carried out at a controlled pressure and atmosphere. [0026] The systems shown in FIGS. 3 and 4 involve the uniform illumination of the deposit during its growth. This concurrent uniform irradiation may modify the properties of the material being deposited, depending on its nature and the characteristics of the light radiation that falls on it. This may produce, for instance, a more stable material with a higher damage threshold, and it may therefore extend its functions at high light intensities, as has been described above on the basis of experimental results. [0027] A real embodiment is described below to illustrate the use of the present invention for manufacturing a refractive axicon that is stable and highly transparent in the IR region. The starting material, in this case, is a circular wafer with a 13 mm diameter, made from 125 mg of powder, compacted for 10 minutes with a 10-ton load, of an amorphous chalcogenide alloy with a composition of As 20 S 80 , which presents an optical gap of 2.1 eV. The pressure in the chamber is reduced to below 10 −4 mbar. The light radiation comes from a Nd:YAG continuous laser generator emitting at 532 nm (2.33 eV), with a power of 400 mW. The laser beam Induces the ejection of the starting material by ablating the surface of the wafer, generating a distribution of the vapour phase in the form of a spindle (plume), which is perpendicular to the irradiated surface of the wafer. The transparent substrate is situated inside the chamber, in the path of the light beam, at 2 mm from the starting material, so that the beam crosses both sides of the substrate before falling on the starting material. The vapour phase of the starting material condenses on the side of the substrate that faces this material, presenting an aspheric spatial distribution on its surface, which has an optical function as shown in FIG. 1 . [0028] The conditions of the system may be adjusted to deposit a uniform profile or a profile of a variable thickness, concentrated on a localised region of the substrate or extended across it according to any other desired distribution. The area covered by the deposit and the thickness profiles may be controlled by moving the light beam over the surface of the starting material and/or the substrate by means of the positioning stages that give the starting material and the substrate the degrees of freedom x, y, z, θ, x′, y′, z′, θ′, φ′, respectively, which are shown in the diagrams in FIGS. 3 and 4 .
A method for the manufacture of refractive optical elements includes (a) placing a substrate close to a starting material, both arranged inside a chamber; (b) vaporizing or subliming the starting material by means of light irradiation; and (c) depositing this vapour phase on the substrate. The coating deposited has a refractive optical functionality on account of its composition and profile and also presents an increase in the threshold of damage at high light intensities.
2
REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation in part of U.S. patent application Ser. No. 10/088,095, currently pending, which is a national stage of International Patent Application Serial No. PCT/GB99/03174, filed on Sep. 22, 1999. The subject matter of this application also is related to that of U.S. patent application Ser. Nos. 10/360,390 and 60/589,748, both of which are currently pending. Each of the foregoing patent applications is expressly incorporated by reference herein in its entirety. FIELD OF THE INVENTION [0002] This invention is concerned with improvements relating to the manufacture of air pillows, in particular air pillows of thin-walled plastic sheet which may be used as an infill or cushioning in the packaging and transportation of fragile articles. BACKGROUND OF THE INVENTION [0003] Conventionally utilized in the manufacture of air-filled pillows is thin walled polythene (a.k.a. polyethylene) tubing, which may be unwound from a continuous supply thereof flat-wound on a reel, and it is in this context that the invention will hereinafter be described, although it is to be appreciated that the invention is not limited to the use of polythene as such, and that other appropriate materials may be utilized as desired. [0004] Numerous suggestions have been made for the manufacture of air-filled pillows of this kind (hereinafter referred to as being of the kind specified), but in general difficulty has been encountered in the injection of air into a section of tubing, and subsequently sealing the tube to form individual pillows. [0005] Examples of such apparatus or systems include U.S. Pat. Nos. 3,366,523, 3,667,593, 3,817,803, 3,868,285, 4,017,351, 4,049,854, 5,824,392, 6,209,286, 6,410,119, 6,582,800, and 6,659,150, and U.S. Patent Application Pub. No. 2003/0163976, each of which is incorporated by reference herein in its entirety. SUMMARY OF THE INVENTION [0006] According to one aspect of the invention there is provided a machine for the manufacture of air-filled pillows comprising, among other things, a) a separator member which may be inserted into a length of plastic tubing drawn from a supply thereof; b) retaining means for retaining the separator member in a desired position in the machine, within the tubing, in such a manner as to allow the tubing to be pulled across the separator member; c) an injector means co-operable with the separator member to inject air through one wall of the tubing into the interior of the tubing; and d) sealing means to seal the tube across the location of the injection point. [0011] By the use of a separator member which is captive within the polythene tubing to separate the walls of the tubing, injection of air through an aperture in the tubing may more reliably be accomplished without the risk of puncturing the tubing at two locations. Specifically by the use of the separator member, such injection may be accomplished without the need for air pressure within the machine to hold the walls of the tube apart, while injection is taking place. [0012] Preferably the separator member additionally provides a supporting surface to support one wall of the tubing whilst an injection nozzle is inserted through the wall, during the injection of air into the space between the walls of the tubing. [0013] Preferably the machine comprises drive means to draw tubing material from the supply thereof, conveniently by intermittent operation. [0014] Preferably the machine comprises control means for the injector means, the drive means and the sealing means, which is operative to cause the injector means to operate while operation of the drive means is momentarily terminated, and subsequent to operation of the injector means to cause the drive means to advance the material a short distance to the sealing means. [0015] Preferably the machine comprises a support member located adjacent to the separator member and between which one wall of the tube is located as the tube is advanced through the machine, and conveniently the support member is provided with an aperture in alignment with an aperture provided in the separator member, through which a nozzle of the injector means passes in the injection of air into the tube. [0016] The retaining means for the separator member may be provided by a housing in which part of the separator member is located in a manner such as to prevent any substantial movement of the separator member from a desired position within the machine, particularly as tends to occur as the tubing is drawn over the separator member in the operation of the machine, but such as to allow the polythene tubing to be drawn through the housing over the separator member as the tubing is advanced through the machine. [0017] Conveniently the housing is split, comprising portions which may be secured together so as to extend partially at least around the separator member whilst within the tube. [0018] Alternatively the retaining means may be provided by one or more drive rollers of the machine with which the separator member is drawn into engagement as the drive means operates to draw tubing through the machine. [0019] Preferably the sealing means is operative to seal the tube along two lines extending transversely of the tube on opposite sides of the injection point, and to provide a tear-line extending between the two seal lines. [0020] According to another aspect of the invention there is provided a machine for the manufacture for air-filled pillows from a continuous supply of plastic tube flatwound onto a reel, the machine comprising, among other things, a) a drive assembly to advance the plastic tube intermittently through the machine; b) injection means operative intermittently to inject air into the space between upper and lower walls of the tube; and c) sealing means operative downstream of the injection means intermittently to seal the upper and lower walls of the tube; characterised in that a separator member is provided which is located within the tube between the upper and lower walls thereof upstream of the injection means, said separator member being maintained in an operative position within the machine during advancement of the tube through the machine by engagement with the drive assembly. [0025] Conveniently said engagement is indirect, in the sense that the separator member engages the drive assembly through the thickness of the polythene tube. [0026] Conveniently the drive assembly engages the tube to draw the tube over the separator member whilst preventing substantial movement of the separator member from a desired position relative to the machine. [0027] Preferably the drive assembly comprises upper and lower rollers operative to engage the upper and lower walls of the tube. [0028] Advantageously the separator member is adapted to co-operate with the injector means, and comprises an aperture through which a nozzle of the injector means passes in the injection of air into the space between the upper and lower walls of the tube. [0029] According to another aspect of the invention there is provided a method of making an air-filled pillow involving the use of continuous thin-walled plastic tube, in which the walls of the tube are retained apart by a separator member which is retained in position whilst the plastic film is drawn from a supply thereof, the separator member retaining the walls of the tube separated during the injection of air into the tube. [0030] An apparatus for manufacturing air-filled pillows from a tube material is also disclosed and includes, among other things, a plurality of support rollers, a drive means, an injector means, and a sealing means. [0031] In accordance with one aspect of the invention, the plurality of support rollers support a roll of a tube material along an outer circumferential extent of the roll. The tube material includes two opposing sheets joined along at least one longitudinal edge thereof. In some embodiments, the tube material is joined along both longitudinal edges. The tube material can be made of a polymer, such as polythene. The support rollers can form a cradle. [0032] In accordance with another aspect of the invention, the drive means draws the tube material from the roll along the support rollers. The drive means can include cooperating drive rollers to engage the tube material. [0033] In accordance with another aspect of the invention, the injector means injects air into an interior space between the two opposing sheets of the tube material drawn from the roll. The injector means can include a nozzle, and the nozzle can include a tubular member with an aperture defined therein. [0034] In accordance with another aspect of the invention, the sealing means seals the two opposing sheets together with the injected air entrapped in the interior space therebetween. The sealing means can include at least one heating element to form a seal line joining the two opposing sheets together. [0035] In accordance with another aspect of the invention, a housing is provided for the drive means, the injector means, and the sealing means. Each of the support rollers can be mounted on at least one upstanding wall of the housing. [0036] In accordance with another aspect of the invention, a control means is provided for controlling operation of at least one of the drive means, the injector means, and the sealing means. The at least one of the drive means, the injector means, and the sealing means can be operated intermittently by the control means. [0037] In accordance with another aspect of the invention, a perforator is provided for perforating the tube material drawn from the roll. [0038] There will now be given a detailed description, to be read with reference to the accompanying drawings, of two machines for the manufacture of air-filled pillows, which are preferred embodiments of the invention, having been selected for the purposes of illustrating the invention by way of example, the method of operation of the machines in the making of an air-filled pillow also being illustrative of the invention in certain of its aspects. BRIEF DESCRIPTION OF THE DRAWINGS [0039] In the accompanying drawings: [0040] FIG. 1 is a side elevation of the machine which is the first embodiment of the invention; [0041] FIG. 2 is a front view of the machine, taken in the direction of the arrow A of FIG. 1 ; [0042] FIG. 3 is a sectional view of the machine, taken on the line III-III of FIG. 2 ; [0043] FIG. 4 is an enlarged view of part of FIG. 1 ; [0044] FIG. 5 is an enlarged view showing a separator member of the first embodiment; [0045] FIG. 6 is a perspective view showing the separator member retained in position within a separator housing of the machine; [0046] FIG. 7 is a side elevation of the machine which is the second embodiment of the invention; [0047] FIGS. 8 and 9 are respectively plan and side elevation views of the separator member of the second embodiment; [0048] FIGS. 10 and 11 are respectively front elevation and plan views of the second embodiment, showing co-operation between the separator member and the drive means of the machine; and [0049] FIG. 12 is an enlarged side elevation showing the action of the separator member in separating the top and bottom sheet of the plastic tube utilized in the performance of this invention. DETAILED DESCRIPTION [0050] The machine which is the first embodiment of this invention is for the manufacture of air-filled pillows which may be used as infill and cushioning in the packaging and transportation of fragile articles. The machine comprises a housing 10 from which side arms 12 extend rearwardly to a mounting 14 upon which a roll 16 of thin-walled plastic tube is mounted, and from which tube may be drawn in the form of a flat sheet, towards a guide roller 18 of the machine. [0051] Mounted a short distance in front of the guide roller 18 is a separator member 20 , comprising a generally elongate, tubular body portion 21 from which side arms 22 extend laterally, said body portion extending in a tail housing 24 (see FIG. 5 ). [0052] The tail housing 24 comprises upper and lower arms 25 a , 25 b , spaced apart for the purposes hereinafter described, as shown at 27 in FIG. 5 . [0053] The separator member is held captive in a separator retaining housing 30 , comprising a lower portion 32 and an upper portion 34 connected to the lower portion by a hinge mechanism (not shown). [0054] The lower portion is provided with a peripheral wall 33 , and in the transverse portions of these walls generally along the centerline of the machine shallow recesses 36 a , 38 a are provided. The upper portion 34 is similarly provided with a peripheral wall 35 (see FIG. 3 ), in an underside of which, at positions corresponding to the recesses 36 a and 38 a , corresponding shallow recesses 36 b and 38 b are provided. [0055] The separator retaining member is shown in FIG. 6 in a closed position. However, by pivotal movement of the upper portion about an axis X, access to the interior of the separator retaining member may be gained. [0056] In use, the separator member 20 is lifted from the lower portion 32 of the retaining housing 30 , and a length of polythene tube is drawn from the roll 16 over the guide roller 18 , and laid over the lower portion 32 , and as shown in FIG. 6 . The separator member is then manually inserted into the end portion of the tube, between the upper and lower walls 16 a , 16 b , the elongate tubular body of the separator member being placed on the shallow recesses 36 a , 38 a of the housing with the side arms 22 being located within the peripheral wall 33 . [0057] When the upper portion 34 of the separator retaining housing 30 is in its closed position, there is a small degree of separation between the peripheral walls 33 and 35 (also seen in FIG. 5 ), and while the separator member 20 is capable of limited axial movement, determined by engagement of the side arms 22 with the peripheral walls, the separator member is generally retained in a specific position within the machine, by the retaining housing 30 . [0058] In the setting of the machine, the leading end portion of polythene tubing is drawn from the supply roll 16 beneath the guide roller 18 , and with the housing 30 open, across the lower portion 32 of the retaining housing, and the separator member is inserted manually into the end portion of the polythene tube. The upper portion 34 of the retaining housing is moved to its closed position, in which position the separator member is retained in position relative to the machine, but in which the polythene tubing may be drawn continuously in the direction of the arrow B over the separator member. [0059] In setting up the machine, the leading end portion of the tubing is drawn through drive mechanism 50 , and through clamping mechanism 60 , shown in FIG. 4 . [0060] The machine comprises an injector manifold 70 (see FIG. 5 ) mounted downstream of the drive mechanism 50 , comprising a support bracket 72 located beneath the tail housing 24 , said support bracket comprising an aperture 74 located directly adjacent to an aperture 26 provided at a central portion of the lowermost part of the tail housing 24 (see FIG. 5 ). [0061] The injection mechanism also comprises an injection needle 76 , and drive means (not shown) to move the needle in a vertical direction from a lowermost, inoperative position, shown in full lines in FIG. 5 , to an operative position shown in dotted lines in FIG. 5 in which the needle projects through the aperture 74 in the support bracket 72 , and through the aperture 26 in the lowermost portion of the tail housing 24 , passing through the lower wall of the plastic tubing drawn over the separator member 20 , the separator member 20 providing a support surface against which the lower wall of the tubing is pressed as the needle passes through the lower wall. [0062] In practice although the separator member 20 is capable of limited movement within the retaining housing 30 , such movement is insufficient to prevent the injector needle aligning correctly with the aperture 26 . [0063] Control mechanism of the machine (not shown in detail but indicated by the number 80 ) is operative, when the nozzle 76 is moved to its uppermost position, to inject a measured, adjustable volume of air through the needle 76 , into the central region of the tail housing 24 , i.e., between the upper and lower walls 16 a , 16 b of the polythene tubing 16 (see FIG. 5 ). [0064] The clamping mechanism 60 is mounted a short distance downstream of the injector mechanism 70 , comprising upper and lower heated clamping bars 62 a , 62 b , (see FIG. 4 ) and power means 64 operative under the control of the control mechanism to bring the clamping bars together to provide a transverse seal across the polythene tubing as it is drawn through the machine. [0065] The drive mechanism 50 comprises upper and lower drive rollers 52 a , 52 b , operative to engage the plastic tubing therebetween, and to draw it in the feed direction B ( FIG. 3 ) under the control of the control mechanism 80 . [0066] A cycle of operation of the machine will now be described, commencing at the position shown in FIG. 4 , in which a quantity of air has just been injected through the injector needle 76 into a section of polythene tubing P 2 . [0067] On retraction of the needle 76 , the drive mechanism operates to advance the polythene tubing a short distance equal to the distance between the needle and the clamping bars, so that the aperture provided in the lower wall 16 b is located directly above the lower clamping bar 62 b . The operating mechanism causes the clamping bars to move together, against the action of internal springs, to cause the clamping mechanism to provide two lines of seal between the upper and lower sheets extending on opposite sides of the aperture; simultaneously providing a row of perforations or similar line of weakness between the seal lines, to complete manufacture of the air pillow P 2 . On completion of a brief dwell time the power means 64 is relaxed, allowing the clamping bars to separate, and a trigger signal applied to the control mechanism causes the drive mechanism to advance the polythene tube over the separator member. [0068] Preferably the leading faces at least of the separator member are coated with PTFE or the like, to assist in the smooth gliding of the polythene over the separator member. [0069] On completion of a desired distance of advance, operation of the drive mechanism is momentarily terminated, and the injector needle 76 is moved from its retracted to its advanced position, again puncturing the lower wall 16 b of the polythene tube, to inject a measured quantity of air in the formation of a further pillow, as is shown in FIG. 4 . Again, the needle 76 is retracted, and the polythene tubing is advanced to bring the aperture into position between the two sealing bars. [0070] It will be appreciated that by the use of the invention above described, separation of the upper and lower walls 16 a , 16 b of the polythene tube is produced by the tail housing of the separator member, and is not dependant upon air injected into the tube. [0071] Naturally, some flow of air rearwardly of the tail housing will take place, which may indeed assist the smooth flow of the polythene tube across the separator member 20 , but this is incidental to the capability of the machine to provide a measured quantity of air injected between the walls 16 a and 16 b. [0072] The control mechanism may comprise, in accordance with conventional practice, adjustment capability for varying the time of operation of the drive mechanism subsequent to the sealing operation, determining the length of the air pillow formed during successive operations of the machine; and the volume of air delivered by the injector needle 76 , and the pressure to which the tube is filled. [0073] By the invention above described air filled pillows may be obtained quickly and reliably, and with relatively few moving parts. [0074] The second embodiment of the machine, shown in FIGS. 7 to 12 , is similar in general to the first embodiment above described, and will be described hereinafter primarily only insofar as it differs in construction and operation from the first embodiment, and similar numerals, provided with the prefix number 1, have been utilized to identify similar parts. [0075] In accordance with one aspect of the second embodiment, support rollers 114 are utilized to support rolls 116 or 116 a of a variety of sizes, from which thin-walled plastic tube may be drawn into the machine (see FIG. 7 ). Conveniently take-up mechanism (not shown) is utilized to provide a constant tension on the tube, and to accommodate for roll over-run. [0076] In the second embodiment the support member 120 comprises a transversely extending tubular body portion 22 , from which a longitudinal body portion 121 a extends in the forward direction, and a body portion 121 b extends in the rearward direction to a tail housing 124 , the body portion 122 providing a continuous exterior tubular surface which has a diameter greater than the thickness of the body portions 121 a or 121 b (see FIGS. 5, 7 , 8 and 9 ). [0077] The drive means of the modified version comprises upper and lower drive 152 b which are operative in the performance of the machine to draw plastic tubing from the supply, and simultaneously to retain the separator member in an operative position within the machine. Thus in the modified version the drive rollers 152 a and 152 b also perform the function of the retaining housing of the first embodiment. [0078] In particular, the rear body portion 121 a is located in recessed or channel sections 153 a , 153 b of the drive rollers 152 a , 152 b . Sufficient clearance is provided between the surfaces of the drive rollers and the surfaces of the separator member to permit polythene tube to be drawn over the separator member as shown in FIG. 12 , to cause separation of the upper and lower walls 16 a , 16 b of the tube so as to allow movement of an injector needle through an aperture 126 in the tail housing and through the bottom wall 16 b , for the injection of air into the space between the top and bottom walls (see FIGS. 12 and 13 ). [0079] As will be appreciated, while engagement of the separator member with the drive rollers prevents any significant degree of movement of the separator member in the longitudinal direction, engagement of the rear housing 124 with the circumferential flanges 154 a , 154 b bounding the recesses 153 a , 153 b prevents any significant degree of lateral movement of the separator member (see FIGS. 10 and 11 ). [0080] Conveniently in the modified version of the preferred embodiment the drive rollers 152 a , 152 b are mounted for separate movement in the setting up of the machine. Thus, tube is initially drawn from the supply roll 116 , and the separator member 120 inserted manually into the leading open end of the polythene tube. The separator member is located as shown in the drawings between the drive rollers 152 a , 152 b , which may then be closed around the separator member into their operative positions, to draw tube from the supply around the separator member. The leading end portion of the tube is then manually drawn through the machine, through the clamping mechanism. [0081] It will be appreciated that in the use of the machine, engagement of the separator member with the drive rollers is indirect, in that sheets of polythene are located between the separator member and the surfaces of the drive rollers. [0082] Thus, conveniently the drive rollers are provided with a high friction coating, such as of rubber or the like, to assist in drawing the polythene tubing around the separator member. [0083] In the present specification “comprise” means “includes or consists of” and “comprising” means “including or consisting of.” [0084] The features disclosed in the foregoing description and as incorporated by reference herein, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof. Such combinations extend to novel combinations of devices and methods expressly disclosed herein, alone or in combination with devices and methods incorporated herein by reference.
Devices and methods for forming air pillows are described. In accordance with embodiments of the invention, an apparatus for manufacturing air-filled pillows from a tube material includes a plurality of support rollers, a drive means, an injector means, and a sealing means. The plurality of support rollers support a roll of a tube material along an outer circumferential extent of the roll, in which the tube material includes two opposing sheets joined along at least one longitudinal edge thereof. The drive means draws the tube material from the roll along the support rollers, the injector means injects air into an interior space between the two opposing sheets of the tube material drawn from the roll, and the sealing means seals the two opposing sheets together with the injected air entrapped in the interior space therebetween.
1
CROSS REFERENCE TO RELATED APPLICATION(S) This is a continuation of application Ser. No. 09/438,253 filed on Nov. 12, 1999, now U.S. Pat. No. 6,664,969 which is hereby incorporated by reference herein. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates generally to a method and apparatus for remotely accessing, interacting and monitoring a computer system independent of the operating system, and more particularly to remotely displaying graphics-mode display data of the accessed computer system. 2. Description of Related Art Advances in computing technology have caused a shift away from centralized mainframe computing to distributed computing using multiple personal computers (PCs) connected to a network. The network typically includes one or more server class personal computers to handle file, print and application services, which are common to all the connected PCs. Therefore, the server becomes an important resource which the entire network depends upon. Oftentimes, businesses may require more than one server. Networks may demand isolation for security reasons. Networks may be logically subdivided for performance or practical reasons. In particular, networks may be in different geographic locations. However, oftentimes the maintenance and management of the servers falls onto a single group or person, called a network administrator. In these cases where the managed server is in an inconvenient location, it is desirable for the network administrator to be able to monitor the health of the managed server without traveling to its location. In the past, the local network administrator operating from a remote management computer could telephonically connect into the operating system of a managed server to monitor its health using a conventional communications package such as PC Anywhere or ProComm. This method required a third communications computer to be attached to the network. Typically, a connection would first be established from the remote management computer to the communications computer attached to the network of the server. If the server was operating, the network administrator would be prompted for a login password to access network resources, including the server. If the server was down, only the communications computer could be accessed (providing that PC had its own modem). After the administrator logged into the network, a server console utility, such as RCONSOLE, could be executed to gain access to the server. Because many times the server would be down, this method had limited usefulness. Additionally, only limited information was provided, since the server would have to be operating before the server console utility would operate. Network administrators also have used products such as Compaq's Insight Manager. This software product is loaded by the operating system to allow users to connect to the operating system through a dedicated modem using (remote access service) RAS/PPP (point to point) protocols. This method also allows insight into the operating system, but only after the server is operating. To help in this regard, an accessory known as Compaq Server Manager R was developed. This accessory was essentially a personal computer system on an add-in board adapted to interact with the host server. Server manager R included a processor, memory, modem and software to operate independently of the server to which it was installed. To monitor the server from a remote location, the network administrator would dial into the server manager R board and establish a communications link. If a connection was established, the processor of server manager R would periodically acquire access to an expansion bus of the server to read the contents of the server video memory. The processor would then send the contents ***[text or graphics]*** to the local computer via the communications link. A separate power supply was provided to the server manager R board so that it would operate even while the server was booting or powered down. Although the functionality provided by the server manager R board was desired, because it was essentially a second computer, the high cost of this solution limited its success. Later, a more integrated approach was taken with a device known as the integrated remote console (IRC) device. This device would connect to a conventional peripheral component interconnect (PCI) bus to monitor video activity. As PCI transactions were passed to a video controller also attached to the PCI bus, the IRC device would snoop the video transactions for the purpose of encoding the screen activity and sending the encoded data to a remote computer. IRC worked best with text-mode operating systems. If the server was running a graphical operating system, such as Microsoft Windows, the IRC device would cease to transmit information when the graphics mode was entered upon boot-up. Thus, although the IRC device was very useful for text-mode operating systems and to monitor graphical operating systems prior to entrance into graphics mode, a more complete solution was desired. SUMMARY OF THE INVENTION In one embodiment of the present invention, a managed server includes a video graphics controller having a frame buffer. The frame buffer may be periodically read to determine if the contents of the frame buffer has changed. Changes are transmitted to a remote console in communication with the managed server. The frame buffer may be divided into a number of blocks with each block having a unique number based on its contents. The unique numbers may be stored in a buffer. As the blocks are periodically read, new unique values are calculated and compared to the previously calculated unique values to determine if the blocks have changed. The changed blocks are transmitted to the remote console via a communications link. Each pixel contained in the frame buffer may be condensed into a smaller 6-bit value before calculating the unique value and transmitting to the remote console. Furthermore, the blocks may be compressed by using a run length-encoding algorithm. If two more blocks are similar, the first block is transmitted followed by a command indicating the number of times to repeat the block. Instead of reading each block of the frame buffer, a fraction of the frame buffer may be read, such as every fourth block. Each pass may read a different fraction of the frame buffer until the entire frame buffer has been read. If changes are detected during a pass, the blocks surrounding the changed block may be “marked” for accelerated reading (i.e. read immediately or on the next pass). The “marks” are cleared once the blocks have been checked. The blocks of the frame buffer comprise rows and columns. Periodically, such as at the end of each row, the video graphics controller is checked for configuration changes. Possible changes include changes to screen resolution, color depth and color mode. If changes are detected, commands are developed to communicate the changes to the remote console. Changes for a pointing device, including position, shape and size are handled similarly. BRIEF DESCRIPTION OF THE DRAWINGS The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein. FIG. 1 is a connection diagram of a managed server and a remote management console according to a preferred embodiment; FIG. 2 is a block diagram of the managed server according to the preferred embodiment; FIG. 3 is a block diagram of the remote management board of FIG. 2 according to the preferred embodiment; FIG. 4 is a block diagram of the managed server according to an alternative embodiment; FIG. 5 is a block diagram of the reading, color converting and hashing processes according to the preferred embodiment; FIG. 6 is a block diagram of the compressing and transmitting processes according to the preferred embodiment; FIGS. 7A-C are flow diagrams illustrating the processes of FIGS. 5 and 6 ; FIGS. 8A-C are flow diagrams illustrating flushing the compression buffer; FIG. 9 is a flow diagram illustrating the block compression process according to the preferred embodiment; FIGS. 10A-C are flow diagrams illustrating the processes of FIGS. 5 and 6 according to the preferred embodiment; and FIGS. 11A-B are block diagrams illustrating pixel block sampling and marking methods according to the preferred embodiment. DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS The following patents or patent applications are hereby incorporated by reference: U.S. Pat. No. 5,898,861, entitled “Transparent Keyboard Hot Plug” by Theodore F. Emerson, Jeoff M. Krontz and Dayang Dai; U.S. Pat. No. 5,790,895, entitled “Modem Sharing” by Theodore F. Emerson and Jeoff M. Krontz; and U.S. patent application Ser. No. 08/733,254, entitled “Video Eavesdropping and Reverse Assembly to Transmit Video Action to a Remote Console” by Theodore F. Emerson, Peter J. Michaels and Jeoff M. Krontz, filed Oct. 18, 1996. Referring first to FIG. 1 , there is illustrated a managed server S connected to a remote console (“C”) by a network N. The managed server S includes a central processing unit (“CPU”) 2 housing processing, memory, communications, interface, and other circuitry as described more fully below, and may be connected to a monitor 4 . The remote console C also includes a CPU 6 and a monitor 8 . The managed server S includes special circuitry and software for capturing, analyzing, compressing and transmitting video activity to the remote console C independent of an operating system (“OS”). The special circuitry and software operate without regard to the existence or type of OS present on the managed server S. Therefore, the present invention is useful for accessing, interacting and monitoring the managed server S from the remote console C even before its OS has been loaded. More specifically, the video displayed on monitor 4 is capable of being viewed on monitor 8 independent of the OS. The network N can be any sort of network capable of transmitting data between two devices. Without limitation, some examples of networks include: a local area network, a wide area network, a hardwired point-to-point connection, a point-to-point connection over a telecommunications line, a wireless connection, and an internet connection. Although the managed server S shown is preferably of an International Business Machines. (IBM) PC variety, the principles of the present invention are equally applicable to other computer platforms or architectures, such as those manufactured by IBM, Apple, Sun and Hewlett Packard. Additionally, the managed server S could be one architecture and the remote console C could be another. For example, the managed server S could be a x86 architecture machine computer running Microsoft Windows NT OS and the remote console C could be a Sun workstation running Solaris OS. In the operation of the present invention, video data is captured, analyzed, compressed and transmitted to the remote console C by special circuitry and software in the managed server S. The remote console C includes special software for receiving and interpreting the transmitted data in order to reproduce on its own monitor 8 the video data displayed on the managed server monitor 4 . The transmitted video data is encoded with special commands to permit the remote console C to interpret the data stream. Now referring to FIG. 2 , there is illustrated a block diagram of the managed server S according to the preferred embodiment. To provide sufficient processing power, the managed server S includes one or more processors 10 , such as a Pentium II Xeon processor manufactured by Intel Corporation. Each processor 10 may include a special non-maskable interrupt, called the system management interrupt (“SMI”), which causes the processor to operate in a special system management mode (“SMM”) independent of the operating system. This functionality is fully explained in literature available from Intel. The processor 10 is coupled to a north bridge 12 , such as an Intel 82451NX Memory and I/O Bridge Controller (MIOC). The north bridge includes a memory controller for accessing a main memory 14 (e.g. dynamic random access memory (“DRAM”)), and a peripheral component interconnect (“PCI”) controller for interacting with a PCI bus 16 . Thus, the north bridge 12 provides the data port and buffering for data transferred between the processor 10 , memory 14 , and PCI bus 16 . In the managed server S, the PCI bus 16 couples the north bridge 12 to a south bridge 18 and one or more PCI slots 20 for receiving expansion cards (not shown). The south bridge 18 is an integrated multifunctional component, such as the Intel: 82371 (a.k.a. PIX4), that includes a number of functions, such as, an enhanced direct memory access (“DMA”) controller; interrupt controller; timer; integrated drive electronics (“IDE”) controller for providing an IDE bus 22 ; a universal serial bus (“USB”) host controller for providing a universal serial bus 24 ; an industry standard architecture (“ISA”) bus controller for providing an ISA bus 26 and ACPI compliant power management logic. The IDE bus 22 supports up to four IDE devices, such as a hard disk drive 28 and a compact disk read only memory (“CD-ROM”) 30 . The universal serial bus 24 is connected to a pair of USB connectors 32 for communicating with USB devices (not shown). The ISA bus 26 couples the south bridge 18 to a multifunction input/output (I/O) controller 34 and a basic input/output system (BIOS) ROM 36 . The multifunction I/O controller 34 , such as a Standard Microsystems Corporation FDC37C68x, typically includes a number of functions, such as a floppy disk drive controller for connecting to a floppy disk drive 42 ; a keyboard controller 38 for connecting to a keyboard and a pointing device; a serial communications controller for providing at least one serial port 44 ; and a parallel port interface for providing at least one parallel port 46 . Alternative multifunction input/output (I/O) controllers are manufactured by National Semiconductor and WinBond. Further attached to the PCI bus 16 via one of the PCI slots 20 is a remote management board 50 . The remote management board 50 connects to the keyboard controller 38 , the network N, a keyboard 52 and a mouse 54 to provide functionality for accessing, interacting and monitoring the managed server S from the remote console C as will be more fully described below. The functions described above may alternatively be implemented in separate integrated circuits or combined differently than described above without departing from the concept of the present invention. Turning now to FIG. 3 , there is illustrated a block diagram of the remote management board 50 . Coupled to the PCI bus 16 is a processor 100 , such as an Intel i960RP. The Processor 100 includes a PCI-to-PCI bridge unit for bridging PCI bus 16 (hereinafter primary PCI bus 16 ) to a secondary PCI bus 102 . Alternatively, a separate processor and bridge could be used. The processor 100 also includes a secondary PCI bus arbitration unit, an integrated memory controller and three direct memory access (“DMA”) channels. The processor 100 operates independently of the processor 10 , and therefore, includes a memory controller for accessing memory (e.g. read only memory 106 and random access memory 108 ) over a local bus 104 in order to boot its own operating system, such as Wind River System's IxWorks RTOS. One or more communications devices are also connected to the local bus 104 , such as a network interface controller (“NIC”) 110 and a modem 112 . Other communications devices can be used as required by the network type. The secondary PCI bus 102 is seen by the processor 10 as a logical extension of the primary PCI bus 16 . Further attached to the secondary PCI bus 102 is a video graphics controller 114 a and a remote management controller 116 a . The video graphics controller 114 a is an integrated video graphics controller, such as an ATI technologies Rage IIC or XL, that supports a wide variety of memory configurations, color depths and resolutions. Connected to the video graphics controller 114 a is a frame buffer 118 a (e.g. synchronous DRAM) for storing video graphics images written by the processor 10 for display on the monitor 4 . The remote management controller 116 a includes circuitry for snooping configuration transactions between the processor 10 and the video graphics controller 114 a to determine configuration and mode information, such as whether the video graphics controller is in text or graphics mode. The remote management controller 116 a also includes circuitry to route keystrokes to the keyboard controller 38 from either the local keyboard 52 or from the remote console C (via the modem 112 a or NIC 110 ). This keyboard functionality is more fully explained in U.S. Pat. No. 5,898,861, entitled “Transparent Keyboard Hot Plug.” In the operation of the remote management board 50 , the processor 100 may periodically read the video graphics data from the frame buffer 114 a in order to determine whether the data has changed. If the data has changed, the processor 100 will compress the video graphics data and transmit the data to the remote console C via one of the communications devices (i.e. modem 112 a or NIC 110 ). The remote console C will decompress and decode the data stream and display it at the remote console C for viewing by a user. Now referring to FIG. 4 , there is illustrated a first alternative embodiment of managed server S offering a more integrated and less expensive solution than that described in FIGS. 2 and 3 . Since many of the components are the same as in FIG. 2 , only the differences will be discussed. Attached to the PCI bus 16 is the remote management controller 116 b and the video graphics controller 114 b . The remote management controller 116 b is connected to the keyboard controller 38 and the keyboard 52 for routing keystrokes based on whether the remote console C is operational. Modem 112 b is connected to the ISA bus 26 in a conventional manner for use by standard communications programs. However, in this embodiment, the modem 112 b may be claimed by the remote management controller for exclusive use with the remote console C. Further details on modem sharing can be found in U.S. Pat. No. 5,790,895, entitled “Modem Sharing.” Although only a modem is shown, it is understood that any type of communications device could be used. In this alternative embodiment, an independent processor, such as the processor 100 is not provided. Instead, the system management mode of the processor 10 is utilized to provide a “virtual” processor. The remote management controller 116 b is configured to periodically interrupt the processor 10 with a system management interrupt, thereby causing processor 10 to enter system management mode and function as a “virtual” processor. When functioning as a “virtual” processor, the processor 10 will read the frame buffer 118 b in order to determine whether the video graphics data has changed. If the data has changed, the processor 10 will compress the video graphics data and transmit the data to the remote console C via a communications device (i.e. modem 112 b ). Thus in this first alternative embodiment, processor overhead is sacrificed for a better-integrated solution. A second alternative embodiment involves using the “virtual” processor 10 for special functions and the processor 100 for the remaining processing. For example, if a communications device was not provided on the remote management board 50 but instead was attached to the ISA bus 26 or PCI bus 16 , the system management mode of processor 10 can be used to handle communications between the managed server S and the remote console C. As another variation, the processor 10 can be configured to trap on writes to the frame buffer 118 b to assist in determining when video graphics data has changed. As a further variation, if the video graphic controller were located on an accelerated graphics port (“AGP”), the processor 10 could be configured to trap on all writes to the frame buffer 118 b to assist in determining when the video graphics data has changed. For purposes of simplicity, the remaining description will correspond with the preferred embodiment, but it is understood that the processes can be adapted according to the first and second alternative embodiments. Reading and Analyzing Now turning to FIG. 5 , there is illustrated a flow diagram of the reading and analyzing processes according to the preferred embodiment of the present invention. Analyzing video graphics data for change starts with dividing the video graphics data of the frame buffer 118 a/b into manageable blocks 200 , such as 16×16 pixel blocks. For example, a 1024×768 display resolution would result in 48 rows and 64 columns for a total of 3072 blocks. Initially, each of the 3072 blocks is transmitted to the remote console C. Thereafter, a given block is only transmitted if it has changed as compared to a previously transmitted block. Generally, changes in a given block's data are determined by comparing the block's previously transmitted data to the block's current data. This determination is simplified in the preferred embodiment by comparing hash codes calculated for each block 200 . A hash code is a unique number mathematically calculated by performing a hashing algorithm 204 , such as a 16-bit cyclic redundancy check or other algorithm resulting in a unique number. The first time the block 200 is hashed the unique number is stored in a hash code table 202 formed in memory 108 . Thereafter, each time the block is read and hashed another unique number is calculated. If the newly calculated number matches the number stored in the hash table 202 , the block 200 has not changed. If the numbers don't match, the block 200 has changed and is transmitted to the remote console C. The process is further simplified and data transmission is more efficient if the pixel values are condensed into a smaller number, such as 6-bits, before performing the hashing algorithm. For this purpose a color converting algorithm 206 is provided, as described in Table I for developing a 6-bit, zero-padded, color pixel block 208 in memory 108 . For color values 8-bits or less a color lookup table is used and for pixel values greater than 8-bits a mathematical calculation is applied to produce a 6-bit value. For example, a 24-bit color value of 0xd5aad5h will result in a 6-bit value of 0x00101010b. The color lookup tables are based on the color lookup tables provided with the video graphics controller 114 a/b. Bit shifting the full color values may be used an alternative to the above color condensing method. Although using the above-described color condensing technique is preferred, it is understood that full color values could be used with proper transmission bandwidth without changing the principles of the present invention. It is noted that if the first alternate embodiment is employed, the 6-bit color code table 208 and the hash code table 202 would be formed in system management memory of the “virtual” processor 10 . TABLE I INPUT COLOR CONVERSION OUTPUT  1 bit color color lookup table 6-bit RGB color value  2 bit color  4-bit color  8-bit color 15-bit color R*3/31, G*3/31, B*3/31 6-bit RGB color value 16-bit color R*3/31, G*3/63, B*3/31 6-bit RGB color value 24-bit color R*3/255, G*3/255, B*3/255 6-bit RGB color value Compressing and Transmitting Referring now to FIG. 6 , there is illustrated a flow diagram of the compression and transmission processes according to the preferred embodiment of the present invention. A pixel block 200 is first converted to a 6-bit color pixel block 208 , as noted above. Then the 6-bit color pixel block 208 may be compressed by a compression function 210 and temporarily stored in a transmit buffer 212 . At least at the end of each row, a transmit packet 214 is developed having a conventional header and footer as required by the particular network transport scheme. For example, a transmission control protocol/internet protocol (“TCP/IP”) header and footer may be appended to the data for transmission over a local or wide area network to the remote console C. In the development of the transmit packet 214 , the video graphics controller is checked for configuration changes and the mouse is checked for positioning changes. Any changes are also appended to the transmission packet 214 . Video graphics changes may include: changes in resolution, mode, and color depth. Mouse changes may include: positioning, and cursor shape and size. For example, if the resolution of the video graphics controller was changed, the change would be appended to the transmission packet 214 and the change would take effect at the remote console C beginning with the next row. Compressing the data is accomplished using run length encoding (RLE) techniques. The image compression algorithm 210 simply looks for long runs of the same pixel value and encodes it into a single copy of the value and a number representing the number of times that value repeats. Since each pixel block 200 is represented by a unique number (hash code) the same encoding can be used to look for long runs of the same pixel block 200 . A repeated block count 216 tracks the number of times a block is repeated. A repeated byte count 218 tracks the number of times a byte is repeated either within a block or across blocks. A repeated data buffer 220 holds the repeated byte as it is compared to subsequent bytes. Other graphics or multimedia compression techniques could be used instead of the RLE compression function 210 , such as motion picture expert group (MPEG) encoding, joint photographic experts group (JPEG) encoding, and graphics interchange format (GIF) encoding. Additionally, these alternative compression techniques may operate better on full-color values instead of the 6-bit condensed color values created by the color converter 206 . Data Transmission Scheme To access, interact and monitor the managed server S, the remote console C initiates a telnet session with the remote management board 50 . If the managed server S is operating in a text display mode, the remote management board 50 will send a text data stream using standard telnet formatted commands to the remote console C, as described in U.S. patent application Ser. No. 08/733,254, entitled “Video Eavesdropping and Reverse Assembly to Transmit Video Action to a Remote Console.” If the managed server S is operating in a graphics display mode, the remote management board 50 will encode the graphics data using one of two types of special commands: an american national standards institute (“ANSI”) escape sequence formated command or a special telnet formated command. The special commands are interpreted by software running on the remote console C. The remote console C communicates its ability to interpret the special commands before the remote management board 50 will send graphics data. If the remote console is a conventional telnet client, the graphics data will not be sent, but the remote management board 50 will still send text mode data. Thus, even if the special client software is not available at a remote console, any telnet session is usable for text mode exchanges. Software running on the remote console is configured to interpret the special commands and escape codes as described below. A command and data typically follow the telnet escape code to complete a data stream. The special telnet commands are defined below in Table II. TABLE II COMMAND USAGE DESCRIPTION Move 0xff 0xe5 X Y Moves the pen to a new x-y coordinate. X and Y are 8-bit values representing the row and column to place the pen. Repeat8 B 0xff 0xe6 R8 Repeats a byte of data B up to 255 times. B and R8 are 8-bit values. R8 specifies the number of repeats. Repeat16 B 0xff 0xe7 R16 Repeats a byte of data B up to 65535 times. B is an 8-bit value and R16 is a 16-bit value. R16 specifies the number of repeats. RepeatBlk8 0xff 0xe8 B8 Repeats the previous block up to 255 times. B8 is an 8-bit number specifying the number of repeats. RepeatBlk16 0xff 0xe9 B16 Repeats the previous block up to 65535 times. B16 is an 16-bit number specifying the number of repeats. Special ANSI escape codes are sent only if the client used by the remote console C is ANSI compliant. The special ANSI escape codes are listed in Table III. TABLE III COMMAND USAGE DESCRIPTION Graphics mode esc] W ; H ; B g Enables graphics mode at the remote console. W is the screen width encoded in ASCII. For example, 640-pixel width would be 545248h. H is the screen height encoded in ASCII. B is a ASCII character specifying the number of bits per pixel color (i.e. 2 or 6). Lowercase g is the command. Text mode esc] G Enables text mode. Uppercase g is the command. Pointer Position esc] X ; Y h Provides an absolute address of the mouse pointer relative to the top left corner of the screen. X is an ASCII encoded set of numbers representing the number of pixel positions to the right. Y is an ASCII encoded set of numbers representing the number of pixel positions down from the top. Lowercase h is the command. Pointer Shape esc] M C1 C2 D Specifies the shape of the pointer. Uppercase m is the command. C1 and C2 are 6-bit, binary, 0- padded numbers representing a color value. D is a 1024 byte data stream representing a 64 × 64 pixel pointer image. Each 2-bit pixel value indicates one of four ways the pixel should be developed: using C1, using C1, XOR with screen or transparent. Operational Description Turning now to FIGS. 7A-C , there is illustrated a flow chart of the methods related to reading, analyzing, compressing and transmitting video graphics data to the remote console C. According to the preferred embodiment, most of these steps are performed by the processor 100 , but alternative embodiments may use the processor 10 , as noted above. Configuration cycles to the registers of the video graphics controller 114 a are captured by the remote management controller 116 a . Hence, the configuration of the video graphics controller, including resolution, color depth and color mode are readily available to the processor 100 . When the remote console C initiates a communications link with the remote management board 50 , the processor is alerted to start sending video graphics data to the remote console C. The process starts at a step 300 where the processor 100 reads one or more video graphics blocks 200 from the frame buffer 118 a . Because the processor 100 and the video controller 114 a are on a secondary PCI bus 102 , the read cycles do not significantly impact the overall operational efficiency of the managed server S. The processor 100 converts the native color values into 6-bit color values and stores the video graphics block 200 in the 6-bit color pixel block 208 located in local RAM memory 108 . At a step 302 , the processor 100 hashes the 6-bit color pixel block 208 to generate a unique number or hashing code. The 16-bit hashing algorithm 204 is preferred since it runs faster than a 32-bit hashing algorithm, but a 32-bit hashing algorithm may be used to increase accuracy. If processing the first screen of data (i.e. first pass), the process branches at step 304 to step 306 where the hash code is stored in the hash code table 202 . Next, if processing the first pixel block 200 of a row that has changed, the process branches from step 308 to step 310 where the pixel block 200 is compressed using the compression algorithm 210 , explained more fully with reference to FIG. 9 . If not processing the first changed pixel block 200 of a row, the process branches from step 308 to step 311 where the process again branches to step 308 if the previously positioned block did not change. For example, if a block was skipped after one or more changed blocks. Otherwise, if the previously positioned block did change, the process branches to step 312 where the hash code corresponding to the current block is compared to the previous block. For example, if processing pixel block (0,1), the hash code of pixel block (0,1) is compared to the hash code of pixel block (0,0) stored in the hash code table 202 . If the hash codes are equal, processing branches from step 314 to step 316 . If processing the first screen of data, the process branches at step 316 to step 318 where a second more detailed comparison is performed. This more detailed comparison is performed to assure that the pixel blocks are indeed equal. It is especially important on this first pass to assure that good data is transmitted. Alternatively, a more accurate hashing code, such as a 32-bit algorithm, could be utilized to avoid this second check. If the bytes of both pixel blocks match, then processing continues from step 320 to step 322 where the byte compression pipeline is flushed to move any previously accumulated “byte repeats” into the transmit buffer 212 . At step 324 , the repeated block count 216 is incremented to start a count of repeated blocks. Referring back to step 314 , if the hash codes are not equal, processing branches from step 314 to step 326 where the block compression pipeline is flushed to move any previously accumulated “block repeats” into the transmit buffer 212 . Next, the new pixel block 200 is compressed using the compression algorithm 210 . Referring back to step 304 , if not processing the first screen of data (i.e. first pass), the process branches from step 304 to step 328 where the hash code generated for the current block is compared to the hash code value stored in the hash code table 202 corresponding to the current block location. If the hash codes are not equal, the process branches from step 330 to step 306 (discussed above). If the hash codes are equal, the process branches from step 330 to step 332 where the block is skipped, meaning that the video graphics data has not changed for this pixel block 200 . Next, the compression pipeline is flushed to move any previously accumulated “block repeats” into the transmit buffer 212 and to assure that the byte repeat counter is cleared. Now referring to FIG. 7C , processing continues from steps 324 , 310 or 334 to step 336 to check for an end of row condition. If not at the row end, processing branches from step 336 to step 338 where the process moves to the next block and continues at step 300 . If at the row end, processing branches from step 336 to step 340 to flush the compression pipeline including the byte and block repeat counters. Next, processing continues at step 342 where the transmit buffer is developed into a transmit packet and transmitted to the remove console C via the modem 112 a or NIC 110 . Next, mouse and video configuration changes are identified. If no changes are detected, processing branches from step 346 to step 338 . If changes are detected, processing branches from step 346 to step 348 to determine if a text mode has been entered. If so, processing terminates. If not so, processing branches from step 348 to step 350 where the mouse and/or video configuration changes are transmitted to the remote console C and processing returns to step 338 to process another row. Although the mouse and video configuration changes are transmitted in a separate packet from the data, it is understood that they could be transmitted in a combined packet. Now turning to FIGS. 8A-C , there is illustrated three variations of flushing the compression pipeline. FIG. 8A illustrates a general flush routine. At a step 400 , the process branches to step 402 if the block repeat count 216 is greater than zero. At step 402 , a repeat block command is formed and written to the transmit buffer 212 . Next at step 404 , the repeat block count is cleared to ‘0’ in preparation for the next repeated block. If at step 400 , the block repeat count 216 is zero the process branches to step 406 . At step 406 , the process branches to step 408 if the byte repeat count is greater than four. At step 408 , a repeat byte command is formed based on the repeated byte in the repeated data buffer 220 and the repeat byte count 218 . The repeat byte command is written to the transmit buffer 212 . For example, if the repeated byte count is 5 for a data byte 0x45, the value 0x45ffe605h would be written to the transmit buffer 212 to communicate that a string of six bytes were compressed. If, at step 406 , the byte repeat count is less than or equal to four the process branches to step 410 where the repeated byte in the repeated data buffer 220 is written to the transmit buffer 212 according to the count. If the count is zero nothing is written. Unless the byte count is greater than four, it is a more efficient use of resources to simply replicate the repeated byte the number of times indicated by the repeated byte count 218 . For example, if the repeated byte count is three for the data byte 0x45, the value 0x45454545h would be written to the transmit buffer 212 to communicate the four bytes. After steps 408 or 410 , the repeated byte count is cleared to ‘0’ in step 412 in preparation for the next repeated byte. FIG. 8B illustrates a flush byte compression pipeline routine. At step 420 , the process branches to step 422 if the byte repeat count is greater than four. At step 422 , a repeat byte command is formed based on the repeated byte in the repeated data buffer 220 and the repeat byte count 218 . The repeat byte command is written to the transmit buffer 212 . If, at step 420 , the byte repeat count is less than or equal to four the process branches to step 424 where the repeated byte in the repeated data buffer 220 is written to the transmit buffer 212 according to the count. If the count is zero nothing is written. After steps 422 or 424 , the repeated byte count is cleared to ‘0’ in step 426 in preparation for the next repeated byte. FIG. 8C illustrated a flush block compression pipeline routine. At a step 430 , the process branches terminates and returns to the calling routine if the block count is equal to zero. Otherwise, the process continues to step 432 , where a repeat block command is formed and written to the transmit buffer 212 . Next at step 434 , the repeat block count is cleared. Now turning to FIG. 9 , there is illustrated the compress block routine called in step 310 . At a step 450 , if the repeated data buffer 220 is empty, the process branches to step 452 to read the first data byte and write it to the repeated data buffer 220 . Otherwise, the process branches to step 454 to read the next data byte. Next, at step 456 , the next data byte is compared to the data byte in the repeated data buffer 220 . If the bytes are not equal, the process branches from step 458 to step 460 where the flush byte compression pipeline is called. After returning from the flush byte compression pipeline routine, at step 462 the next data byte (read at step 454 ) is written to the repeated data buffer 220 . If at step 458 , the bytes are equal, the process branches from step 458 to step 464 where the repeat byte count 218 is incremented. From steps 462 and 464 , the process loops back to step 450 if not at the end of the 6-bit color pixel block 208 . If at the end of a block, the routine returns to the calling process. Referring now to FIGS. 10A-C , there is illustrated the methods related to reading, analyzing, compressing and transmitting video graphics data to the remote console C according to the preferred embodiment of the present invention. Generally, the process is similar that described in FIGS. 7A-B , except that instead of reading every pixel block 200 sequentially, the screen is sampled for changing data based on a pattern or count. For example, every second, third, fourth (as indicated by ‘X’), etc., pixel block 200 can be read as illustrated in FIG. 11A . The sampling rotates every pass of the screen so that every pixel block 200 is eventually read. For example, if sampling every fourth pixel block, it would take four passes of the screen to read every pixel block of the screen. Once a changed pixel block 200 is located, the surrounding pixel blocks 200 may be marked for accelerated checking based on the likelihood that the surrounding pixel blocks 200 would also change. One example of marking surrounding pixels blocks is illustrated in FIG. 11B . A changed pixel block 200 was located at row 4 , column 4 . The surrounding pixel blocks are marked (as indicated by ‘M’) in a proximity table 222 so that they will be checked next rather than wait for the next sampling. This results in changed data being passed to the remote console C faster than the method described in FIGS. 7A-B . It is noted that the marked pixel block above and left of the current block will not be read until the next pass. At a step 500 , the process branches to step 502 if processing the first screen of data (i.e. first pass). At step 502 , a pixel block 200 is read and converted to 6-bit color. Next, at step 504 , the process hashes the 6-bit color pixel block 208 to generated a unique number or hashing code. If not processing the first screen of data, the process branches at step 500 to step 506 . At step 506 , the process branches to step 508 if the pixel block 200 is not marked in the proximity table 222 for accelerated reading. At step 508 , the process branches to step 510 to move to the next pixel block 200 if the pixel block 200 is not designated for reading on this pass. Designating pixel blocks 200 for sampling can be accomplished with row and column modulo counters. For example, if every fourth block is to sampled, on a first pass every ‘0’ block will be read according to the column modulo-4 counter. On the second pass every ‘1’ block will be read. A second modulo-4 counter can control the offset according to the row. FIG. 11A illustrates the resulting pattern. Other patterns can be designed according to the types of images that are displayed. For example, instead of reading rows from top to bottom, a diagonal or circular scheme could be developed. Thus, if the pixel block 200 is not a surrounding “marked” block or a block designated for sampling, the process branches from step 508 to step 510 to move to the next block. Otherwise, the process branches to step 512 from steps 506 and 508 to read the pixel block 200 and convert to 6-bit color. Next, at step 514 , the process hashes the 6-bit color pixel block 208 to generated a unique number or hashing code. When a block is hashed, its corresponding bit in the proximity table 222 is cleared. At step 516 the hash code generated for the current block is compared to the hash code value stored in the hash code table 202 corresponding to the current block location. If the hash codes are equal, the process branches from step 518 to step 520 where the block is skipped and the block is unmarked, meaning that the video graphics data has not changed for this pixel block 200 . Next at step 522 , the compression pipeline is flushed to move any previously accumulated “block repeats” into the transmit buffer 212 and assure that the repeated byte count is cleared. If at step 518 the hash codes are not equal, the process branches from step 518 to step 524 to mark the current block and surrounding blocks as illustrated in FIG. 11B . The process continues from steps 524 and 504 to step 526 where the calculated hash code is stored in the hash code table 202 . Next, if processing the first pixel block 200 of a row that has changed, the process branches from step 528 to step 530 where the pixel block 200 is compressed using the compression algorithm 210 , explained more fully with reference to FIG. 9 . If not processing the first changed pixel block 200 of a row, the process branches from step 528 to step 531 where the process again branches to step 530 if the previously positioned block did not change. For example, if a block was skipped after one or more changed blocks were processed. Otherwise, if the previously positioned block did change, the process branches to step 532 where the hash code corresponding to the current block is compared to the previously positioned block. For example, if processing pixel block (0,1), the hash code of pixel block (0,1) is compared to the hash code of pixel block (0,0) stored in the hash code table 202 . If the hash codes are equal, processing branches from step 534 to step 536 . If processing the first screen of data, the process branches at step 536 to step 538 where a second more detailed comparison is performed. This more detailed comparison is performed to assure that the pixel blocks are indeed equal. It is especially important on this first pass to assure that good data is transmitted. Alternatively, a more accurate hashing code, such as a 32-bit algorithm, could be utilized to avoid this second check. If the bytes of both pixel blocks match, then processing continues from step 540 to step 542 where the byte compression pipeline is flushed to move any previously accumulated “byte repeats” into the transmit buffer 212 . At step 544 , the repeated block count 216 is incremented to start a count of repeated blocks. Referring back to step 534 , if the hash codes are not equal, processing branches from step 534 to step 546 where the block compression pipeline is flushed to move any previously accumulated “block repeats” into the transmit buffer 212 . Next, the new pixel block 200 is compressed using the compression algorithm 210 . Now referring to FIG. 10C , processing continues from steps 544 , 530 or 522 to step 548 to check for an end of row condition. If not at the row end, processing branches from step 548 to step 510 where the process moves to the next block and continues at step 500 . If at the row end, processing branches from step 548 to step 550 to clear the marked pixel blocks on the current row. Additionally, the second “column” modulo is decremented to offset the next row of sampled pixel blocks by one block as illustrated in FIG. 11A . Next, processing continues to step 552 where the repeated byte and block data is flushed into the transmit buffer 212 . Next, processing continues at step 554 where the transmit buffer is developed into a transmit packet and transmitted to the remove console C via the modem 112 a or NIC 110 . Next, mouse and video configuration changes are identified. If no changes are detected, processing branches from step 558 to step 548 . If changes are detected, processing branches from step 558 to step 560 to determine if a text mode has been entered. If so, processing terminates. If not so, processing branches from step 560 to step 562 where the mouse and/or video configuration changes are transmitted to the remote console C. Thus, there has been described and illustrated herein, a method and apparatus for reading, analyzing, compressing and transmitting video graphics data to a remote console C. However, those skilled in the art should recognize that many modifications and variations in the size, shape, materials, components, circuit elements, wiring connections and contacts besides those specifically mentioned may be made in the techniques described herein without departing substantially from the concept of the present invention. Accordingly, it should be clearly understood that the form of the invention described herein is exemplary only and is not intended as a limitation on the scope of the invention.
A method and apparatus for updating video graphics changes of a managed server to a remote console independent of an operating system. The screen (e.g. frame buffer) of the managed server is divided into a number of blocks. Each block is periodically monitored for changes by calculating a hash code and storing the code in a hash code table. When the hash code changes, the block is transmitted to the remote console. Color condensing may be performed on the color values of the block before the hash codes are calculated and before transmission. Compression is performed on each block and across blocks to reduce bandwidth requirements on transmission. Periodically, the configuration of a video graphics controller and a pointing device of the managed server are checked for changes, such as changes to resolution, color depth and mouse movement. If changes are found, the changes are transmitted to the remote console. The method and apparatus may be performed by a separate processor as part of a remote management board, a “virtual” processor by causing the processor of the managed server to enter a system management mode, or a combination of the two.
7
FIELD OF THE INVENTION The current invention relates to processes for the production of polymers. More particularly, the current invention relates to processes for the production of polymers of α-methylstyrene. BACKGROUND OF THE INVENTION Poly α-methylstyrene has many applications including, as processing aids and fusion enhancer/modifiers in applications such as vinyl flooring, as a processing aid in the extrusion and injection molding of PVC piping and profile extrusions such as vinyl siding and windows. Traditional processes for the polymerization of α-methylstyrene to poly α-methylstyrene have made use of boron trifluoride or other protic acid catalyst/initiators, such as tetrafluorboric acid, hexafluorophosphoric acid and pentafluoroantimonate. Other work has focused on the use of Lewis acids as coinitiators with cationic carbon species. This work includes: Li et al, “Living Carbocationic Polymerization of α-Methylstyrene Using Tin Halides as Coinitiators”, Macromolecules, 1996, 29, 6061-6067; Cotrel et al, “Kinetic Study of the Cationic Polymerization of p-Methoxystyrene Initiated by Trityl Hexachloroantimonate”, Macromolecules , November-December 1976, vol. 9, No. 6, 931-936; Hotzel et al, “Studies on Cationic Copolymerization of α-Methylstyrene and Indene”, Polymer Bulletin 6, 521-527 1982; and Matsuguma et al, “The Effect of Counteranions on the Polymer Steric Structure in the Cationic Polymerization of α-Methylstyrene”, Polymer Journal , vol. 2, No. 3, 353-358, 1971. A drawback of most current art methods using cationic and Lewis acid initiators is that they require cold temperatures to control the polymerization and obtain polymers of the desired molecular weight and molecular weight distribution. Li et al report in “Living Carbocationic Polymerization of α-Methylstyrene Using Tin Halides as Coinitiators” that a rapid and uncontrolled polymerization may lead to side reactions and a broad molecular weight distribution. A typical industrial process that was run by Amoco utilized boron trifluoride as an initiator to produce poly α-methylstyrene homopolymer. The process was run in a chlorohydrocarbon solvent at −25 to −80° C. In addition to the costs introduced by such extreme temperatures, the use of an environmentally unfavorable solvent such as chlorohydrocarbon, which is typical in similar processes, makes this an unattractive process. Typical anionic catalyst/initiators are alkyl lithiums (U.S. Pat. Nos. 4,614,768, 4,725,654 and 4,748,222) and metal naphthalides, in “Ionic Polymerization of p-Isopropyl-α-Methylstyrene”, Journal of Macromolecular Sci.-Chem. , A11(11), 2087-2112, 1977. Léonard et al. A drawback of anionic initiators is that they are particularly sensitive to impurities. Unrefined α-methylstyrene, such as what may be obtained directly from an α-methylstyrene manufacturing facility, generally contains a number of trace oxygenated impurities, which adversely affect a number of commonly used polymerization initiators. These impurities include, but are not limited to 3-methyl-2-cyclopentanone (3-MCP), acetophenone, 2-methylbenzofuran (2-MBF) and acetone. In many cases, the presence of these trace impurities has the effect of inhibiting or killing an anionic polymerization initiator, with the result that little or no conversion of the monomer is obtained. As a result, it has been found to be necessary to pre-treat the monomer feed stream, such as with an acidic alumina or via distillation, to remove these trace impurities before proceeding to the polymerization step, adding time and costs to production. U.S. Pat. No. 4,614,768 to Lo, U.S. Pat. No. 4,725,654 to Priddy et al and U.S. Pat. No. 4,748,222 to Malanga disclose the necessity of purifying reactants in processes for polymerizing α-methylstyrene using an organolithium initiator. Lack of viable alternatives for the production of poly α-methylstyrene homopolymer has led to a lapse in its production and the adoption of alternative co-polymers of α-methylstyrene, such as α-methylstyrene/styrene and α-methylstyrene/vinyltoluene. Hence, it would be desirable to provide a process for producing polymers of α-methylstyrene that can be efficiently run and controlled at ambient temperatures, does not make use of environmentally unfavorable solvents and consistently produces a polymer of the desired molecular weight. It would further be desirable to provide a process for producing polymers of α-methylstyrene that does not require expensive and time-consuming pre-treatment of the monomer prior to polymerization. The advantages of such a process would include lower costs, a more robust reproducible process, increased efficiency and more controllable process temperature exotherms. SUMMARY OF THE INVENTION The current invention provides a process for the polymerization of α-methylstyrene that can manageably be carried out at ambient temperature. The current invention also provides a process for the polymerization of α-methylstyrene, which does not require extensive purification of the monomer prior to polymerization. The invention achieves this through the use of tin IV chloride as an initiator for the polymerization of α-methylstyrene. According to one embodiment of the invention, α-methylstyrene monomer is provided as a solution in an organic solvent, preferably toluene or cumene. A small amount of tin IV chloride is then added to initiate polymerization of the α-methylstyrene. Preferably, the amount of tin IV chloride added is from about 0.10 to about 0.40% by weight based on the weight of α-methylstyrene in solution. The process is run at a temperature greater than about 0° C., preferably greater than about 10° C., and more preferably greater than about 20° C. The initiator may be added either neat or as a solution in a suitable solvent. Preferably, the initiator is added in a suitable solvent. The process may be run as a batch process or in continuous production. According to one embodiment, the process may be run with α-methylstyrene and one or more co-monomers including, but not limited to propylene, ethylene, styrene, butadiene, acrylonitrile and methylmethacrylate to produce an α-methylstyrene co-polymer. DETAILED DESCRIPTION The process according to the current invention uses tin IV chloride as an initiator for the polymerization of α-methylstyrene to produce a poly α-methylstyrene polymer. It has been discovered that the use of tin IV chloride as an initiator for the polymerization of α-methylstyrene eliminates the need for tedious and expensive purification of the monomer prior to the polymerization. Additionally, it has been discovered that using tin IV chloride as an initiator, the polymerization can be initiated at ambient or higher temperatures without resulting in uncontrolled polymerization. Examples 1 through 4 and the data in Tables I through IV demonstrate the superiority of the inventive process using tin IV chloride as a polymerization initiator. EXAMPLE 1 A series of polymerizations were run using unpurified plant grade α-methylstyrene monomer and tin IV chloride as a polymerization initiator. Typical plant grade α-methylstyrene contains approximately 700 to 900 ppm of 3-MCP. All polymerizations were run using a 75% by weight solution of α-methylstyrene in toluene. The initiator was added at 0.20% by weight, based on the quantity of α-methylstyrene. The reaction time for each polymerization was three hours. Table I summarizes the data. All five reactions in Table I show a significant conversion the α-methylstyrene monomer to polymer. TABLE I Peak % Monomer Concentration Initial Exotherm Conversion of AMS Temperature Temperature Percent Percent Percent Based on Reaction weight % ° C. ° C. Polymer Oligomer Monomer recovered yield 1 75 30 31 87.5 10.7 1.8 32 2 75 20 21.5 88.8 7.8 3.35 67 3 75 20 29 63 36.5 0.84 80 4 75 20 30.2 59.2 40 0.25 80 5 75 10 13.4 85 11.7 3.29 78 EXAMPLE 2 A series of polymerizations were run using unpurified plant grade α-methylstyrene monomer and tin IV chloride as a polymerization initiator as in Example 1, except that the solvent used is cumene. Table II summarizes the data. All seven reactions in Table II show a significant conversion of the α-methylstyrene monomer to polymer. TABLE II Peak Concentration Initial Exotherm % Monomer of AMS Temperature Temperature Percent Percent Percent Conversion Based Reaction weight % ° C. ° C. Polymer Oligomer Monmomer on recovered yield 6 75 35 35 86.6 12.2 0.55 59.8 7 75 30 30.2 60 39.3 0.7 80 8 75 25 32 94.2 2.9 2.3 79 9 75 25 27 72 27.1 1.61 96 10 75 20 29 71.5 25.3 3.2 89 11 75 15 26 53 41.5 5.5 81 EXAMPLE 3 A series of comparative example polymerizations were run using unpurified plant grade α-methylstyrene monomer, as in examples 1 and 2, except that trityl tetrakis (pentafluorophenyl) borate, TFABA, was used as the polymerization initiator. All of the comparative examples here used a 25% by weight solution of α-methylstyrene in hexane. The TFABA was added at 0.00156 to 0.0156% by weight based on α-methylstyrene. The reaction time allowed in each comparative example was 60 minutes. Table III summarizes the data. All seven reactions in Table III show zero conversion of the α-methylstyrene monomer to polymer. TABLE III Peak Initial Exotherm % Monomer Temperature Temperature Conversion Based on Reaction ° C. ° C. recovered yield 12 −8.5 −8.5 0 13 −8.5 −8.5 0 14 −8.5 −8.5 0 15 −8.5 −8.5 0 16 −8.5 −8.5 0 17 −8.5 −8.5 0 18 −8.5 −8.5 0 EXAMPLE 4 A final series of comparative example polymerizations were run with α-methylstyrene monomer that was purified by pre-treatment with acidic alumina. Pre-treatment with acidic alumina decreases the 3-MCP content to approximately 5 ppm. All of the comparative examples here used either a 20 or 43.3% by weight solution of α-methylstyrene in toluene. The TFABA was added at 0.0039% by weight based on α-methylstyrene. Table IV summarizes the data. All six reactions in Table IV show almost complete conversion of the α-methylstyrene monomer. TABLE IV Peak Concentration Initial Exotherm % Monomer of AMS Temperature Temperature Percent Percent Percent Conversion Based Reaction weight % ° C. ° C. Polymer Oligomer Monmomer on recovered yield 19 43.3 25 103.5 20 80 0 100 20 43.3 10 85.9 30 68.5 1.5 98.5 21 43.3 0 63.3 40 54 6 94 22 20 20 48.3 9 89 1 99 23 20 10 39.2 20 79.6 0.4 99.6 24 20 0 18.6 50 49.8 0.2 99.8 Comparative Examples 3 and 4 demonstrate the deleterious effects of 3-MCP and other oxygenated impurities on TFABA as a polymerization initiator for the polymerization of α-methylstyrene. Additional trials run using trityl-pentachlorostannate, t-SnCl 5 , demonstrated a similar effect of these impurities in retarding polymerization of α-methylstyrene. Conversely, Examples 1 and 2 demonstrate that efficient conversion of α-methylstyrene monomer to poly α-methylstyrene can be obtained even without pre-treatment of the monomer feed stream to remove 3-MCP and other oxygenated impurities. Additionally, it can be seen by comparing the data in Tables I and II with Table IV, that using tin IV chloride as the polymerization initiator results in a much milder exotherm and a higher proportion of polymer relative to oligomer than TFABA, even using much more concentrated solutions of α-methylstyrene or in neat monomer. This indicates that the polymerization is much more controlled than with TFABA. The process of the current invention offers clear advantages over current art methods in that it does not require the use of extreme sub-zero temperatures and avoids the use of environmentally unfavorable solvents. The process is run efficiently at ambient temperature in solvents commonly available in facilities producing AMS monomer or even neat. Further, the process is capable of being run at high weight concentrations of the AMS monomer with an economical amount of initiator. Further, the polymerization can be controlled to minimize reaction exotherm, reducing costs, production time and simplifying product handling. Further, the use of tin IV chloride yields a significant amount of polymer relative to TFABA and other cationic initiators. Additionally, the process may be run with α-methylstyrene and one or more co-monomers including, but not limited to; propylene, ethylene, styrene, butadiene, acrylonitrile and methylmethacrylate to produce an α-methylstyrene co-polymer. The solvents and concentrations demonstrated in the examples are however, not to be considered limiting of the process. Those skilled in the art will recognize that the actual reaction conditions used may be adjusted to fit the manufacturing scale and equipment desired. All of these variations are considered to be within the scope of the present invention.
A process for producing polymers of α-methylstyrene uses tin IV chloride as a polymerization initiator. Use of tin IV chloride as an initiator allows polymerization to proceed without purification of the monomer prior to processing. Polymerization can be carried out at ambient temperatures with mild exotherms and good polymer yields. The process uses solvents commonly found in a plant producing α-methylstyrene.
2
CROSS-REFERENCE TO RELATED APPLICATION AND CLAIM OF PRIORITY [0001] The present application is related to and claims priority from and the benefit under 35 U.S.C. §119(a) of Korean Patent Application No. 10-2013-0105175, filed on Sep. 3, 2013, which is hereby incorporated by reference for all purposes as if fully set forth herein. TECHNICAL FIELD [0002] The present disclosure relates generally to a dual monitor system and method, and more particularly to a dual monitor system and method using a terminal including a touch screen and a computing device including a screen. BACKGROUND [0003] Electronic devices including recently developed computers can provide users with various functions by executing application programs through processors. As various application programs have been developed and specifications of electronic devices have been improved, the electronic device can simultaneously perform several tasks and connect a main body of the electronic device to two or more screens to meet a multitasking environment, so as to support a dual monitoring mode in which respective task environments are displayed. [0004] Meanwhile, various terminals are used as electronic devices which can be carried by users today. According to the development of technologies, the electronic devices in a comprehensive multimedia device type having complex functions such as not only a voice call but also a video call, taking a picture or a video, reproducing music and a video file, receiving a broadcast, playing a game and wireless Internet and the like are released. Specifications of a processor installed in the terminal are being improved at an alarming rate and terminals which provide light and large screens within a portable range are being developed. Further, a terminal including a touch screen is currently provided to increase the interface convenience of the user. [0005] A portable terminal and a computing device provided to process various tasks in a fixed location may provide the user with different functions as necessary. Accordingly, the user may require simultaneously use of the terminal and the computing device, but it is inconvenient for the user to separately control the terminal and the computing device. [0006] Therefore, a method of supporting a dual monitoring mode of the computing device through interworking between the terminal and the computing device and also executing a function of the terminal is required. SUMMARY [0007] A method for dual screen presentation, using a touch screen of a terminal and a screen of a computing device includes recognizing a connection between the mobile terminal and the computing device, detecting an application program window moving into a scope of a screen of the mobile terminal from a scope of a screen of the computing device, and displaying the application program window on a touch screen of the mobile terminal. [0008] In some embodiments, the method further includes detecting a pointer moving from the scope of the screen of the mobile terminal onto the scope of the screen of the computing device; and transmitting the pointer to the computing device, where the screen of the computing device displays the pointer. [0009] In some embodiments, the method further includes moving a user interface of the mobile terminal onto the screen of the computing device. [0010] In some embodiments, a function of the mobile terminal is provided through the user interface of the terminal which is copied to the screen of the computing device. [0011] In some embodiments, the terminal is attached to one side of the screen of the computing device. [0012] In some embodiments, when the connection between the terminal and the computing device is recognized, functions of the computing device and the terminal are controlled by a user input means of the computing device. [0013] In some embodiments, moving the predetermined application program window comprises, when the predetermined application program window is moved in a preset direction by a predetermined distance or more, moving the predetermined application program window to the touch screen of the terminal from the screen of the computing device. [0014] In some embodiments, the method further includes moving the user interface of the terminal which is copied to the screen of the computing device to the touch screen of the terminal in response to the user input. [0015] In some embodiments, the moving of the user interface comprises, when an application program window executed by the computing device exists on the touch screen of the terminal, blocking movement of the copied user interface to the touch screen of the terminal. [0016] In some embodiments, when the user interface of the terminal which is copied to the screen of the computing device is moved to the touch screen of the terminal in response to the user input, an application program window, which is executed on the touch screen of the terminal by the computing device, is generated on the screen of the computing device. [0017] A mobile terminal includes a transceiver configured to communicate data with a computing device, a touch screen configured to display an image or a video, and a controller configured to detect an application program window moving into a scope of a screen of the mobile terminal from a scope of a screen of the computing device, and cause the touch screen to display the application program window. [0018] A computing device for dual screen presentation includes a transceiver configured to communicate data with a mobile terminal, a screen configured to display an image or a video, and a controller configured to receive a user interface of the mobile terminal from the mobile screen, and cause the screen to display the user interface. [0019] Before undertaking the DETAILED DESCRIPTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases. BRIEF DESCRIPTION OF THE DRAWINGS [0020] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts: [0021] FIGS. 1A and 1B illustrate a dual monitoring system according to an embodiment of the present disclosure; [0022] FIG. 2 illustrates a detailed embodiment of the terminal of FIGS. 1A and 1B ; [0023] FIG. 3 illustrates a detailed embodiment of the computing device of FIGS. 1A and 1B ; [0024] FIGS. 4A to 4C illustrate a method in which a dual monitoring system switches a dual monitor mode according to an embodiment of the present disclosure; [0025] FIG. 5A illustrates an example of a dual monitor system in a single monitor mode according to an embodiment of the present disclosure; [0026] FIG. 5B illustrates an example of a dual monitor system in a dual monitor mode according to an embodiment of the present disclosure; [0027] FIGS. 6A to 6C illustrate a method in which a dual monitor system ends a dual monitor mode according to an embodiment of the present disclosure; and [0028] FIG. 7 is a flowchart illustrating a dual monitor method according to an embodiment of the present disclosure. DETAILED DESCRIPTION [0029] FIGURES 1 A through 7 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged electronic devices. Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the accompanying drawings. It is noted that, where possible, the same reference numerals are designated to the same components in the accompanying drawings. Further, a detailed description of a known function and configuration which may make the subject matter of the present disclosure unclear will be omitted. [0030] Prior to the detailed description through embodiments, a computing device described in the specification and drawings may include all electronic devices which provide a user with various functions by executing application programs through a process stored in a memory. [0031] A “dual monitor mode” used in the specification and drawings refers to a case where a task environment of an application program executed by the computing device is implemented on not only a screen of the computing device but also a touch screen of a terminal connected to the computing device. That is, the “dual monitor mode” refers to a case where the touch screen of the terminal operates as an additional screen of the computing device. [0032] A “single monitor mode” described in the specification and drawings refers to a case where functions of the terminal and the computing device executed by corresponding processors are independently displayed on respective screens in a state where the terminal and the computing device are connected to each other. That is, the “single monitor mode” refers to a case where a task environment of the terminal is implemented on the touch screen of the terminal and a task environment of the computing device is implemented on the screen of the computing device. [0033] FIGS. 1A and 1B illustrate a dual monitor system according to an embodiment of the present disclosure. [0034] The dual monitor system includes a terminal 100 and a computing device 200 as illustrated in FIGS. 1A and 1B . The terminal 100 can include a touch screen and display a user interface on the touch screen. The computing device 200 can include a screen and display an application program window executed by the computing device on the screen. The terminal 100 and the computing device 200 are executed by processors stored in respective memories thereof. [0035] A dual monitor system connects the terminal 100 and the computing device 200 to allow the terminal 100 and the computing device 200 to exchange signals. The terminal 100 and the computing device 200 can be connected to each other through a wire or wirelessly connected to each other by using a wireless network. Meanwhile, a connection device 300 a for connecting one side of the terminal 100 and one side of the screen of the computing device 200 can be further included as illustrated in FIG. 1A , or a connection device 300 b for fixing the terminal 100 and connecting the terminal 100 to the computing device 200 can be further included for convenience of the user. Embodiments of the present disclosure include all methods of disposing the terminal 100 and the computing device 200 such that the user can have secured view for the touch screen of the terminal 100 and the screen of the computing device 200 can be secured. [0036] FIG. 2 illustrates a detailed embodiment of the terminal 100 according to an embodiment of the present disclosure. [0037] The terminal 100 can include a processor 210 , a touch screen 220 , and an input/output unit 230 . The processor 210 can control general operations of the terminal 100 . That is, the processor 210 can perform a function of providing a user interface to the touch screen 220 , receiving a user input through the user interface, and executing a corresponding application program. The processor can receive a user input through the touch screen 220 and also receive a user input through the input/output unit 230 . [0038] The touch screen 220 can receive a touch input by the user and also receive an output signal from the processor 210 or the input/output unit 230 and display an output screen. That is, the touch screen 220 can display a user interface and an executed application program and the displayed user interface and application program can be intuitively controlled by a touch input on the touch screen 220 by the user. [0039] The input/output unit 230 is provided to connect the terminal 100 and an external device, for example, the computing device 200 . When the input/output unit 230 is connected to the computing device 200 , an output signal of the processor 210 can be transmitted to the screen of the computing device 200 , a user input signal by the computing device 200 can be transmitted to the processor 210 of the terminal 100 , and an output signal of the computing device 200 can be transmitted to the touch screen 230 of the terminal 100 . [0040] The dual monitor system according to the embodiment of the present disclosure can include a dual monitor controller 400 for operating the terminal 100 and the computing device 200 in a dual monitor mode. The dual monitor controller 400 is connected to the terminal 100 and the computing device 200 to control switching to the dual monitor mode or the single monitor mode. At this time, the dual monitor controller 400 can be located outside the terminal 100 as illustrated in FIG. 2 , but can be located inside the terminal 100 . A dual monitor controller 400 which will be described below can be located inside the computing device 200 . That is, the dual monitor controller 400 should be interpreted based on the function of the configuration rather than an arrangement of the configuration in the present disclosure. [0041] FIG. 3 illustrates a detailed embodiment of the computing device 200 according to an embodiment of the present disclosure. [0042] The computing device 200 can include a main body 310 and peripherals 320 to 340 . The main body can include a processor 311 for controlling general operations of the computing device 200 and an input/output unit 312 provided to connect the peripherals 320 to 340 and the terminal 100 . [0043] A screen 320 , a keyboard 330 , and a mouse 340 transmit/receive signals through the input/output unit 312 . The screen 320 can receive an output signal of the processor 311 and an output signal of the terminal 100 through the input/output unit 312 and display an output screen. The keyboard 330 and the mouse 340 are user input means and input signals input by the keyboard 330 and the mouse 340 can be transmitted to the processor 311 and the terminal 100 through the input/output unit 312 . [0044] The dual monitor controller 400 is connected to the terminal 100 and the computing device 200 to control switching to the dual monitor mode or the single monitor mode. The dual monitor controller 440 can be located outside or inside the computing device 200 as described above. [0045] FIGS. 4A to 4C illustrate that a dual monitor system operates in the dual monitor mode according to an embodiment of the present disclosure. Referring to FIG. 4A , the terminal 100 and the computing device 200 are connected through a wire or wirelessly, using any suitable communication technologies including cellular, Wifi, Bluetooth, and Near Field Technologies (NFC). In some embodiments, the terminal 100 and the computing device 200 are attached to each other by a connection device 300 . [0046] Each of the terminal 100 and the computing device 200 operates in the single monitor mode. The terminal 100 displays a user interface 410 a on the touch screen. The computing device 200 displays one or more application program windows 420 a and 430 a being executed on the screen. [0047] Thereafter, as illustrated in FIG. 4B , the application program window 420 a displayed on the screen of the computing device 200 is dragged using a mouse connected to the computing device 200 and moved in a direction in which the terminal 100 is located by a predetermined distance. At this time, the direction in which the terminal 100 is located can be preset by the user. When the application program window 420 a is dragged by a threshold or more, switching to the dual monitor mode is made as illustrated in FIG. 4C . That is, the dragged application program window 420 disappears from the screen of the computing device 200 and the application program window 420 b is generated on the touch screen of the terminal 100 . That is, the touch screen of the terminal 100 operates as one of a dual screen of the computing device 200 . Meanwhile, a user interface 410 b of the terminal 100 is copied to the screen of the computing device 200 . Accordingly, even in the dual monitor mode, the user can execute a function of the terminal 100 through the user interface 410 b of the terminal 100 copied to the screen of the computing device 200 . [0048] Referring to FIG. 5A , when the dual monitor system is in the single monitor mode, a mouse cursor 500 can move on the screen of the computing device 200 and the touch screen of the terminal 100 through a control of the mouse by the user. That is, in the single monitor mode, through a mouse and a keyboard corresponding to input means connected to the computing device 200 , a function of the terminal 100 can be executed on the screen of the terminal 100 or a function of the computing device 200 can be executed on the screen of the computing device 200 . [0049] Referring to FIG. 5B , when the dual monitor system is in the dual monitor mode, the touch screen of the terminal 100 operates as one of the dual screen of the computing device 200 . That is, the mouse cursor 500 can move on the touch screen of the terminal 100 as well as on the screen of the computing device 200 , so as to control the application program window executed by the computing device 200 . Further, the user interface 410 b of the terminal 100 is copied to the screen of the computing device 200 . The user can execute the function of the terminal 100 through the copied user interface 410 b. That is, in the dual monitor mode, through the mouse and the keyboard corresponding to the input means connected to the computing device 200 , the application program window executed by the computing device 200 can be controlled on both the touch screen of the terminal and the screen of the computing device 200 and the function of the terminal 100 can be executed on the copied user interface 410 b. [0050] Meanwhile, according to an embodiment of the present disclosure, since the terminal 100 and the computing device 200 are connected to each other, a file displayed on the touch screen of the terminal 100 can be copied to the computing device 200 by dragging the file through a mouse cursor 500 and a file displayed on the screen of the computing device 200 can be copied to the terminal 100 by dragging the file. [0051] FIGS. 6A to 6C illustrate a method in which a dual monitor system ends a dual monitor mode according to an embodiment of the present disclosure. [0052] Referring to FIG. 6A , the dual monitor system is in a state where the dual monitor mode is operated. That is, the terminal 100 is connected to the computing device 200 and the touch screen of the terminal 100 operates as one of the dual screen of the computing device 200 . The user interface 410 b of the terminal 100 is copied to the screen of the computing device 200 . [0053] Thereafter, as illustrated in FIG. 6B , the user interface 410 b of the terminal 100 copied to the screen of the computing device 200 is moved to the terminal 100 . For example, the copied user interface 410 b can be dragged using a mouse. Since the touch screen of the terminal 100 and the screen of the computing device 200 operate in the dual monitor mode, the copied user interface 410 b can be moved to the touch screen of the terminal 100 according to the drag. According to an embodiment, only when an application program window executed by the computing device 200 does not exist on the touch screen of the terminal 100 , the movement of the copied user interface 410 to the touch screen of the terminal 100 is allowed. That is, when the touch screen of the terminal 100 displays a function actually executed by the computing device 200 in the dual monitor mode, it can be preset to not end the dual monitor mode. [0054] Alternatively, according to another embodiment, when an application program window executed by the computing device 200 is displayed on the touch screen of the terminal 100 , if the copied user interface 410 is moved to the touch screen of the terminal 100 , the corresponding application program window can be displayed on the screen of the computing device 200 . [0055] As illustrated in FIG. 6C , when the user interface 410 a reaches the terminal 100 , the dual monitor mode ends. That is, each of the touch screen of the terminal 100 and the screen of the computing device 200 operates in the single monitor mode. [0056] FIG. 7 is a flowchart illustrating a dual monitor method according to an embodiment of the present disclosure. [0057] The dual monitor method illustrated in FIG. 7 will be described below with reference to FIGS. 4 and 6 . [0058] First, the terminal 100 and the computing device 200 are connected to each other in step S 710 . Each of the connected terminal 100 and computing device 200 performs a task in the single monitor mode in step S 720 . That is, the terminal 100 provides a user interface through the touch screen of the terminal 100 and the computing device 200 provides an application program window through the screen of the computing device 200 . [0059] In step S 730 , the terminal 100 and the computing device 200 are switched to the dual monitor mode. Specifically, when the application program window 420 a displayed on the screen of the computing device 200 is moved to the touch screen of the terminal 100 in step S 731 , the user interface 410 b of the terminal 100 is copied to the screen of the computing device 200 in step S 732 . Thereafter, in step S 740 , the terminal 100 and the computing device 200 perform tasks in the dual monitoring mode. [0060] In step S 750 , the terminal 100 and the computing device 200 end the dual monitor mode. Specifically, the user interface 410 b copied to the screen of the computing device 200 is moved to the touch screen of the terminal 100 . Thereafter, in step S 760 , the terminal 100 and the computing device 200 perform tasks in the single monitor mode. [0061] Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims.
A method for dual screen presentation, using a touch screen of a terminal and a screen of a computing device includes recognizing a connection between the mobile terminal and the computing device, detecting an application program window moving into a scope of a screen of the mobile terminal from a scope of a screen of the computing device, and displaying the application program window on a touch screen of the mobile terminal. A mobile terminal includes a transceiver configured to communicate data with a computing device, a touch screen configured to display an image or a video, and a controller configured to detect an application program window moving into a scope of a screen of the mobile terminal from a scope of a screen of the computing device, and cause the touch screen to display the application program window. Other embodiments including a computing device are also disclosed.
6
BACKGROUND OF THE INVENTION This invention relates to a modular bus seat construction. In particular this invention is directed to school bus seats. Specifically, this invention relates to a new bus seat construction or to a retrofit of an existing bus seat. This new inventive bus seat is comprised of a front modular portion, a rear modular portion, a collar portion and a seat portion. The front, rear and seat portions are comprised of wood and a elastomer skinned urethane foam. The elastomer skinned urethane foam is adhered to the plywood. The collar portion is comprised of an elastomer skinned urethane foam. The front modular portion, the rear modular portion, and the collar portion comprise the bus seat back. Existing school bus seats are comprised of a metal frame and a plywood superstructure. In particular, for the bus seat back the plywood is inserted into the metal frame and it is maintained in place by means of the plywood being crimped into position within a channel. In regard to the bus seat, plywood is affixed to the metal frame by hinge and locking means. A rebonded foam is used on the existing school bus seats. A vinyl is stretched over the rebonded foam and is sewn together. One deficiency of the existing school bus seat is that the vinyl which is stretched over the rebonded foam is easily torn. Vandalism on school buses is quite common. The usual site of the vandalism is on the rear of the bus seat. SUMMARY OF THE INVENTION The present invention relates to a bus seat which is comprised of a front modular portion, a rear modular portion, collar portion, and a seat portion. The front modular portion comprises a first piece of plywood which has adhered to it an elastomer skinned urethane foam. The front modular portion is manufactured by coating the inside of a mold with a spray elastomer. A piece of plywood is then inserted into the mold. The mold is next injected with a urethane foam which adheres to the plywood and to the sprayed on elastomer such that the wood-urethane foam-elastomer skin becomes a single integral construction. The same process is used to manufacture the rear and seat modular portions of the present invention. In a similar fashion, the collar portion is of an integral construction although the collar portion does not have a plywood or a wood superstructure. In particular, the present invention is designed primarily, although not exclusively, to meet the needs of retrofitting existing school bus seats. The existing school bus seats are inadequate such that the materials they are manufactured from, to wit, a vinyl which is sewn and stretched over a rebonded foam, is easily torn by vandals. Additionally, in the case of the existing school bus seats, the entire seat back or seat needs to be repaired when a section thereof has been vandalized. For instance, if a vandal rips the back of a bus seat back, the entire vinyl covering must be removed and repaired or replaced. The present invention provides an integrally bonded elastomer skinned urethane foam plywood structure. The elastomer skin of the present invention can be made in different thicknesses; therefore, if a thicker surface is desired on the back side of the bus seat back which is typically the case, such a thickness can be easily provided. It is an object of the present invention to provide a bus seat of modular construction. Specifically, the bus seat of the present invention comprises a front modular portion, a rear modular portion, a collar portion, and a seat portion. It is an object of the present invention to provide a modular bus seat which may be used to replace existing bus seats. This is accomplished through the simple removal of the existing plywood used in the school bus seat. It is then replaced with the appropriate modular portion of the present invention. The rear modular portion of the bus seat back is affixed to the front modular portion. The seat modular portion is affixed to the bus seat frame. The collar portion generally surrounds the existing metal frame of the bus seat back and is affixed to the front modular portion of the bus seat. It is an object of the present invention to provide a modular bus seat which enables the replacement of one portion of the bus seat at a time. For instance, the present invention permits replacement of the back or rear modular portion of the bus seat back through the simple disconnection of the rear modular portion by means of loosening a few bolts. It is an object of the present invention to provide a school bus seat which is durable. In particular, the present invention provides a school bus seat having an elastomer skinned surface which is durable and which may be of varying thicknesses in various places. It is an object of the present invention to provide a process for retrofitting existing school bus seats which comprise the steps of removing existing plywood from the existing bus seat frame, spraying a mold with an elastomer spray, inserting a piece of wood into the mold, and then injecting the mold with the urethane foam which bonds to the wood and integrally forms an elastomeric skin thereon, and then finally by inserting the wood with the elastomer skinned urethane foam adhered thereto into engagement with the bus seat frame. These and other objects of the invention will be best understood in connection with the brief description of the drawings and the description of the preferred embodiment and claims which follow. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is front perspective view of the modular bus seat back of the invention; FIG. 2 is a front perspective view of an existing bus seat back frame illustrating a metal frame and a single piece of plywood; FIG. 3 is a perspective view of the modular bus seat of the present invention illustrating the front modular portion, the bus seat back frame, the collar and the rear modular portion; FIG. 4 is a rear view with parts broken away of the modular bus seat illustrating the bus seat back frame, the front and rear pieces of plywood and the collar; FIG. 5 is an enlarged cross-sectional view of the modular bus seat back taken along the lines 5--5 of FIG. 1. FIG. 5 illustrates the front modular portion, the rear modular portion, the collar portion and the bus seat frame. FIG. 5 also illustrates the elastomer skinned urethane foam adhered to the front and rear pieces of plywood. FIG. 5 also illustrates the tongue of the collar portion within the front and rear modular portions of the bus seat back. FIG. 5 also illustrates the contour of the rear modular portion of the bus seat; FIG. 6 is a further enlarged cross-sectional view taken along the lines 6--6 of FIG. 1. FIG. 6 illustrates the connection of the first and second pieces of wood and the connection of the first piece of wood to the metal frame; FIG. 7 is a block diagram of the retrofitting steps; FIG. 8 is a front perspective view of the bus seat back and the bus seat of the present invention; FIG. 9 is a cross-sectional view of the bus seat and the bus seat back taken along the lines 9--9 of FIG. 8; FIG. 10 is a partial cross-sectional view of the bus seat taken along the lines 10--10 of FIG. 9; and FIG. 11 is a cross-sectional view of the bus seat taken along the lines 11--11 of FIG. 9. DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 is a front perspective view of the modular bus seat back of the present invention. FIG. 1 illustrates the front view of the modular bus seat back 69 and as can be seen from FIG. 1, the front of the bus seat is substantially planar. The front surface 27 of the collar 1 is substantially in the same plane as the front surface 29 of the front modular portion 2. The rear exterior surface 28 of collar 1 is contoured. See, FIG. 6. Additionally from FIG. 6 it can be seen that the collar 1 includes flexible urethane foam 8 within an integrally bonded elastomer skin 1'. From FIG. 6 it can be seen that there is more urethane foam 8 rearwardly than forwardly. Reference numeral 2 refers to the front modular portion of the invention. The front modular portion 2 includes an integrally bonded elastomer skin 2'. The collar portion 1 similarly includes an integrally bonded elastomeric skin 1' thereon. FIG. 1 also illustrates the front plywood 3 extending across and beyond the breadth or width of the front modular portion 2. It will be understood by those skilled in the art that the present invention is not limited to the use of a specific kind or type of wood. FIG. 1 partially illustrates the existing superstructure of today's bus seat backs. In particular, the superstructure or frame of the existing bus seats is comprised of a tubular structure 4 which is additionally supported with a rectangular channel 5. FIG. 2 illustrates the existing superstructure 68 of a school bus seat back. FIG. 2 illustrates the tubular structure 4 which goes all the way up and down the sides of the school bus seat and across the top. FIG. 2 also illustrates the rectangular channel 5 which extends approximately midway up the tubular support. Also shown in FIG. 2 is the channel 6 which secures the plywood in place. The plywood 26 illustrated in FIG. 2 is held in place within the channel 6 by means of crimps 30 and connector 10. In the retrofitting process the crimps are simply removed by drilling or boring a hole at the location of the crimp. This allows the plywood 26 to be removed by sliding it out of the channel in a downward direction. The various frame components, to wit, the tubular support 4, the rectangular channel 5 and the plywood channel 6 are tack welded together. The existing superstructure 68 of the school bus seat back is used in the present invention provided, of course, it has not been damaged. The existing superstructure 68 also supports the modular seat portion 80 as shown in FIGS. 8, 9, 10 and 11. FIG. 3 is a perspective view of the modular bus seat back of the present invention illustrating the assembly of the front modular portion, the frame, the rear modular portion, and the collar. FIG. 3 illustrates the front plywood 3 positioned to be assembled into the metal frame superstructure 68. The plywood slides into channel 6 and is bolted in place. The rear modular portion 14 is then affixed to the front modular portion 2 by means of connector 12. Collar 1 is then affixed to the front plywood by means of connector 11. In the preferred embodiment the connectors are screws and sockets. However, those skilled in the art will recognize that there are a plurality of fastening mechanisms available to affix the various modular portions of the invention together. FIG. 4 is a rear view of the present invention. FIG. 4 illustrates the front piece of plywood 3 and the rear piece of plywood 7. It can be seen from FIG. 4 that the front piece of plywood 3 extends upwardly into the channel 6. The plywood is held in place by connector 10. FIG. 4 also illustrates the rear plywood 7 connected to the front plywood 3 by means of connector 12. In the preferred embodiment, the connector 12 is simply a screw and a socket. Also, see FIG. 6 which illustrates connectors 10, 11 and 12. FIG. 4 also illustrates the upward extent of the first piece of plywood 3. The first piece of plywood 3 extends upwardly in the vicinity of the tubular support 4. However, it will be seen from FIG. 4 that the plywood 3 does not extend quite up to the tubular support 4. Rather, it terminates before the support 4 leaving a gap 18 between the tubular support 4 and the plywood 3. The collar 1 includes a tongue shaped portion 9. This is best viewed in FIGS. 5 and 6. The tongue shaped portion is also indicated in FIG. 4 and it will be seen from FIG. 4 that the tongue shaped portion is affixed to the first piece of plywood by means of connector 11. Connector 11 is a screw and socket arrangement as can best be seen in FIG. 6. The tongue shaped portion 9 extends around the interior of the collar as can be seen in FIGS. 3 and 4. FIG. 4 also illustrates tack welds 23 and 24 for affixing the tubular support 4 to the rectangular support 5 and the rectangular support 5 to the channel 6. FIG. 4 also illustrates the first beveled surface 16 on the rear modular portion 14 and the second beveled surface 17 on the rear modular portion 14. This rear modular portion 14 of the present invention is beveled so as to accommodate room for students' legs sitting in the seat behind the present seat being discussed. FIG. 4 shows the rear modular portion 14 and also the integral skin 14'. The rear modular portion 14 is affixed to the front plywood by means of connector 12. The front piece of plywood 3 and the rear piece of plywood 7 are alternatively referred to herein as the front substrate or first piece of plywood or the second substrate or second piece of plywood. Connector 12 affixes the rear plywood module 14 to the front plywood module 3. FIG. 6 illustrates the screw and receptacle which comprises the connector 12. Various connectors designated by the reference numerals 10, 11 and 12 are illustrated in FIG. 4. FIG. 5 is a cross-sectional view of the present invention taken along the lines 5--5 of FIG. 1. FIG. 5 illustrates the front modular portion 2 of the present invention. The front modular portion 2 is comprised of the front plywood 3, the urethane foam 2", and the elastomer skin 2'. It must be understood that the process and structure of the present invention enables the urethane foam to be bonded and secured directly to the front piece of plywood 3. It must be understood that the elastomer skin 2' is bonded directly to the urethane foam 2". The structure is a one piece structure such that the plywood, urethane foam, and the elastomer skin are one piece and are not separable. FIG. 5 also illustrates the rear modular portion 14. In a similar fashion, the rear modular portion 14 is comprised of the rear plywood 7, the urethane foam 14" and the elastomer skin 14'. The rear module is of one piece construction, the plywood-urethane foam-elastomer skin being a single unit. Reference numeral 19 indicates the interface between the front plywood 3 and the urethane foam 2". The reference numeral 19' indicates the bonding of the elastomer skin 2' to the urethane foam 2". In a similar fashion, the reference numeral 20 indicates the attachment and bonding of the urethane foam 14" to the rear plywood 7. Reference numeral 20' indicates the attachment of the elastomer skin 14' to the urethane foam 14". Similarly, in FIG. 5, reference numeral 21 indicates the bonding and adherence of the integral skin 1' to the urethane foam 1". FIG. 5 illustrates a good view of the tongue portion 9 of the collar 1. It can be seen from FIG. 5 that the tongue 9 extends downwardly along the first piece of plywood and into the front 2 and rear modular 14 portions of the invention. The collar 1, however, is primarily affixed to the first piece of plywood by means of connectors 11 as best seen in FIG. 4. FIG. 5 also illustrates the tubular support 4 and the channel 5 as previously discussed. FIG. 5 also illustrates the first beveled portion 16 of the rear modular portion of the invention and the second beveled portion 17 of the rear modular portion 14 of the invention. FIG. 5 also illustrates a gap 18 between the front piece of plywood 3 and the tubular support 4. FIG. 6 is a cross-sectional view taken along the lines 6--6 of FIG. 1. FIG. 6 illustrates the collar 1 and the front modular portion 2 and the rear modular portion 14 connected together. FIG. 6 illustrates the simplicity of removing and repairing the rear modular portion 14 when necessary. Access holes 15 permit easy disconnection of the rear modular portion 14 from the front modular portion 2. It is anticipated, however, that the present invention will obviate the need for repairing or replacing bus seats with any frequency. This is due to the unique construction of the elastomer skin surfaces and their integral construction with the urethane foam and their respective plywood pieces. It can be seen, however, that if for some reason the rear modular portion 14 of the bus seat would have to be replaced, it can easily be done so through loosening the screws 12 and disconnecting the rear modular portion 12 from the front modular portion 2. Similarly from a review of FIG. 4, it can be seen that if it is desired that the collar can be removed or replaced by removing the screws from connector 11. To remove the collar 1, the rear modular portion 14 can be bent back by hand to access connectors 11 which secure the collar 1 to the front plywood 3. Reference numeral 71 as illustrated in FIG. 6 is a point where the rear modular portion 14 can be pulled back to access connectors 11. If it becomes necessary to remove the front modular portion 2 of the invention, it is necessary to remove the connectors 10 which release the first (front) piece of plywood 3. However, it is not anticipated that the first piece of plywood or that the front modular portion of the present invention will be replaced with a high frequency. The front, rear and seat modular portions of the present invention are manufactured by molding the plywood, the urethane foam, and the elastomer skin into a single piece. The mold is manufactured in the shape of the desired front module, rear module or the collar. The mold is a chamber. The chamber is sprayed with an elastomer spray. The thickness of the elastomer spray determines the thickness of the elastomer skin on the integral modular portion obtained from the molding process. The mold is first sprayed interiorally and then the plywood is inserted therein. Next, the mold is charged with the urethane foam. The urethane foam bonds directly to the plywood and to the elastomer skin. The mold is then separated and the modular portion is thus obtained. This process yields a unified construction having plywood, urethane foam and an elastomer skin. The exact same process for molding the collar is followed; the elastomer skin is formed by the spraying of the interior of the mold with the elastomer spray. In the case of the collar 1 no plywood is used. However, another material is inserted into the mold which does not adhere to the urethane foam so as to form a void 31 in the collar so that it may be used as indicated in the drawing figures. FIG. 7 illustrates in diagrammatic form the molding process. In particular, FIG. 7 illustrates the mold schematically, the spraying (coating) of the mold, the insertion of the plywood or wood into the mold, and the injection of the urethane foam into the mold. In addition, the process is identical in the case of the formation of the collar with the exception that a material is used which does not adhere to the urethane foam so as to form the void 31. FIG. 8 is a front perspective view of the bus seat module 80 and the bus seat back 69. FIG. 9 is a cross-sectional view of the bus seat module 80 and the back 69. Bus seat module 80 includes a third piece of plywood 83 and an elastomer skinned urethane foam bonded thereto. The seat module 80 is molded by the same process as the rear 14 and front 2 modules are molded. Reference numeral 81 represents the elastomer skin bonded to the urethane foam 82. FIG. 9 illustrates a void 85 between the elastomer skinned urethane foam 82 and plywood 83. A latch mechanism 84, known in the art, is employed to restrain the seat module 80 in place. Latch mechanism 84 engages a tubular portion 68' of the metal frame superstructure 68. FIG. 1 also illustrates the tubular portion 68' of the metal frame superstructure 68. FIG. 9 illustrates that the third piece of plywood 83, alternatively referred to herein as the bottom piece of plywood or the bottom substrate, is hinged by means of hinge 86 to the superstructure 68 enabling the seat module 80 to be rotated upwardly for cleaning beneath the seat. Reference numeral 87 signifies the cohesion of the urethane foam 82 to the elastomer skin 81. Similarly, reference numeral 88 signifies the cohesion of the urethane foam to the third piece of plywood 83. It will be observed from FIG. 9 that latch 84 is rotatably released to raise the bus seat module 80. FIG. 10 illustrates a partial cross-sectional view taken along the lines 10--10 of FIG. 9. FIGS. 10 and 11 are views taken along the aisle side of the bus seat. FIG. 10 is a cross-sectional view taken along the lines 10--10 of FIG. 9. FIG. 10 illustrates latch 84 positioned relatively closer to the aisle side 99 of the bus seat. See, FIG. 8 wherein reference numeral 99 denotes the aisle side of the bus seat. FIG. 11 is a cross-sectional view taken along the lines 11--11 of FIG. 9. FIG. 11 illustrates the relative positioning of the latch 84. FIG. 11 also illustrates the relative positioning of the latch 84. FIG. 11 also illustrates the void 85 and the integral bond 88 of the urethane foam 82 to the third piece of plywood 83. In the preferred embodiment the elastomer skin is formed by spraying an elastomeric polyurethane spray known as BAYTEC SPR-066A manufactured by Bayer Corporation, 100 Bayer Road, Pittsburgh, Pa. 15205-9741 on the mold surfaces. BAYTEC SPR-066A is a two-component system having an isocyanate component (modified diphenylmethane diisocyanate (MDI) prepolymer)) and a polyol component (polyether polyol blend). In the preferred embodiment the urethane foam employed is known as BAYFIT 566 manufactured by Bayer Inc., Mobay Road, Pittsburgh, Pa. 15205-9741. BAYFIT 566 foam is a two component system having a polymeric MDI (isocyanate component) and a polyol blend (resin) component. The invention has been described in detail with particular emphasis on the preferred embodiments thereof, but it should be understood that variations and modifications within the spirit and scope of the invention may occur to those skilled in the art to which the invention pertains.
A bus seat comprising a metal frame, a bus seat back and a bus seat; said bus seat back includes a front modular portion; a rear modular portion; and a collar portion; said front modular portion affixed to said metal frame; said rear modular portion affixed to said front modular portion; and said collar portion affixed to said front modular portion adjacent said front and rear modular portions. The bus seat is affixed to the metal frame. The modular construction of the bus seat back enables replacement of a specific section or sections of the bus seat. The bus seat back and bus seat can be used in retrofit installations or in new installations. The bus seat back and bus seat are constructed of an elastomer skinned urethane foam which adheres to front, rear and bottom pieces of plywood. The collar portion is constructed of the elastomer skinned urethane foam but does not include a plywood portion. The collar portion is affixed to the front plywood portion.
8
CROSS REFERENCE TO RELATED APPLICATIONS [0001] None STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not applicable THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT [0003] Not applicable INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC [0004] Not applicable BACKGROUND OF THE INVENTION [0005] The present invention relates generally to those surface mounted devices providing a means to releaseably secure items against a surface. [0006] A common problem faced when attempting to store bulky or heavy items against a vertical surface such as a wall by leaning is the tendency of these items to fall forward and away from the wall if not leant at a sufficient angle. Inevitably, this means that valuable floor space is wasted trying to get the item to “stay” against the wall. Most people don't have unlimited floor space to accommodate such waste. A typical example is the case of a ladder or bicycle leant against a garage wall. One solution has been to hang the item from a peg or hook mounted on the wall. However some of these items can be too bulky or heavy for many people to lift; this is especially the case with elderly or infirm persons. [0007] U.S. Pat. No. 3,664,163 to Foote, describes a base plate and tether for the securing of firearms, but the base plate has no swiveling capability. [0008] U.S. Pat. No. 4,826,193 to Davis, describes a base plate, bracket and straps as a wheelchair restraint, but the straps have no swiveling capability. [0009] U.S. Pat. No. 5,174,543 to Corson et al. describes a tip-over protection apparatus with wall mounted bracket and cord, but has no swiveling capability. [0010] U.S. Pat. No. 6,220,562 to Konkle, describes a furniture tipping restraint with wall mounted bracket and cord, but has no swiveling capability. [0011] U.S. Pat. No. 6,318,941 to Guenther, describes a fastening anchor assembly for fastening an object to a hollow wall, but provides a clamp as the object fastening means which limits the size and shapes of the objects to be retained. BRIEF SUMMARY OF THE INVENTION [0012] The present invention is a surface mountable retention system to releasably secure large, irregularly shaped or bulky items against a multiple surface types; for example drywall, masonry or wood as well as others. It enables a person to secure items tightly against a surface such as a wall or crate without having to lean the item, thus saving floor space and creating a safer environment. [0013] In one embodiment, the device consists of a single rotatable flanged face plate with a centered aperture through which a fastener such as a wood screw or hollow wall anchor is placed to affix the plate to a surface such as a wall or crate. [0014] The preferred as well as alternate embodiments share the common element of a rotatable flanged plate having at least two winged flanges opposing each other, each flange punctuated by a slit aperture. Once installed, a flexible strap of shear resistant material with a fastening means at its terminal ends such as male and female buckles, is threaded through the slit aperture such that the terminal ends may encircle an item and fasten together thus securing the item to the surface. [0015] In the preferred embodiment, the invention is an assembly of two principal plates, one having winged flanges, and another that is primarily flat having a centered aperture and a formed sleeve encircling the centered aperture. The two plates are held in place by a hub which is a flanged T-shaped bushing whereby both plates are independently rotatable about the axis provided by the bushing prior to being installed on a surface. [0016] In another embodiment, the second plate is generally planar having no raised sleeve, and the hub is a common cylindrical bushing press fit into place forming a lip at each end of the bushing sufficient to hold the two plates together yet allowing the plates to rotate independently around a common axis provided by the bushing. [0017] In yet another embodiment, the base plate has a resilient fastener formed into the body in place of the bushing and formed sleeve of the preferred embodiment so that the two plates may be pressed together and releasably reatained in position by the resilient fastener which allows the plates to rotate independently of each other. It is envisioned that the base plate of this embodiment will be secured to a surface by an adhesive such as 3M™ Foam Tapes. Thus the means to affix this embodiment differs from the other embodiments because no screw or drywall fastener is required. [0018] With the exception of the embodiment of the previous paragraph, the steps to install the surface mountable retention system are as follows: [0000] If affixing to a stud, or a wood surface, the assembled present invention is placed against the surface and a wood screw of sufficient length is placed through the centered aperture and screwed into the wooden surface thus holding the retention system in place. The plate assembly should fit snug against the wall while allowing the top plate to rotate 360 degrees. One unbuckled end of the flexible strap is then threaded through the slit apertures of the top plate, and an either a male or female buckle is cinched to the strap which is then joined to its mating portion being snapped around the item to be secured. [0019] If affixing to drywall with a typical hollow wall anchor, the expandable sleeve element of a hollow wall anchor is fitted first into the wall, followed by the plate assembly and then a threaded bolt element is passed through the centered aperture of the plate assembly and into the expandable sleeve element of the wall anchor. The plate assembly should fit snuggly against the wall while allowing the top plate to rotate 360 degrees. One unbuckled end of the flexible strap is then threaded through the slit apertures of the top plate, and an either a male or female buckle is cinched to the strap which is then joined to its mating portion being snapped around the item to be secured. [0020] If affixing to drywall with a toggle bolt, the bolt element of the toggle bolt is first passed through the centered aperture of the plate assembly and the toggle element affixed to its terminal end. The toggle element is them placed through a pre-drilled hole in the drywall and the bolt is tightened in the customary way. The plate assembly should fit snuggly against the wall while allowing the top plate to rotate 360 degrees. One unbuckled end of the flexible strap is then threaded through the slit apertures of the top plate, and an either a male or female buckle is cinched to the strap which is then joined to its mating portion being snapped around the item to be secured. [0021] One object of the present invention is to provide an easy means for the releasable retention of heavy or bulky items against a surface without the need to lift or hoist the item. [0022] Another object of the present invention is to provide an easy means for the releasable retention of irregularly shaped items by providing 360 degrees of attachment. [0023] A further object of the present invention is to provide a means to releaseably retain large items securely against a vertical surface such as a wall minimizing the required floor space. [0024] The applicant is not aware of any previously described art having the features and advantages of the present invention. [0025] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein by way of illustration and example, a preferred embodiment of the present invention is disclosed. BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS [0026] FIG. 1 is perspective view of one embodiment of the present invention with rotatable flanged face plate; [0027] FIG. 2 is an exploded view of the preferred embodiment showing T-shaped bushing and base plate element; [0028] FIG. 3 is a partial cut-away view of the stacked plate assembly of one alternate embodiment of the present invention; [0029] FIG. 4 is perspective view of the non-flanged bushing; [0030] FIG. 5 is perspective view of a non-flanged base plate; [0031] FIG. 6 is an edge view of the alternate embodiment of FIG. 3 fastened to a hollow wall by a toggle bolt and the flexible belt and buckle elements; [0032] FIG. 7 is an edge view of the assembled preferred embodiment of FIG. 2 fastened to a stud by a wood screw and the flexible belt and buckle elements; [0033] FIG. 8 is an exploded view of an alternate embodiment of present invention; [0034] FIG. 9 is an edge view of the assembled alternate embodiment of FIG. 8 and fastened to a surface by way of an adhesive strip; [0035] FIG. 10 plan view of the base plate of FIG. 8 with molded resilient bullet fastener DETAILED DESCRIPTION OF THE INVENTION [0036] FIG. 1 shows an exploded view of one embodiment of the present invention with a flanged face plate 10 having two winged flanges, each having a rectangular slit 20 , and a centered aperture 17 , and typical fastening means; in this case, a hollow wall anchor with a sleeve element 9 and screw 8 . In this embodiment, the flanged face plate 10 rotates 360 degrees once the entire assembly is affixed to a surface. Fastening straps with buckling means as shown in ( FIG. 6 ) are passed through the rectangular slits 20 , to encircle the object to be retained. [0037] FIG. 2 Shows an exploded view of the preferred embodiment of the present invention that uses a T-shaped bushing having an aperture 17 a there through, a capped flange 15 , a beveled countersunk recess 19 to accept the beveled head of a typical wood screw 8 . Assembly requires the area 14 below the capped flange 15 is seated into the aperture 17 b , and the integrally formed sleeve 17 c of base plate 12 is interiorly seated within the body of the T-shaped bushing. Once assembled, the T-shaped bushing acts as a hub around which the flanged face plate 10 and base plate 12 are seated and whereby the two plates may rotate 360 degrees relative to each other prior to the affixing of the present invention to a surface, after which, the flanged face plate 10 is rotatable and the base plate 12 is fixed against a surface and immobilized. [0038] FIG. 3 shows a partial cut away view of an alternate embodiment of the present invention where a planar base plate 12 a and flanged face plate 10 are held together by a non-flanged bushing that is situated within apertures of equal diameter 17 e , 17 d of the flanged face plate and the planar base respectively, which is press fitted during assembly so that a lip is formed at either end of the bushing to retain both plates together about a common axis. The flanged face plate rotates 360 degrees once the entire assembly is affixed to a surface. Fastening straps with buckling means as shown in ( FIG. 6 ) are passed through the rectangular slits 20 , and encircle an object to be retained. [0039] FIG. 4 shows the non-flanged bushing 21 of the embodiment of ( FIG. 3 ). [0040] FIG. 5 shows the planar base plate 12 a of the embodiment of ( FIG. 3 ). [0041] FIG. 6 is an edge view illustrating the alternate embodiment of ( FIG. 3 ) in typical use being affixed to a hollow wall surface. Visible is the strap 23 having at the respective ends a male and female buckle portion 24 , where the strap is meant to encircle a retained article. Although the edge view shows the flanged wings of the face plate 10 , it should be understood that flanged face plate 10 is fully rotatable about the axis provided by the press fit bushing 21 . [0042] FIG. 7 is an edge view illustrating the preferred embodiment of ( FIG. 2 ) in typical use being affixed to a hollow wall surface. Shown is strap 23 having at each terminal end a male or female buckle portion, where the strap is meant to encircle a retained article. Although the edge view shows the flanged wings of the face plate 10 , it should be understood that face plate 10 is rotatable about the axis provided by the T-shaped bushing 15 . It should also be understood that while the male and female buckle pairs are are illustrated here, other types of fasteners such as Velcro™, or buckle and cinch loops, are suitable. [0043] FIG. 8 is an exploded view illustrating an alternate embodiment of the present invention that substitutes a resilient fastener 26 formed into base plate 12 b as a substitute for the bushing elements of the other embodiments. The base plate with resilient fastener are of a thermoplastic material such as polystyrene or fiber reinforced thermoplastic. Assembly requires that the flanged face plate 10 b be pressed against the base plate 12 b aligning the aperture 17 with the head of the resilient fastener having a generally bullet shaped profile and which is partially divided into four sections so that the head of the fastener may contract to allow force fitting through an aperture upon which the sections resume their position, thus releasably securing the two plates together. The completed assembly is attached to a surface by means of double sided adhesive such as 3M™ Foam Tapes. Alternately, it is possible to separate the two plates and simply use the device in the manner described in ( FIG. 1 ) thus omitting the base plate. [0044] FIG. 9 is an edge view illustrating the alternate embodiment of ( FIG. 8 ) in typical use being affixed to a hollow wall surface. Shown is a layer of foam tape 27 of the same circumference as base plate 12 b . Visible is the strap 23 b having at each terminal end a hook or loop fastener portion so that the straps may be fastened together, so the strap can encircle a retained article. Although the edge view shows the flanged wings of the face plate 10 , it should be understood that face plate 10 is rotatable about the axis provided by the resilient fastener 26 . [0045] FIG. 10 is an plan view illustrating the base plate of ( FIGS. 8 , 9 ) with the sections partially bisection the bullet shaped head of the resilient fastener 26 . [0046] While the invention has been described in connection with only two principal embodiments, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
A device for the retention and release of heavy, bulky or irregularly shaped items to a surface that includes a rotatable winged flanged plate with strap admitting slots through which a strap and coupling means are passed, and a surface affixing means providing for the releasable retention of large or irregularly shaped items against a wall or other surface.
5
BACKGROUND OF THE INVENTION [0001] The present invention relates to a method and apparatus for determining channel degradation information in which a known data sequence is compared to a transmitted version of the known data sequence to provide such information. [0002] Signals carried over telecommunications links can undergo considerable transformations, such as digitisation, encryption and modulation. They can also be distorted due to the effects of lossy compression and transmission errors. [0003] Objective processes for the purpose of measuring the quality of a signal are currently under development and are of application in equipment development, equipment testing, and evaluation of system performance. [0004] A number of patents and applications relate to this field, for example, European Patent 0647375, granted on 14 Oct. 1998. In this invention two initially identical copies of a test signal are used. The first copy is transmitted over the communications system under test. The resulting signal, which may have been degraded, is compared with the reference copy to identify audible errors in the degraded signal. These audible errors are assessed to determine their perceptual significance—that is, errors that are considered significant by human listeners are given greater weight than those that are not considered so significant. In particular inaudible errors are perceptually irrelevant and need not be assessed. [0005] The automated system provides an output comparable to subjective quality measures originally devised for use by human subjects. More specifically, it generates two values, Y LE and Y LQ , equivalent to the “Mean Opinion Scores” (MOS) for “listening effort” and “listening quality”, which would be given by a panel of human listeners when listening to the same signal. The use of an automated system allows for more consistent assessment than human assessors could achieve, and also allows the use of compressed and simplified test sequences, which give spurious results when used with human assessors because such sequences do not convey intelligible content. [0006] In the patent specification referred to above, an auditory transform of each signal is taken, to emulate the response of the human auditory system (ear and brain) to sound. The degraded signal is then compared with the reference signal in the perceptual domain, in which the subjective quality that would be perceived by a listener using the network is determined from parameters extracted from the transforms. [0007] Such automated systems require a known (reference) signal to be played through a distorting system (the communications network or other system under test) to derive a degraded signal, which is compared with an undistorted version of the reference signal. Such systems are known as “intrusive” measurement systems, because whilst the test is carried out the channel under test cannot, in general, carry live traffic. [0008] The present invention has applications in, but is not limited to, measuring the signal degradation caused by transmission over a digital radio channel. European patent application EP 01306950.5 describes how the perceived transmission quality of a digital radio channel can be evaluated using channel degradation information in the form of error patterns to generate a reference and degraded signal pair for use with an intrusive measurement system. Error patterns store the difference between a reference digital sequence and a degraded version received after transmission over an error-prone channel. In patent application EP 01306950.5, a novel means of generating a known test sequence for the purposes of generating error patterns is presented. [0009] When testing the performance of a public land mobile radio network (PLMN), it is desirable to locate the apparatus used to perform the signal quality measurement apparatus in the network rather than the mobile station. Network based apparatus can be utilized more efficiently than mobile station based apparatus, by dynamically allocating it to active channels. Apparatus located in a mobile station will only be utilized when the mobile station is active, which in most cases represents a small fraction of time. This requirement to perform the quality measurement in the network presents a problem when measuring the performance of the downlink (network to mobile station) channel, because the degraded digital sequence used to form an error pattern is received at the mobile station. [0010] European Patent application No. 00304497.1 describes a method and apparatus for measuring the performance of a communications channel while in normal use by exploiting periods of spare capacity. The invention described therein can be implemented according to the arrangements described below. The inventors of said patent solve the problem of downlink measurement by making provision to send an error protected version of the degraded digital sequence received at the mobile station back to the network, where it can be compared with a copy of the original to produce an error pattern. [0011] A problem with transmitting an error corrected version of the degraded digital sequence is that the forward error correction process increases the amount of data that must be sent. If the transmission of the degraded signal is to be robust over a wide range of radio conditions, a powerful forward error correction code must be used, causing a substantial increase in the amount of data to be sent. For example, a rate 1/6 convolutional code will increase the amount of data to be transmitted by more than a factor of six. In many systems this increase in data will exceed the capacity of the transmission channel, especially if transmission is limited to periods of spare capacity, and the fraction of time for which signal quality measurements can be reported will be reduced. There will also be a need for a large buffer in which to store the degraded data sequences awaiting transmission. [0012] The present invention provides a means of generating channel degradation information on the network side of a digital transmission channel that is derived from the error performance of the downlink channel. The invention alleviates the problem of buffering and transmitting large amounts of data over the uplink channel by sending a statistical representation characterising the errors in the degraded data sequence. This information is used to generate a representation of the channel degradation information with characteristics similar to the channel degradation information generated directly from the degraded data sequence. The statistical representation can be represented in relatively few bits, and can therefore be protected by powerful forward error correction codes without exceeding the transmission capacity of the channel. If transmission is limited to periods of spare capacity, the smaller amount of information also reduces the memory requirements of the buffer. [0013] In some PLMN systems, provision is made to characterise the error performance in one direction, and return this information over the reverse channel. An example of this technique is the RXQUAL value that is calculated in GSM receivers (see GSM 05.08). However, the present invention is distinct from RXQUAL type measurements, because errors are accurately identified by comparing the received sequence with a local copy of the original sequence; RXQUAL is based on an estimate of the error rate calculated over 480 ms, and has been shown in the literature to provide an unreliable predictor of speech quality (Radio link parameter based speech quality index-SQI Karlsson, A.; Heikkila, G.; Minde, T. B.; Nordlund, M.; Timus, B.; Wiren, N. and Electronics, Circuits and Systems, 1999. Proceedings of ICECS '99. The 6th IEEE International Conference on , Volume: 3, 1999 Page(s): 1569-1572 vol.3.) SUMMARY OF THE INVENTION [0014] According to a first aspect of the present invention there is provided a method of determining a representation of channel degradation information for a communication channel, comprising the steps of generating a known data sequence within a transmitter; transmitting a coded data sequence based on the known data sequence via said communication channel; receiving data received via the communication channel to provide a received data sequence at a receiver; generating said coded data sequence based on the known data sequence within the receiver; and comparing the coded data sequence generated within the receiver with the received data sequence to provide said channel degradation information; characterised in that the method further comprises the steps of generating a statistical representation of the channel degradation information; transmitting the statistical representation to a receiver; and generating said representation of the channel degradation information according to the statistical representation. [0015] According to a second aspect of the invention there is also provided a method in which a test data sequence is degraded using channel degradation information obtained according to the first aspect of the invention, comprising the steps of encoding the test data sequence to produce an encoded data sequence; modifying the encoded data sequence according to said representation of the channel degradation information; decoding the modified data sequence to produce a decoded data sequence; and comparing the decoded data sequence to the test data sequence. [0016] The statistical representation of the channel degradation information may conveniently comprise a representation of the number of differences detected in the comparing step for each corresponding pair of frames of the known data sequence and the received data sequence. [0017] Groups of bits in an output frame of a signal encoder may be channel encoded with different levels of error protection. In this case the representation of the number of differences detected may advantageously comprise a plurality of representations each representation corresponding to the number of differences detected for a set of symbols within a frame, each symbol of the set being encoded at a similar level of error protection. [0018] When the channel degradation information is generated by comparing the data sequences at the output of a channel encoder with the input of a channel decoder. The channel degradation information may include soft-decision values produced by a demodulator in addition to the value of each received symbol. Soft-decision values indicate the likelihood that a symbol has been received in error, and, when used in combination with a maximum likelihood decoding algorithm such as the Viterbi algorithm, can improve the performance of the channel decoder. [0019] In this case it is advantageous if the statistical representation of the channel degradation information further comprises a representation of a set of statistical values each of which is derived from the probability that a symbol within the received data sequence has been decoded correctly. [0020] Information may be transmitted for each statistical representation by selecting, from a stored set of histograms, for example, an entry which is the best match to the statistical representation, so that the generation of a representation of the channel degradation information comprises selecting a representation of the channel degradation information from a set of stored representations according to the statistical representation. [0021] A computer readable medium carrying a computer program for implementing the method of the invention and a computer program for implementing the method of the invention are also provided. [0022] According to a third aspect of the invention there is provided an apparatus for determining a representation of channel degradation information for a communications channel comprising a generator arranged to generate a known data sequence; a transmitter including a coder and being arranged to transmit a coded data sequence based on the known data sequence; a receiver being arranged to receive the transmitted coded data sequence; a generator arranged to generate the coded data sequence based on the known data sequence; and a comparator arranged to compare the coded data sequence based on the known data sequence with the transmitted coded data sequence to provide channel degradation information characterised in that the apparatus also comprises a generator arranged to generate a statistical representation of the channel degradation information; a transmitter arranged to transmit the statistical representation to a receiver ( 60 ); and a generator arranged to generate the representation of the channel degradation information in dependence upon said statistical representation. [0023] According to a further aspect of the invention there is provided an apparatus for determining a representation of channel degradation information for the communication channel according the third aspect of the invention; an encoder arranged to encode a reference signal; an error insertion device arranged to modify the encoded reference signal according to the representation of channel degradation information; a decoder arranged to decode the modified signal; and a comparator arranged to compare the decoded signal and the reference signal. [0024] In one embodiment, the encoder comprises a signal encoder and a channel encoder and the decoder comprises a signal decoder and a channel decoder. BRIEF DESCRIPTION OF THE DRAWINGS [0025] Embodiments of the invention will now be described with reference to the accompanying drawings, in which: [0026] [0026]FIG. 1 is a block diagram illustrating a conventional transmitter and a receiver; [0027] [0027]FIG. 2 illustrates the output of an error insertion device in response to a signal and an error pattern; [0028] [0028]FIG. 3 is a block diagram illustrating apparatus for measuring channel transmission accuracy; [0029] [0029]FIG. 4 is a block diagram illustrating an apparatus according to one aspect of the present invention; [0030] [0030]FIG. 5 is a flow diagram illustrating operation of a method according to one aspect of the present invention; and [0031] [0031]FIG. 6 is an illustration of a statistical representation of one embodiment of the invention. DETAILED DESCRIPTION [0032] It will be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately, or in any suitable combination. [0033] The present invention is applicable to digital systems using symbols with any number levels, for example ternary or quaternary symbols. However, for the purposes of clarity, the embodiments of the invention are described with reference to data sequences comprising binary data symbols, or bits. [0034] Before describing embodiments of the invention, known intrusive measurement systems will firstly be described with reference to FIG. 1 to FIG. 3. FIG. 1 illustrates a known communications system comprising a transmitter 100 and a receiver 200 . A source encoder 101 encodes a signal into an encoded data sequence in order to reduce the data rate for a signal to be transmitted using appropriate compression techniques. The data is in the form of a sequence of symbols, which are binary digits (bits). [0035] A channel encoder 102 further encodes the data sequence so that transmission errors can be detected and corrected by the receiver—a process that generally increases the data rate of the encoded sequence. An interleaver 103 reorders the symbols in the data sequence in a manner that improves the performance of the channel encoder 102 , together with a channel decoder 202 , in the presence of short radio fades (i.e. short bursts of errors). An encryptor 104 encrypts the data sequence to prevent decoding of the data sequence by third parties. Finally, the encrypted data sequence is converted into a radio signal by a modulator 105 and the radio signal is transmitted via a transmission channel to the receiver 200 . [0036] The received signal is converted into a data sequence by a demodulator 205 , the data sequence is decrypted by the decryptor 204 and reordered by a de-interleaver 203 . The channel decoder 202 corrects errors in the de-interleaved data sequence before passing it to a source decoder 201 along with information about errors that have been detected but not corrected. Finally, the source decoder 201 reconstructs a version of the original signal. [0037] The signal at the output of the source decoder 201 will differ from the original signal at the input to the source encoder 101 if the source coding process is lossy or if the channel decoder is unable to detect or correct symbols received in error by the demodulator 205 . Demodulation errors are generally caused by a poor signal-to-noise ratio on the radio channel, due to Raleigh fading, signal attenuation, or interference from other radio sources. [0038] The source encoder 101 , channel encoder 102 , interleaver 103 and encryptor 104 operate independently of each other. Not all of the stages shown in FIG. 1 are included in every communication system. [0039] The present invention is concerned with the generation of channel degradation information in the form of error patterns. The term ‘raw’ error pattern refers to a pattern constructed by comparing the data sequences at the output of the channel encoder and the input of the channel decoder. A raw error pattern may include soft-decision values produced by the demodulator 201 in addition to the value of each received symbol. Soft-decision values indicate the likelihood that a symbol has been received in error, and, when used in combination with a maximum likelihood decoding algorithm such as the Viterbi algorithm, can improve the performance of the channel decoder. Soft-decision values are often defined such that: s =ln((1 −p )/ p ) [0040] where s is the soft-decision value and p is the probability of the symbol being received in error. Soft-decision error patterns are often used in the development of source and channel codecs, and typically include the soft-decision value of the received symbol with an indication of whether the symbol was received correctly or not. Such error patterns are typically produced using software simulations of the radio channel. [0041] The term ‘residual’ error pattern refers to a pattern constructed by comparing the data sequences at the input of the channel encoder and the output of the channel decoder. Residual error patterns may include information about uncorrected but detected errors, often in the form of a binary bad frame indicator, which indicates an error in one or more of the most sensitive bit positions. [0042] An apparatus for assessment of transmission channel performance is illustrated in FIG. 3. In a first arrangement, channel degradation information in the form of a raw error pattern is used to degrade a reference signal. A test signal 301 , which need not be the same as that used to generate the channel degradation information, is passed through a signal encoder 302 and a channel encoder 303 . An error insertion device 304 processes the output such that symbols with sequence positions corresponding to those indicated by the channel degradation information are modified. The channel degradation information is stored at 305 . The output of the error insertion device 304 is input to a channel decoder 306 and a source decoder 307 . Finally, a signal quality assessment algorithm 308 , such as but not restricted to that described in European Patent number 0647375, estimates the performance of the channel under test by using the test signal 301 and the output of the source decoder 307 as the reference-degraded signal pair. [0043] It is possible to use this first arrangement to investigate how different signal codecs and channel codecs would perform with the modulator and radio channel used to generate the channel degradation information. This can readily be achieved by changing the signal codec ( 302 and 307 ) and channel codec ( 303 and 306 ) in FIG. 3. [0044] In a second arrangement, channel degradation information in the form of a residual bit-error pattern is used to degrade a reference signal. A reference and degraded signal pair can be generated from the residual error pattern using processing stages similar to those in FIG. 3, omitting the channel encoder 303 and channel decoder 306 . The channel degradation information may, in this case, include information about uncorrected but detected errors which can be used by the signal decoder to conceal the effects of said errors. The second arrangement can be used to investigate how different signal codecs ( 302 and 307 ) would perform with the channel codec, modulator and radio channel used to generate the channel degradation information in the form of the residual bit-error pattern. [0045] If the signal encoder produces frames comprising multiple bits, it is important that the residual error pattern is aligned with the frame boundaries of the signal encoder. This is because the channel coder and the channel decoder may apply different levels of error correction to different to bit positions within a frame to take into account variations in error-sensitivity. This alignment is illustrated for three frames in FIG. 2, where bit-sequence 401 is the output of a signal encoder; bit-sequence 402 is an error pattern; and bit-sequence 403 is the output of the error insertion device. A value of ‘1’ in the error pattern indicates that the bit in that position was received in error, and should therefore be inverted. [0046] The invention will now be described with reference to FIG. 4 which illustrates an apparatus according to the invention, together with FIG. 5 which illustrates a method according to the present invention. [0047] At step 82 a known data sequence is generated by a data sequence generator 8 and stored in a buffer 10 . The known data sequence is coded using a signal encoder 21 and a channel encoder 22 and transmitted at step 84 over a channel under test by a downlink transmitter 20 to a downlink receiver 30 . For the purposes of clarity, the transmitter 20 is shown comprising only the signal encoder 21 and the channel encoder 22 . The transmitted data sequence is received at step 86 by a downlink receiver 30 and decoded by a channel decoder 32 and a signal decoder 31 . [0048] At step 88 a local copy of the known data sequence once it has been signal encoded and channel encoded is generated by a coded sequence generator 6 and stored in a buffer 42 . At step 90 an error pattern generator 41 is used to compare the data sequence at the input of the channel decoder 32 with the encoded version of the known data sequence 42 to produce channel degradation information in the form of a raw error pattern which is stored in a buffer 43 . At step 92 a statistical representation of the channel degradation information is generated by a characterisation unit 44 and stored in the buffer 43 . The characterisation unit 44 counts the number of differences detected between the data sequence at the input of the channel decoder 32 with the encoded version of the known data sequence 42 which are recorded in each frame of the channel degradation information and stores this statistical representation of the channel degradation information in a buffer 45 . [0049] The statistical representation is encoded by a channel encoder 51 prior to transmission at step 94 by an uplink transmitter 50 . In an uplink receiver 60 , a channel decoder 61 extracts the statistical representation from the received signal. [0050] Finally, at step 96 , an error pattern synthesiser 70 constructs a representation of the channel degradation information and stores it in a buffer 80 . [0051] Each frame of the synthesised error pattern is generated from the received characterisation value by generating the required number of errors in randomly chosen positions within the representation of the channel degradation information. Using the representation of the channel degradation information format illustrated in FIG. 2, this is achieved by the following steps: [0052] 1) set all of the positions in the frame to ‘0’; [0053] 2) initialize a counter to zero; [0054] 3) select a random position in the frame; [0055] 4) if the selected position is equal to ‘0’, set it to one and increment the counter; if the selected position is equal to ‘1’, repeat Step 3 ; [0056] 5) compare the counter with the number of desired errors; [0057] 6) if the counter is less than the number of desired errors go to Step 3 . [0058] In the special case where the number of desired errors is zero, only Step 1 is performed. The selection of the bit error positions in Step 3 may be performed entirely randomly such that all frame positions are equally likely to be selected. Alternatively, if the channel under test has known error characteristics such as burstiness, the position of the bit errors may be calculated using an error generation model. For example, a two-state Markov model is a well-known method of generating random error bursts; the transition probabilities of the model determining the error characteristics. The channel degradation information synthesised represents a raw error pattern and can be used according to the first arrangement described above, with reference to FIG. 3, to evaluate the transmission performance of the downlink channel under test. The presence of signal and channel codecs is not essential to this embodiment. [0059] In a second embodiment, synthesised channel degradation information is selected from a set of stored representations 72 containing pre-stored channel degradation information with known total numbers of errors. The representation with the number of errors closest to the desired number of errors is selected. Prior to generation of the synthesised channel degradation information, the selected representation is cyclically rotated such that all phase offsets are equally likely, thus ensuring that on average all frame positions in the error pattern are equally likely to be used. This embodiment is useful in systems where errors occur in bursts, because the pre-stored representations in the set can simulate the error burst characteristics of the channel. [0060] In a third embodiment, the characterisation information for channel degradation information represented by a raw error pattern includes information indicating the distribution of soft decision values at the output of the demodulator 205 (FIG. 1). For example, this information may be transmitted for each statistical representation by selecting, from a stored set of histograms 4 , the entry best matching the distribution of received soft decision values for the current frame. [0061] The statistical information, in this embodiment, includes an indicator of the selected histogram, and the error pattern synthesiser uses the indicated histogram from a copy of the set of histograms 3 to generate soft decision values with the appropriate frequency of occurrence. [0062] In a further embodiment, a local error pattern 43 is formed by comparing the output of the channel decoder 32 with a local copy 42 of the input of the channel encoder 22 . The channel degradation information represents a residual error pattern and can be used according to the second arrangement described above to evaluate the transmission performance of the downlink channel under test. [0063] As previously discussed, groups of bits in an output frame of a signal encoder may be channel encoded with different levels of error protection. Bits receiving the highest level of protection are commonly referred to as ‘Class 1 bits’; the bits receiving the next highest level of protection being referred to as ‘Class 2 bits’, and so on. When used with such a transmission system, the characterization unit 44 , counts the number of bit errors in each class of bits in the local error pattern 43 . The number of errors in each Class is then transmitted to the error pattern synthesizer 71 , which generates a representation of channel degradation information for each class of bits according to the methods described previously. [0064] If the channel decoder 32 produces information pertaining to the presence of detected but uncorrected residual bit errors, for example the result of a cyclic redundancy check (CRC), this information may also be included in the statistical representation transmitted to the error pattern synthesizer 71 . [0065] In some cases it may be possible to deduce if errors have been detected but not corrected from the statistical representation, for example, if a powerful CRC check is performed over a complete class of bits. [0066] [0066]FIG. 6 illustrates an example of a statistical representation comprising a representation of the number of differences detected for a plurality of sets of bits, each set of bits being encoded at a difference level of error protection. [0067] In this example, the channel encoder applies two levels of error protection, thus the error pattern frame 500 is divided into Class 1 bits 501 and Class 2 bits 502 , each containing sixteen bits. The statistical representation comprises two 4-bit values 601 and 602 representing the number of received bit errors in Class 1 and Class 2 . Vectors 701 and 702 are the stored representations with the number of errors best matching the statistical representation for each class of bits. The representation of the channel degradation information 800 comprises randomly rotated versions of vectors 801 and 802 . In this case the Class 1 vector has been rotated right by 10 bit positions, and the Class 2 vector has been rotated right by 5 bit positions. [0068] The embodiments described above have been described with reference to transmitting information characterising downlink errors over an error protected uplink channel. The invention is equally applicable to the reverse situation—that is where information characterizing uplink errors is transmitted over an error protected downlink channel. [0069] It will be understood by those skilled in the art that the methods described above may be implemented on a conventional programmable computer, and that a computer program encoding instructions for controlling the programmable computer to perform the above methods may be provided on a computer readable medium. [0070] It is to be recognized that various alterations, modifications, and/or additions may be introduced into the constructions and arrangements of parts described above without departing from the spirit or ambit of the present invention.
The present invention relates to a method and apparatus for determining channel degradation information in which a known data sequence is compared to a transmitted version of the known data sequence to provide such information. To asses performance of a public land mobile network, it is convenient if assessment apparatus is located in the network rather than in a mobile station. The invention provides a technique for efficiently sending data characterising channel degradation caused by the network to mobile station communication channel from the mobile station back to the network, where the channel degradation information is reconstructed.
7
CROSS REFERENCE TO RELATED APPLICATIONS The present application is related to provisional patent application No. 60/688,769, filed Jun. 8, 2005 entitled “Obtaining heterostructures with quantum dots by liquid-phase epitaxy for solar cells”, the details of which are hereby incorporated by reference, and the benefit of the earlier Jun. 8, 2005 filing date is claimed in accordance with 35 USC 119(e) (1). DESCRIPTION 1. Field of the Invention The present invention relates to a nanotechnology, pulse cooling of substrate (PCS) method enabling formation of III-V compound semiconductor low-dimensional slab and column-like features and also to a method of fabrication of variety of commercially viable optoelectronic and photonic devices based on III-V column materials structures. 2. Description of the Related Art The method of liquid phase epitaxy (LPE) was developed at 1960 and had been a dominant method for production of semiconductor structures for lasers, power diodes, and photovoltaic devices. LPE had been used for the mass production worldwide until advent of generation of novel semiconductor devices demanding method of growing deep submicron structures with superior control over chemical composition, uniformity and growth rates. Nowadays, major methods of [nano] low-dimensional embedded in semiconductor structures growth are Molecular Beam Epitaxy (MBE) and Metal Organic Chemical Vapor Deposition (MOCVD). These methods allow growing low dimensional features [with size less than 0.1 μm] with high degree of control of chemical composition and growth rates. High cost of technological equipment, specific defects in the structures manufactured by MBE and MOCVD technologies stimulate searching of alternative methods of their fabrication, particularly based on crystallization from a liquid phase. SUMMARY OF THE INVENTION The invention is essentially a method for growth of features with size at least in one direction less than 1 μm, for example nano-dimensional layers; two dimensional (2D), and three dimensional (3D) island matrix. Compared to MBE and MOCVD methods, PCS method allow obtaining higher density of islands (˜10 12 cm −2 ), lower defect density and higher growth rates. Epitaxial growth of nano dimensional features was realized from III-V and IV column materials low-melting temperature solution-melts in slider-type cassette placed in quartz reactor in the atmosphere of pure hydrogen ( FIG. 1 ). In one of the embodiments of the present invention using resistive heater, temperature T 1 in the reactor was maintained within the range of 300-500° C. during growth process. The on-axis as well as off-axis cut GaAs substrates were used for structures with 2D nano-dimensional island matrix growth. The main steps of epitaxial growth method of the present invention are as follows: a) solution-melt and substrate are heated up to the saturation temperature of solution-melt T 1 ; b) the working (growth) surface of the substrate is brought into contact with the solution-melt; c) back surface of the substrate is brought into contact with the heat-absorber (the temperature T p of which is lower than that of the substrate and solution-melt ΔT=T 1 −T p ) that creates the pulse cooling in the range of 0.5-15° C., the duration of the interval is 5×10 −2 −5 s and the speed of growing the fore front of the cooling pulse is in the range of 5×10 3 −0.5×10 3 ° C./s; The heat-absorber temperature had been chosen so that an overcooling at crystallization front did not exceeded 5-9° C. to avoid homogeneous nucleation in liquid phase volume. After some time τ the heat-absorber was heated to the temperature T 1 , but during this time there was a cooling at the interface of the substrate and solution-melt, that resulted in crystallization of a dissolved in solution-melt material. The shape of the formed features in particular, low-dimensional layers, 2D and 3D island matrix depends on several factors, for example, stress between substrate and growing feature's material, substrate orientation, and concentration of the material in the solution-melt. EXAMPLE 1 The Structure with Nano-Dimensional 2D Island Matrix The Scanning Tunnel Microscopy (STM) images of InAs uncapped islands grown on (100) GaAs substrate at T 1 =400° C., ΔT=5° C. and heat-absorber thickness δ=0.3 cm from In solution-melt is presented in FIG. 2 . The observed surface density of islands is ˜10 12 cm −2 . The photoluminescence (PL) spectra of this sample at 77K demonstrate variation in peak position in the 1.24<hv<1.26 eV range, FIG. 3 . Photons with energy of 1.25 eV correspond to photoluminescence from 7.8 nm InAs islands in GaAs. Seven times PL intensity increase is observed when excitation power increases from 5 mW to 20 mW. Further excitation power increase up to 2 W does not significantly effect PL peak position as well as intensity that prove presence of the quantum dots. The PL peak position measured at different spots on the sample was in the 10 meV range what correspond island size variation around 10%. EXAMPLE 2 The structure with two populations of nano-dimensional islands grown simultaneously during one cooling pulse FIG. 4 presents photoluminescence spectra of two samples. Sample 1 (curve 1) has been grown on (100) GaAs substrate cut 4 degrees off in [110] direction; Sample 2 (curve 2) has been grown on (100) on-axis substrate. Coincidence of long wavelength part of PL spectrum of the samples demonstrates that size distribution of “large” islands is identical for these two samples. At the same time PL spectrum of misoriented sample reveals island size distribution broadened towards smaller sizes featuring split peak. In this case misoriented substrate provided growth front consisting of two steps with different nucleation conditions that resulted in two “independent” populations of InAs islands. Resulting PL spectrum is a superposition of PL from this two populations of InAs islands each having its own Gaussian-like size distribution. The structures containing nano-dimensional islands grown on misoriented substrates can be utilized in photovoltaic devices or diodes due to wider range light absorption or emission; or achieving several specific wavelength light absorption or emission. Additional advantages and features of the present invention are described in the following Appendix A, entitled “OBTAINING HETEROSTRUCTURES WITH QUANTOM DOTS BY LIQUID-PHASE EPITAXY FOR SOLAR CELLS”, published August, 2004 (World Renewable Energy Congress), the details of which are hereby incorporated by reference.
The features with size at least in one direction 1 μm growth method was developed by modifying liquid phase epitaxy. Number of processes was developed where duration and amplitude of the cooling pulse at the substrate interface were chosen in order to form low-dimensional features before system return to the equilibrium condition. This method allows obtaining low-dimensional features with observed quantum effect such as quantum layers, dots and superlattices. The shape of the features strongly depends on substrate orientation, stress and growth conditions.
2
FIELD OF THE INVENTION [0001] The present invention relates to a wool fabric and a finishing method for the same, in particular to a superhydrophilic wool fabric with wash fastness and a nano-finishing method for preparing the same. The nano-finishing method provided by the present invention is especially suitable for superhydrophilic finishing of high-end wool fabrics. BACKGROUND OF THE INVENTION [0002] Fiber hydrophilicity is an important factor for normal functioning of the natural regulation system of human body and comfortability of wear of clothing. Fiber hydrophilicity covers two aspects: hygroscopicity and water absorption of fibers. When the human body sweats out, the fibers absorb vaporous water from the skin on one hand, behaving as the hygroscopicity of fabric; on the other hand, the fibers absorb water in liquid phase from the skin, behaving as the water absorption of fabric. The hygroscopicity and water absorption of fibers are not only related with the chemical structure of the fibers but also related with the physical structure and morphological structure of the fibers, such as pores and cavities in the fabric structure, and specific surface area of fiber surface. [0003] Rabbit wool, sheep wool, and alpaca wool are ideal natural clothing-making materials, owing to their characteristics such as light weight, warmth retention, and soft. These natural wool fabrics have high hygroscopicity but poor water absorption, which is to say, they can't absorb the great deal of sweat produced by the human body in a hot environment or during strenuous exercises and transfer out the sweat timely; as a result, the human body will feel damp, sultry, and uncomfortable. If the microstructure of the wool can be modified to have superhydrophilicity and can transfer out the sweat timely, the comfortability of the wool fabrics will be greatly improved. [0004] To improve the hydrophilicity of fabrics, a low-temperature plasma treatment technique is disclosed in Chinese Patent Application No. 01110561.5 (titled as Super-Amphipathic Textile Fibers and Producing Method and Application Thereof). The technique utilizes the action between plasma and textile surface in an appropriate atmosphere to introduce new groups to the surface of the textile, so as to improve the hydrophilicity of the textile; however, the hydrophilicity of textile treated in a plasma atmosphere can't last long, and the equipment used for the treatment is costly. A method for producing vapor permeable and sweat absorbent fibers or fabrics is disclosed in Chinese Patent Application No. 200410037803.0 (titled as Application of Superhydrophilic and/or Superlipophilic Nanometer Porous Material). In that method, a nanometer porous material such as silicon oxide and/or titanium oxide is coated on the surface of the fibers or fabric. However, in that method, to prepare the nanometer porous material, the pore template agent has to be removed at a high temperature, and the fabric has to be pre-treated through a plasma treatment to increase the polar component on the surface. A method for improving hydrophilicity and comfortability of fabrics by fixing a nanometer functional material to different kinds of porous keratin fabrics through dipping-rolling-baking process is disclosed in Chinese Patent Application No. 200710002393.X (titled as Hydrophiling Nanometer-Level Surface Finishing Method for Porous Keratin Fabrics). That method is simple in process, easy to operate, and low in production cost; however, the treated fabrics have poor hand feeling and poor wash fastness. SUMMARY OF THE INVENTION [0005] An object of the present invention is to provide a superhydrophilic wool fabric with wash fastness (i.e., with zero contact angle between the fiber surface of the wool fabric and water), the superhydrophilic wool fabric with wash fastness has nanometer particles grafted by chemical bond on the surface of wool fiber; the nanometer particles comprise nanometer silicon dioxide with a particle diameter of 10-800 nm; based on the total mass of the wool fabric, the content of the nanometer silicon dioxide is 0.05-5% by mass. Preferably, the particle diameter of the nanometer silicon dioxide particles is 10-400 nm. [0006] Another object of the present invention is to provide a multi-functional superhydrophilic wool fabric with wash fastness. The surface of the multi-functional superhydrophilic wool fabric with wash fastness has nanometer particles grafted by chemical bond. The nanometer particles comprise nanometer silicon dioxide particles with a particle diameter of 10-800 nm and functional nanometer particles; the functional nanometer particles are at least one selected from the group consisting of nanometer gold with a particle diameter of 1-100 nm, nanometer silver with a particle diameter of 1-100 nm, nanometer copper with a particle diameter of 1-100 nm, nanometer titanium oxide with a particle diameter of 5-500 nm, and nanometer zinc oxide with a particle diameter of 5-500 nm. Based on the total mass of the wool fabric, the content of the nanometer silicon dioxide is 0.05-5% by mass, and the content of the functional nanometer particles is 0.05-5% by mass. [0007] Another object of the present invention is to provide a nano-finishing method for producing the superhydrophilic wool fabric with wash fastness, to add water-absorbing and quick-drying characteristics to the fabric. [0008] Another obj ect of the present invention is to provide a nano-finishing method for producing the multi-functional superhydrophilic wool fabric with wash fastness. [0009] The nano-finishing method for producing a superhydrophilic wool fabric with wash fastness provided by the present invention comprises: [0010] first, pre-treating the wool fabric with a coupling agent; [0011] then, adding silicon dioxide particles with a particle diameter of 10-800 nm to the reacting solvent, immersing the wool fabric treated by step (1) into the reacting solvent, adjusting the pH value of the reacting solution, oscillating the solution at a constant temperature for a period of time, taking out the wool fabric, after rinsing the wool fabric, drying the wool fabric; or [0012] adjusting the pH value of the reacting solvent, immersing the pre-treated wool fabric into the reacting solvent, agitating at a constant temperature for a period of time, adding a solution that contains an appropriate amount of precursor of silicon dioxide into the reacting solvent where the wool fabric is immersed, adjusting the pH value of the reacting solution, oscillating at a constant temperature for a period of time, taking out the wool fabric, after rinsing the wool fabric, drying the wool fabric. [0013] The nano-finishing method for producing the superhydrophilic wool fabric with wash fastness provided by the present invention, comprising the following steps: [0014] (1) rinsing and drying the wool fabric to be treated, immersing the wool fabric into a solution that contains coupling agent at a concentration of 2-2000 mmol/L and keeping for 2 min-10 h, taking out the wool fabric, and drying it naturally or at 40-100° C..; [0015] (2) adding silicon dioxide particles with a particle diameter of 10-800 nm into a reacting solvent to make the mass fraction of the silicon dioxide particles in the reacting solvent be 0.1-10%, immersing the wool fabric treated by step (1) into the reacting solvent and keeping the bath ratio at 1:5-1:100, adjusting the pH value of the reacting solution to 1-7 by an acid, and then oscillating at a constant temperature within a range of 40-100° C..; or [0016] adjusting the pH value of the reacting solvent with an inorganic base to 8-14, immersing the wool fabric treated by step (1) into the reacting solvent and keeping the bath ratio at 1:5-1:100; agitating; adding a solution that contains a precursor of silicon dioxide and controlling the content of the precursor of silicon dioxide in the reacting solvent at a mass fraction of 0.1-10%, and agitating at a constant temperature within a range of 30-100° C..; adjusting the pH value of the reacting solution to 1-7 by an acid, and then oscillating at a constant temperature within a range of 40-100° C..; [0017] (3) taking out the wool fabric treated by step (2), and rinsing and drying it, to obtain a superhydrophilic wool fabric with wash fastness. [0018] The reacting solvent is at least one selected from the group consisting of water, methanol, ethanol, propanol, butanol, toluene, tetrachloroethylene, methylene chloride, N,N-dimethyl formamide and dimethyl sulfoxide. [0019] The superhydrophilic wool fabric with wash fastness obtained by the above nano-finishing method has nanometer particles grafted by chemical bonds on the wool surface; the nanometer particles comprise silicon dioxide particles with a particle diameter of 10-800 nm and/or nanometer silicon dioxide particles with a particle diameter of 10-800 nm obtained by hydrolization of the precursor of silicon dioxide. [0020] The nano-finishing method for producing the superhydrophilic wool fabric with wash fastness provided by the present invention may further comprise the following steps: [0021] adding functional nanometer particles, before or after adding silicon dioxide particles with a particle diameter of 10-800 nm and before adjusting the pH value of the reacting solution with an acid to 1-7 and before oscillating at a constant temperature within a range of 40-100° C..; or [0022] adjusting the pH value of the reacting solvent with an inorganic base to 8-14, and adding solid powder of a precursor of the functional nanometer particles into the reacting solvent or adding a solution that contains a precursor of the functional nanometer particles, and agitating at a constant temperature within a range of 30-100° C.., before or after adding the silicon dioxide particles with a particle diameter of 10-800 nm and before adjusting the pH value of the reacting solution with an acid to 1-7 and oscillating at a constant temperature within a range of 40-100° C.; or [0023] adding functional nanometer particles to the reacting solvent, or adding solid powder of a precursor of the functional nanometer particles to the reacting solvent, or adding a solution that contains a precursor of the functional nanometer particles to the reacting solvent, before or after adding the solution that contains a precursor of silicon dioxide and before agitating at a constant temperature within a range of 30-100° C., and after immersing the wool fabric treated by step (1) into the reacting solvent adjusted the pH value with an inorganic base to 8-14; then, agitating at a constant temperature within a range of 30-100° C., and performing subsequent steps after the agitation at a constant temperature within a range of 30-100° C. [0024] Wherein, the mass fraction of the functional nanometer particles or the precursor of the functional nanometer particles added into the reacting solvent is 0.1-10% in the reacting solvent. [0025] The multi-functional superhydrophilic wool fabric with wash fastness obtained in that way has nanometer particles grafted by chemical bonds on the wool surface; the nanometer particles comprise silicon dioxide particles with a particle diameter of 10-800 nm and/or nanometer silicon dioxide particles with a particle diameter of 10-800 nm obtained by hydrolization of the precursor of silicon dioxide, and the functional nanometer particles and/or functional nanometer particles obtained by hydrolization of the precursor of functional nanometer particles. [0026] The superhydrophilic refers to that the contact angle between the fiber surface of wool fabric and water is zero. [0027] The bath ratio refers to the mass ratio of the wool fabric to the reacting solvent. [0028] The mass fraction refers to the mass ratio of the silicon dioxide particles with a particle diameter of 10-800 nm, precursor of silicon dioxide, functional nanometer particles, or precursor of functional nanometer particles to the reacting solvent with a pH value of 8-10. [0029] The functional nanometer particles is at least one selected from the group consisting of nanometer gold with a particle diameter of 1-100 nm, nanometer silver with a particle diameter of 1-100 nm, nanometer copper with a particle diameter of 1-100 nm, nanometer titanium oxide with a particle diameter of 5-1,000 nm, and nanometer zinc oxide with a particle diameter of 5-1,000 nm. Preferably, the particle diameter of the nanometer titanium oxide is 5-500 nm, and the particle diameter of the nanometer zinc oxide is 5-500 nm. [0030] The solution that contains the precursor of functional nanometer particles is obtained by dissolving solid powder of the precursor of functional nanometer particles into the solvent, wherein, the solvent is at least one selected from the group consisting of water, methanol, ethanol, propanol, isopropanol, and butanol. The present invention has no special restriction to the concentration of the solution that contains the precursor of functional nanometer particles, as long as the concentration and amount of the solution can ensure the mass fraction of the precursor of functional nanometer particles is within the range of 0.1-10% in the reacting solvent. [0031] The solid powder of the precursor of functional nanometer particles is at least one selected from the group consisting of precursor of nanometer gold with a particle diameter of 1-100 nm, precursor of nanometer silver with a particle diameter of 1-100 nm, precursor of nanometer copper with a particle diameter of 1-100 nm, precursor of nanometer titanium oxide with a particle diameter of 5-1,000 nm or 5-500 nm, and precursor of nanometer zinc oxide with a particle diameter of 5-1,000 nm or 5-500 nm. [0032] Accordingly, the obtained particles are at least one selected from the group consisting of nanometer gold with a particle diameter of 1-100 nm, nanometer silver with a particle diameter of 1-100 nm, nanometer copper with a particle diameter of 1-100 nm, titanium oxide with a particle diameter of 5-1000 nm, and nanometer zinc oxide with a particle diameter of 5-1000 nm. Preferably, the nanometer titanium oxide obtained by hydrolization of the precursor of functional nanometer particles is nanometer titanium oxide with a particle diameter of 5-500 nm, and the nanometer zinc oxide obtained by hydrolization of the precursor of functional nanometer particles is nanometer zinc oxide with a particle diameter of 5-500 nm. [0033] The precursor of nanometer gold is chloroauric acid. [0034] The precursor of nanometer silver is silver nitrate. [0035] The precursor of nanometer copper is selected from one of cupric chloride, cuprous chloride, cupric sulfate, cuprous sulfate, cupric nitrate, and cuprous nitride. [0036] The precursor of nanometer titanium oxide is selected from one of tetrabutyl titanate, isopropyl titanate, titanium tetrachloride, and titanium tetrafluoride. [0037] The precursor of nanometer zinc oxide is selected from one of zinc chloride, zinc sulfate, zinc nitrate, and zinc acetate. [0038] The time of natural drying described in step (1) is 30 min-10 h; the time of the drying performed at a temperature of 40-100° C. is 5-300 min. [0039] In step (2), the time of agitation performed at a constant temperature within the range of 30-100° C. is 2-300 min; the time of oscillation performed at a constant temperature within the range of 40-100° C. is 20-200 min.; there is no special restriction to the time of agitation in step (2), as long as the agitation ensures the wool fabric is evenly dispersed in the reacting solvent; usually, the agitation time may be 2-30 min. [0040] The present invention has no special restriction to the rinsing and drying method for the wool fabric to be treated in step (1), which is to say, the method may be any method well-known by those skilled in the art. In addition, there is no special restriction to the amount of the solution that contains coupling agent used for immersing the wool fabric, as long as the amount of the solution that contains coupling agent is enough to ensure the wool fabric is completed immersed and the content of coupling agent in the solution that contains coupling agent meets the requirement. On the premise that the silicon dioxide particles and the functional nanometer particles may be grafted to the surface of the wool fabric, the amount of the solution that contains coupling agent may be 5-50 L for 1 kg wool fabric. [0041] The rinsing described in step (3) may be performed with any method known by those skilled in the art; preferably, the rinsing is performed with tap water; the present invention has no special restriction to the drying described in step (3), which is to say, the drying may be performed with any common method in the field. [0042] The solvent used for preparing the solution that contains coupling agent is at least one selected from the group consisting of methanol, ethanol, propanol, butanol, amyl alcohol, toluene, tetrachloroethylene, methylene chloride, N,N-dimethyl formamide and dimethyl sulfoxide. [0043] The coupling agent may be at least one selected from the group consisting of silane coupling agent with epoxy group, silane coupling agent with amino group, silane coupling agent with vinyl group, silane coupling agent with alkyl group, and coupling agent based on titanate. [0044] The silane coupling agent with epoxy group is γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilicane, or their mixture. [0045] The silane coupling agent with amino group is at least one selected from the group consisting of γ-aminopropyl trimethoxysilane, γ-aminopropyl triethoxysilane, bis[3-(triethoxysilye propyl]amine, γ-aminopropyl methyl dimethoxysilane, N-methyl-γ-aminopropyl trimethoxysilane, and N-methyl-γ-aminopropyl triethoxysilane. [0046] The silane coupling agent with vinyl group is at least one selected from the group consisting of vinyltrimethoxysilane, vinylmethyldimethoxysilane, vinyltriethoxysilane, and vinylmethyldiethoxysilane. [0047] The silane coupling agent with alkyl group is at least one selected from the group consisting of methyltrimethoxysilane, methyltriethoxysilane, propyltrimethoxysilane, and propyltriethoxysilicane. [0048] The coupling agent based on titanate is at least one selected from the group consisting of isopropyl triisophthaloyl titanate, isopropyl dodecylbenzenesulfonyl titanate, isopropyl tri(dioctyl pyrophosphate) titanate, tetraisopropyl bis(dioctyl phosphite) titanate, tetraoctyl bis[di(dodecyl) phosphite] titanate, tetra(2,2-diallyloxy-methyl-1-butyl) bis[di(tridecyl) phosphite] titanate, bis(dioctyl pyrophosphate)oxyacetate titanate, and bis(dioctyl pyrophosphate)ethylene titanate. [0049] The inorganic base is at least one selected from the group consisting of lithium hydroxide, sodium hydroxide, potassium hydroxide, and ammonia. [0050] The precursor of silicon dioxide is at least one selected from the group consisting of sodium silicate, tetramethyl orthosilicate, tetraethyl orthosilicate, tetrapropyl orthosilicate, and tetrabutyl orthosilicate. [0051] The solvent for preparing the solution that contains the precursor of silicon dioxide may be at least one selected from the group consisting of water, methanol, ethanol, propanol, isopropanol, and butanol. [0052] The present invention has no special restriction to the concentration of the solution that contains the precursor of silicon dioxide, as long as the concentration and amount of the solution ensure the mass fraction of the precursor of silicon dioxide in the reacting solvent is within the range of 0.1-10%. Usually, the concentration of the solution that contains the precursor of silicon dioxide may be 0.5-5 mol/L. [0053] The acid described in step (2) may be at least one selected from the group consisting of hydrochloric acid, formic acid, oxalic acid, acetic acid, nitric acid, phosphoric acid, and sulfuric acid; preferably, the acid is hydrochloric acid, oxalic acid, or acetic acid. [0054] The present invention has no special restriction to the concentration and use of the acid in step (2). The acid may be at any concentration suitable for adjusting the pH value of the solution and may be used with any method well-known to those skilled in the art. [0055] The wool fabric comprises rabbit wool fabric, sheep wool fabric, cashmere fabric, alpaca wool fabric, or blend fabric produced from these fabrics at any blend ratio. [0056] The wool fabric according to the present invention has superhydrophilicity (with zero contact angle between the fiber surface of wool fabric and water). Since water drops can diffuse quickly in the wool fabric, the comfortability of wear and functionality of the wool fabric are greatly improved; in addition, the wool fabric is quite resistant to washing. A multi-functional wool fabric can be obtained, by adding a solution that contains other functional nanometer particles or the precursors of other functional nanometer particles in the finishing process. [0057] In principle, the method provided by the present invention is to select an appropriate coupling agent, and graft a layer of nanometer silicon dioxide with a particle diameter of 10-800 nm obtained by nanometer silicon dioxide particles or a precursor of silicon dioxide on the fiber surface of the wool fabric by chemical bonds, so as to from a nanometer-level unevenness structure on the micron-level fiber surface, and thereby increase the roughness of fiber surface and further improve the hydrophilicity of the hydrophilic silicon dioxide rich in hydroxyl, to obtain a superhydrophilic wool fabric. As a result, the diffusion rate and range of water in liquid phase on the surface of the superhydrophilic wool fabric provided by the present invention are greatly increased, and thereby the effects of water absorption, sweat absorption, and quick-drying are attained. The chemical bonds formed between the nanometer silicon dioxide particles on the wool surface and the fibers enhance the bonding force between the fibers and the nanometer silicon dioxide particles, and thereby enhance the wash fastness of the wool fabric. In addition, a multi-functional wool fabric can be obtained by adding a solution that contains other functional nanometer particles or the precursors of other functional nanometer particles; moreover, the uniform and dense nanometer silicon dioxide layer formed on the surface of the wool fabric can increase the bonding force between the wool fabric and other functional particles, so that the wash fastness of the wool fabric is improved. [0058] Apparent differences between the method provided by the present invention and the existing methods in the prior art include: in the method provided by the present invention, the preparation of the superhydrophilic nanometer silicon dioxide particles is performed simultaneously with the surface functionalization of the wool fabric; in addition, other functions, such as antibacterial and self-cleaning functions, may be added to the wool fabric, while superhydrophilicity is bestowed to the wool fabric. Therefore, the production process is simplified, the energy consumption and cost are reduced, and the method is suitable for mass production of wool fabric. The method provided by the present invention is easy to use, can implement functional design of fabrics at microscopic level, and incorporates water-absorbing, quick-drying, anti-bacterial, and self-cleaning functions, etc. BRIEF DESCRIPTION OF THE DRAWINGS [0059] FIG. 1 is an X-ray energy spectrogram of the superhydrophilic sheep wool cloth with wash fastness according to Example 1 of the present invention. [0060] FIG. 2 is an X-ray photoelectron energy spectrogram of the untreated sheep wool cloth used in Example 1 of the present invention. [0061] FIG. 3 is an X-ray photoelectron energy spectrogram of sheep wool cloth treated with coupling agent according to Example 1 of the present invention. [0062] FIG. 4 is an X-ray photoelectron energy spectrogram of the superhydrophilic sheep wool cloth with wash fastness according to Example 1 of the present invention. [0063] FIG. 5 is a Fourier transform infrared spectrogram, wherein, curve a shows the case of untreated sheep wool cloth, curve b shows the case of sheep wool cloth treated with coupling agent, curve c shows the case of superhydrophilic sheep wool with wash fastness according to Example 1 of the present invention. [0064] FIG. 6 is a structural diagram of the wool fibers in the untreated sheep wool cloth used in Example 1 of the present invention. [0065] FIG. 7 is a structural diagram of the wool fibers in the superhydrophilic sheep wool cloth with wash fastness in Example 1 of the present invention. [0066] FIG. 8 is a photograph of the static contact angle on the untreated sheep wool cloth used in the Example 1 of the present invention. [0067] FIG. 9 is a photograph of the static contact angle on the superhydrophilic sheep wool cloth with wash fastness according to Example 1 of the present invention. [0068] FIG. 10 shows the water absorption situation of the superhydrophilic sheep wool cloth with wash fastness according to Example 1 of the present invention after machine washing for different times. [0069] FIG. 11 is a structural diagram of the fibers in the superhydrophilic sheep wool cloth with wash fastness according to Example 1 of the present invention after machine washing for 20 times. [0070] FIG. 12 shows the water absorption situation of the sheep wool cloth according to Comparative Example 1 after machine washing for different times. [0071] FIG. 13 is an anti-bacterial effect diagram of the superhydrophilic and anti-bacterial sheep wool cloth according to Example 3 of the present invention. [0072] FIG. 14 is a comparison diagram of stains degradation between the superhydrophilic and self-cleaning wool cloth according to Example 5 of the present invention and untreated wool cloth, wherein, the photographs on the left side are photographs of untreated wool cloth before and after exposure to light irradiation, the photographs on the right side are photographs of the superhydrophilic and self-cleaning wool cloth according to Example 5 of the present invention before and after exposure to light irradiation. DETAILED DESCRIPTION OF THE EMBODIMENTS [0073] Hereinafter, the present invention will be detailed in Examples, with reference to the accompanying drawings. The Examples are provided here only for describing the technical scheme of the present invention, but should not be deemed as constituting any limitation to the protected domain of the present invention. [0074] In the following Examples, the X-ray photoelectron spectrograms are obtained on a MKII X-ray photoelectron spectrograph from VG Company (UK), under Al Ka X-Ray (1486.6 eV). [0075] The Fourier transform infrared spectrograms are obtained on a FTIR-1730 Fourier transform infrared spectrometer, in attenuated total reflection mode. [0076] The total content of nanometer silicon dioxide particles and functional nanometer particles grafted on the fiber surface of wool fabric is obtained by calculating the mass change before and after treatment of the wool fabric, and the mass ratio between nanometer silicon dioxide particles and functional nanometer particles is calculated from the content ratios of elements obtained in the X-ray energy spectrum test, so as to obtain the content of nanometer silicon dioxide particles and the content of functional nanometer particles on the fiber surface of the wool fabric, respectively. [0077] The X-ray energy spectrum analysis and scanning electron microscope (SEM) analysis are performed on a Hitachi S-4300 cold-field emission scan electronic microscope, at 15 kV and 10 kV operating voltages, respectively. The surface of sample is sprayed with gold to increase electrical conductivity of the sample. [0078] The static contact angle with water drops is measured on a Phoenix-300 surface tension analyzer, at a temperature of 20° C.±2° C. and a relative humidity of 65%±2%. [0079] The wash fastness is evaluated by testing the water absorption times of wool cloth after machine washing for different times. The machine washing method is: with reference to the AATCC Test Method No. 135-2004, use a Haier household washing machine with 20 L capacity, add the AATCC Standard Reference Detergent in appropriate amount, and wash for 8 min at a water temperature of 40° C. [0080] The water absorption time is tested with the method specified in British Standard 4554:1970, and the water absorption time of each sample group is the average of three test results. According to the standard, fabrics with water absorption time longer than 200 s are regarded as non-infiltrated fabrics. Therefore, the water absorption time of any sample with a water absorption time longer than 200 s in the test is recorded as 200 s. [0081] The anti-bacteria test is performed according to the method specified in Chinese Standard GB/T20944.1-2007. [0082] The self-cleaning performance testing method is: drop 0.1 mL 10 −5 M ethanol solution of Rhodamine B on the wool cloth, and keep the wool cloth exposed to the irradiation of a 40 W ultraviolet lamp for 1 h. Example 1 [0083] (1) Rinse and dry the sheep wool cloth to be treated, and weigh 100 g sheep wool cloth, immerse the wool cloth into 1 L methanol solution that contains 2 M γ-aminopropyltriethoxysilane, hold for 2 min, and then take out the wool cloth and dry 5 min at 100° C.; [0084] (2) Immerse the wool cloth treated by step (1) in water with pH adjusted to 8 by ammonia, at a bath ratio of 1:80, and agitate for 5 min at room temperature; then, add ethanol solution of tetraethyl orthosilicate at a concentration of 4 mol/L, and control the mass fraction of tetraethyl orthosilicate in the water with pH=8 at 10%, and agitate for 10 min at a constant temperature of 80° C.; adjust the pH value the reacting solution with hydrochloric acid to 4, and then oscillate for 20 min at a constant temperature of 70° C.; [0085] (3) Take out the wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic wool cloth with wash fastness. [0086] FIG. 1 is an X-ray energy spectrogram of the obtained superhydrophilic sheep wool cloth with wash fastness. It is seen from FIG. 1 that silicon element exists on the surface of the superhydrophilic wool cloth with wash fastness of the present invention, wherein, the gold element that appears in the spectrogram comes from the gold layer coated on the surface of the sample. [0087] FIGS. 2-4 show photoelectron energy spectrograms of untreated wool cloth, wool cloth treated with coupling agent, and the obtained superhydrophilic wool cloth with wash fastness. By comparing FIG. 3 and FIG. 4 , with FIG. 2 , it can be seen that after the wool cloth is treated with a coupling agent (i.e., γ-aminopropyltriethoxysilane), the characteristic peak of element N on the surface of the wool cloth appears, indicating the surface of the wool cloth has grafted coupling agent; then, after silicon dioxide is grafted chemically, the characteristic peak of element N on the surface of the wool cloth disappears, while the characteristic peak of element Si appears instead, indicating silicon dioxide is grafted successfully onto the fiber surface of the wool cloth. [0088] FIG. 5 is a Fourier transform infrared spectrogram. As indicated by the curve b in FIG. 5 , after the wool cloth is treated with a coupling agent, the peaks that appear at 1046 cm −1 and 1076 cm −1 correspond to linear polysiloxane; the new peak that appears at 876 cm −1 is the stretching vibration peak of Si—N, and indicates that the coupling agent is grafted to the fiber surface of the wool cloth by chemical bonds; as indicated by the curve c in FIG. 5 , after nanometer silicon dioxide particles are grafted further to the fiber surface of the wool cloth, the peaks that appear at 1721 cm −1 and 1683 cm −1 corresponds to the stretching vibration peak of C═O, resulted from the new ester bonds and amido bonds; the broad peak that appears at 1099 cm −1 is the characteristic peak of Si—O—Si, and indicates new silicon dioxide particles are grafted to the fiber surface of the wool cloth. [0089] FIG. 6 and FIG. 7 show structural diagrams of the wool fibers of untreated wool cloth and the wool fibers of the superhydrophilic wool cloth with wash fastness of the present invention, obtained on a SEM. The SEM analysis indicates that the superhydrophilic wool cloth with wash fastness of the present invention has a layer of nanometer silicon dioxide with a particle diameter of about 30 nm obtained from hydrolization of tetraethyl orthosilicate and grafted to the fiber surface of the wool cloth by chemical bonds. 105 g wool cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the wool cloth, the content of the nanometer silicon dioxide is about 5% by mass. [0090] The hydrophilicity of the wool cloth can be evaluated by measuring the static contact angle with water drops. FIG. 8 and FIG. 9 show photographs of the static contact angle between untreated wool cloth and water drops and the static contact angle between the superhydrophilic wool cloth with wash fastness of the present invention and water drops, wherein, the static contact angle between untreated wool cloth and water drops is 112 degree, while the static contact angle between the superhydrophilic wool cloth with wash fastness of the present invention and water drops is zero. FIG. 10 shows the wash fastness of the superhydrophilic wool cloth with wash fastness of the present invention. As shown in FIG. 10 , the water absorption time after machine washing for 20 times is 2.8 s, which indicates that the water absorption rate is high. The structural diagram of wool fibers of the superhydrophilic wool cloth with wash fastness according to the present invention obtained by SEM analysis after machine washing for 20 times is shown in FIG. 11 . It is seen from FIG. 11 that the wool fiber surface still has a large quantity of nanometer silicon dioxide particles after machine washing for 20 times, and therefore the superhydrophilicity of the wool cloth is remained. Comparative Example 1 [0091] Treat the wool cloth with the same method as described in Example 1, but don't treat the wool cloth with the coupling agent as described in step (1). Test the wash fastness of the obtained wool cloth with the same method as described in Example 1. The result is shown in FIG. 12 . The result indicates that the water absorption time of the superhydrophilic wool cloth that is not treated with a coupling agent is longer than 200 s after machine washing for 10 times, indicating the wool cloth is not hydrophilic any more. Example 2 [0092] (1) Rinse and dry the cashmere cloth to be treated, and weigh 200 g cashmere cloth, immerse the cashmere cloth into 1 L toluene solution that contains 2 mM γ-aminopropyltrimethoxysilane, hold for 10 h, and then take out the cashmere cloth and dry for 300 min at 40° C.; [0093] (2) Immerse the cashmere cloth treated by step (1) in a mixed solution of water and ethanol (mixed at a volume ratio of 1:1) with pH adjusted to 14 by potassium hydroxide, at a bath ratio of 1:100; agitate for 10 min at room temperature; then, add methanol solution of tetramethyl orthosilicate at a concentration of 5 mol/L, and control the mass fraction of the tetramethyl orthosilicate in the mixed solution of water and ethanol with pH=14 at 0.1%, and agitate for 300 min at a constant temperature of 60° C.; adjust the pH value of the reacting solution with hydrochloric acid to 1, and then oscillate for 60 min at a constant temperature of 100° C.; [0094] (3) Take out the cashmere cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic cashmere cloth with wash fastness. [0095] The result of static contact angle test indicates that the contact angle between the surface of cashmere cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated cashmere cloth has a layer of nanometer silicon dioxide with a particle diameter of 700-800 nm obtained from hydrolization of tetramethyl orthosilicate and grafted to the fiber surface by chemical bonds. 202 g cashmere cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the cashmere cloth, the content of silicon dioxide is about 1.0% by mass. Example 3 [0096] (1) Rinse and dry the sheep wool cloth to be treated, and weigh 100 g sheep wool cloth, immerse the wool cloth into 1 L tetrachloroethylene solution that contains 200 mM γ-glycidoxypropyltrimethoxysilane, hold for 30 min., and then take out the wool cloth and dry for 20 min at 60° C.; [0097] (2) Immerse the wool cloth treated by step (1) in water solution of sodium hydroxide and ammonia (at a molar ratio of 1:1) with pH=10, at a bath ratio of 1:50; agitate for 15 min at room temperature; then, add water solution of sodium silicate at a concentration of 1 mol/L, wherein, the mass fraction of sodium silicate in the water solution of sodium hydroxide and ammonia with pH=10 is 1%; then, add nanometer silver particles with a particle diameter of 60 nm into the solution, wherein, the mass fraction of the nanometer silver particles in the water solution of sodium hydroxide and ammonia with pH=10 is 0.2%; agitate for 2 min at a constant temperature of 80° C., adjust the pH value of the reacting solution with acetic acid to 3, and then oscillate for 30 min at a constant temperature of 80° C.; [0098] (3) Take out the wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a multi-functional superhydrophilic wool cloth with wash fastness. [0099] The result of static contact angle test indicates that the contact angle between the surface of wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated wool cloth has a particle layer composed of nanometer silicon dioxide with a particle diameter of 10-20 nm obtained from hydrolization of sodium silicate and nanometer silver particles with a particle diameter of 60 nm, and grafted by chemical bonds. 100.9 g wool cloth grafted with nanometer silicon dioxide is obtained; the mass ratio between silicon and silver obtained by X-ray energy spectrum test is 3.73:1. Based on the total mass of the wool cloth, the content of nanometer silicon dioxide is about 0.7% by mass, and the content of the nanometer silver particles is about 0.2% by mass. [0100] Perform anti-bacteria test for the multi-functional superhydrophilic wool cloth. The result is shown in FIG. 13 . It is seen that the anti-bacteria zone is wider than 2 mm; therefore, the multi-functional superhydrophilic wool cloth has high anti-bacterial performance. Example 4 [0101] (1) Rinse and dry the sheep wool cloth to be treated, and weigh 200 g sheep wool cloth, immerse the wool cloth into 1 L mixed methylene chloride and tetrachloroethylene solution (at a volume ratio of 1:3) that contains 50 mM vinyltriethoxysilane, hold for 20 min., and then take out the wool cloth and dry for 10 min at 100° C.; [0102] (2) Immerse the wool cloth treated by step (1) in butanol with pH adjusted to 10 by potassium hydroxide and ammonia (at a molar ratio of 1:1), at a bath ratio of 1:5; agitate for 20 min at room temperature; then, add butanol solution of tetrabutyl orthosilicate at a concentration of 3 mol/L and butanol solution of tetrabutyl titanate at a concentration of 0.5 mol/L in sequence, and control the mass fraction of tetrabutyl orthosilicate in the butanol solution with pH=10 at 5% and the mass fraction of tetrabutyl titanate in the butanol solution with pH=10 at 5%, and agitate for 30 min at a constant temperature of 80° C.; adjust the pH value of the reacting solution with oxalic acid to 4, and then oscillate for 30 min at a constant temperature of 80° C.; [0103] (3) Take out the wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a multi-functional superhydrophilic wool cloth with wash fastness. [0104] The result of static contact angle test indicates that the contact angle between the surface of wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated wool cloth has a particle layer composed of nanometer silicon dioxide with a particle diameter of about 200 nm obtained from hydrolization of tetrabutyl orthosilicate and nanometer particles with a particle diameter of about 300 nm obtained from hydrolization of tetrabutyl titanate, and grafted by chemical bonds. 201.5 g wool cloth grafted with nanometer silicon dioxide is obtained; the mass ratio between silicon and titanium obtained in X-ray energy spectrum test is 1.55:1. Based on the total mass of the wool cloth, the content of nanometer silicon dioxide is about 0.5% by mass, and the content of the nanometer titanium oxide particles is about 0.3% by mass. Example 5 [0105] (1) Rinse and dry the sheep cloth to be treated, and weigh 100 g sheep wool cloth, immerse the wool cloth into 5 L ethanol solution that contains 2 mM vinyltrimethoxysilane, hold for 2 h, and then take out the wool cloth and dry for 20 min at 100° C.; [0106] (2) Immerse the wool cloth treated by step (1) in ammonia water solution with pH=9, at a bath ratio of 1:60, and agitate for 25 min at room temperature; then, add ethanol solution of tetraethyl orthosilicate at a concentration of 4 mol/L and nanometer titanium oxide particle with a particle diameter of 20 nm in sequence, and control the mass fraction of tetraethyl orthosilicate in the ammonia water solution with pH=9 at 5% and the mass fraction of nanometer titanium oxide particles in the ammonia water solution at 0.1%, and agitate for 20 min at a constant temperature of 80° C.; adjust the pH value of the reacting solution with acetic acid to 7, and then agitate for 2 min, and oscillate for 200 min at a constant temperature of 40° C.; [0107] (3) Take out the wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a multi-functional superhydrophilic wool cloth with wash fastness. [0108] The result of static contact angle test indicates that the contact angle between the surface of wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated wool cloth has a particle layer composed of nanometer silicon dioxide with a particle diameter of about 50 nm obtained from hydrolization of tetraethyl orthosilicate and nanometer titanium oxide particles with a particle diameter of 20 nm, and grafted by chemical bonds. 101 g wool cloth grafted with nanometer silicon dioxide is obtained; the mass ratio between silicon and titanium obtained by X-ray energy spectrum test is 16.3:1. Based on the total mass of the wool cloth, the content of nanometer silicon dioxide is about 0.9% by mass, and the content of the nanometer titanium oxide particles is about 0.06% by mass. [0109] The obtained multi-functional superhydrophilic wool cloth with wash fastness has a self-cleaning feature. As shown in FIG. 14 , after exposure to UV-irradiation for 1 h, the dye stains on the surface of the untreated wool cloth have no change, while almost all of the dye stains on the surface of the multi-functional superhydrophilic wool cloth with wash fastness treated with the method of the present invention are degraded completely. Example 6 [0110] (1) Rinse and dry the alpaca wool cloth to be treated, and weigh 200 g alpaca wool cloth, immerse the alpaca wool cloth into 1 L dimethyl sulfoxide solution that contains 100 mM γ-glycidoxypropyltriethoxysilicane, hold for 10 h, and then take out the alpaca wool cloth and dry for 3 h at 80° C.; [0111] (2) Immerse the alpaca wool cloth treated by step (1) in ethanol with pH=12 adjusted by ammonia, at a bath ratio of 1:30, and agitate for 5 min at room temperature; then, add methanol solution of tetramethyl orthosilicate at a concentration of 5 mol/L, and control the mass fraction of tetramethyl orthosilicate in the ethanol with pH=12 at 10%, and agitate for 300 min at a constant temperature of 30° C.; adjust the pH value of the reacting solution with phosphoric acid to 3, and then oscillate for 100 min at a constant temperature of 100° C.; [0112] (3) Take out the alpaca wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic alpaca wool cloth with wash fastness. [0113] The result of static contact angle test indicates that the contact angle between the surface of alpaca wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated alpaca wool cloth has a layer of nanometer silicon dioxide with a particle diameter of about 250 nm obtained from hydrolization of tetramethyl orthosilicate and grafted to the fiber surface by chemical bonds. 200.4 g alpaca wool cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the alpaca wool cloth, the content of silicon dioxide is about 0.2% by mass. Example 7 [0114] (1) Rinse and dry the rabbit wool cloth to be treated, and weigh 1 kg rabbit wool cloth, immerse the rabbit wool cloth into 20 L toluene solution that contains 10 mM vinyltrimethoxysilane, hold for 10 h, and then take out the wool cloth and dry for 2 h at 80° C.; [0115] (2) Immerse the rabbit wool cloth treated by step (1) in mixed solution of water and methanol (at a volume ratio of 2:1) with pH=13 adjusted by ammonia, at a bath ratio of 1:10, and agitate for 10 min at room temperature; then, add water solution of sodium silicate at a concentration of 1 mol/L, and control the mass fraction of sodium silicate in the mixed solution of water and methanol with pH=13 at 5%, and agitate for 2 min at a constant temperature of 100° C.; adjust the pH value of the reacting solution with nitric acid to 4, and then oscillate for 100 min at a constant temperature of 80° C.; [0116] (3) Take out the rabbit wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic rabbit wool cloth with wash fastness. [0117] The result of static contact angle test indicates that the contact angle between the surface of rabbit wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated rabbit wool cloth has a layer of nanometer silicon dioxide with a particle diameter of about 80 nm obtained from hydrolization of sodium silicate and grafted to the fiber surface by chemical bonds. 1000.5 g rabbit wool cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the rabbit wool cloth, the content of silicon dioxide is about 0.05% by mass. Example 8 [0118] (1) Rinse and dry the blended wool and cashmere cloth (at a mass ratio of 7:3) to be treated, and weigh 200 g cloth, immerse the cloth into 5 L ethanol solution that contains 10 mM methyltrimethoxysilane and 10 mM isopropyl tri(dioctyl pyrophosphate) titanate, hold for 3 h, and then take out the cloth and dry for 1 h at 80° C.; [0119] (2) Immerse the blended wool and cashmere cloth treated by step (1) in water with pH adjusted to 14 by lithium hydroxide, at a bath ratio of 1:60; agitate for 15 min at room temperature; then, add ethanol solution of tetramethyl orthosilicate at a concentration of 3 mol/L and ethanol solution of tetraethyl orthosilicate at a concentration of 2 mol/L in sequence, and control the mass fraction of tetramethyl orthosilicate and mass fraction of tetraethyl orthosilicate in the water solution with pH=14 at 5% respectively, and agitate for 300 min at a constant temperature of 30° C.; adjust the pH value of the reacting solution with oxalic acid to 3, and then oscillate for 80 min at a constant temperature of 70° C.; [0120] (3) Take out the blended wool and cashmere cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic blended wool and cashmere cloth with wash fastness. [0121] The result of static contact angle test indicates that the contact angle between the surface of blended wool and cashmere cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated blended wool and cashmere cloth has a layer of nanometer silicon dioxide with a particle diameter of about 150 nm obtained from hydrolization of tetramethyl orthosilicate and tetraethyl orthosilicate and grafted to the fiber surface by chemical bonds. 208 g blended wool and cashmere cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the blended wool and cashmere cloth, the content of silicon dioxide is about 3.8% by mass. Example 9 [0122] (1) Rinse and dry the sheep wool cloth to be treated, weigh 100 g cloth, and immerse it into 1 L ethanol solution that contains 10 mM tetra-(2,2-diallyloxy-methyl-1-butyl) bis[di(tridecyl) phosphate] titanate, hold for 200 min, and then take out the cloth and dry for 30 min naturally; [0123] (2) Immerse the sheep wool cloth treated by step (1) in mixed solution of methanol and ethanol (at a volume ratio of 1:1) with pH=12 adjusted by ammonia, at a bath ratio of 1:60, and agitate for 25 min at room temperature; then, add water solution of sodium silicate at a concentration of 1 mol/L, and control the mass fraction of sodium silicate in the mixed solution of methanol and ethanol with pH=12 at 10%, and agitate for 300 min at a constant temperature of 40° C.; adjust the pH value of the reacting solution with hydrochloric acid to 1, and then oscillate for 80 min at a constant temperature of 80° C.; [0124] (3) Take out the wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic wool cloth with wash fastness. [0125] The result of static contact angle test indicates that the contact angle between the surface of sheep wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated sheep wool cloth has a layer of nanometer silicon dioxide with a particle diameter of about 400 nm obtained from hydrolization of sodium silicate and grafted to the fiber surface by chemical bonds. 100.6 g sheep wool cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the sheep wool cloth, the content of silicon dioxide is about 0.6% by mass. Example 10 [0126] (1) Rinse and dry the sheep wool cloth to be treated, and weigh 200 g sheep wool cloth, immerse the wool cloth into 2 L toluene solution that contains 50 mM N-methyl-γ-aminopropyl trimethoxysilane and 50 mM N-methyl-γ-aminopropyl triethoxysilane, hold for 2 h, and then take out the sheep wool cloth and dry for 10 h naturally; [0127] (2) Immerse the sheep wool cloth treated by step (1) in a mixed solution of water and dimethyl sulfoxide (mixed at a volume ratio of 5:1) with pH adjusted to 11 by sodium hydroxide, at a bath ratio of 1:40; agitate for 30 min at room temperature; then, add methanol solution of tetramethyl orthosilicate at a concentration of 5 mol/L and zinc acetate powder in sequence, and control the mass fraction of tetramethyl orthosilicate in the mixed solution of water and dimethyl sulfoxide with pH=11 at 5% and the mass fraction of zinc acetate in the mixed solution of water and dimethyl sulfoxide at 10%, and agitate for 300 min at a constant temperature of 60° C.; adjust the pH value of the reacting solution with acetic acid to 3, and then oscillate for 20 min at a constant temperature of 100° C.; [0128] (3) Take out the sheep wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a multi-functional superhydrophilic wool cloth with wash fastness. [0129] The result of static contact angle test indicates that the contact angle between the fiber surface of sheep wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated sheep wool cloth has a particle layer composed of nanometer silicon dioxide with a particle diameter of about 200 nm obtained from hydrolization of tetramethyl orthosilicate and nanometer zinc oxide particles with a particle diameter of 30-50 nm obtained from hydrolization of zinc acetate, and grafted by chemical bonds. 214 g wool cloth grafted with nanometer silicon dioxide is obtained; the mass ratio between silicon and zinc obtained by X-ray energy spectrum test is 0.23:1. Based on the total mass of the sheep wool cloth, the content of nanometer silicon dioxide particles is about 1.2% by mass, and the content of the nanometer zinc oxide particles is about 5% by mass. Example 11 [0130] (1) Rinse and dry the sheep wool cloth to be treated, and weigh 100 g sheep wool cloth, immerse the wool cloth into 2 L toluene solution that contains 50 mM N-methyl-γ-aminopropyl trimethoxysilane and 50 mM N-methyl-γ-aminopropyl triethoxysilane, hold for 2 h, and then take out the wool cloth and dry for 10 h naturally; [0131] (2) Add silicon dioxide particles with a particle diameter of 50 nm into water at a mass fraction of 1%, agitate for 5 min, and immerse the sheep wool fabric treated by step (1) into the reacting solvent, at a bath ratio of 1:50; adjust the pH value of the reacting solution to 3 with hydrochloric acid, and then oscillate for 20 min at a constant temperature of 80° C.; [0132] (3) Take out the sheep wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a superhydrophilic wool cloth with wash fastness. [0133] The result of static contact angle test indicates that the contact angle between the surface of wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated sheep wool cloth has a layer of nanometer silicon dioxide with a particle diameter of 50 nm grafted by chemical bonds. 100.1 g sheep wool cloth grafted with nanometer silicon dioxide is obtained. Based on the total mass of the sheep wool cloth, the content of silicon dioxide is about 0.1% by mass. Example 12 [0134] (1) Rinse and dry the sheep wool cloth to be treated, and weigh 100 g sheep wool cloth, immerse the sheep wool cloth into 2 L ethanol solution that contains 20 mM bis[3-(triethoxysilyl) propyl] amine, hold for 1 h, and then take out the sheep wool cloth and dry for 20 min at 80° C.; [0135] (2) Add silicon dioxide particles with a particle diameter of 50 nm and nanometer titanium oxide particles with a particle diameter of 30 nm into water, and control the mass fraction of silicon dioxide particles in water at 1% and the mass fraction of nanometer titanium oxide particles in water at 1%; agitate for 10 min, and immerse the wool fabric treated by step (1) into the reacting solvent, at a bath ratio of 1:10; adjust the pH value of the reacting solution to 4 with acetic acid, and then oscillate for 20 min at a constant temperature of 100° C.; [0136] (3) Take out the sheep wool cloth treated by step (2), rinse it with tap water for three times, and dry it, to obtain a multi-functional superhydrophilic wool cloth with wash fastness. [0137] The result of static contact angle test indicates that the contact angle between the surface of sheep wool cloth and water is zero. The result of SEM analysis indicates that the fiber surface of the treated sheep wool cloth has a particle layer composed of nanometer silicon dioxide with a particle diameter of 50 nm and nanometer titanium oxide with a particle diameter of 30 nm, and grafted by chemical bonds. 103.4 g sheep wool cloth grafted with nanometer silicon dioxide is obtained; the mass ratio between silicon and titanium obtained in X-ray energy spectrum test is 1.43:1. Based on the total mass of the sheep wool cloth, the content of nanometer silicon dioxide is about 2% by mass, and the content of the nanometer titanium oxide is about 1.4% by mass.
A superhydrophilic wool fabric with wash fastness and a preparation method thereof are disclosed. Nanometer particles are grafted on the fiber surface of the superhydrophilic wool fabric with wash fastness by chemical bonds. The nanometer particles include nanometer silicon dioxide whose particle diameter is 10-800 nm. Based on the total mass of the superhydrophilic wool fabric with wash fastness, the amount of the nanometer silicon dioxide is 0.05-5% by mass. The preparation method of the present application includes the following steps: pretreating a wool fabric with a coupling agent; then adjusting the pH value of the reactive solution, immersing the pretreated wool fabric in the reactive solvent and stirring under constant temperature; adding silicon dioxide particles with a particle diameter of 10-800 nm or a solution that contains precursor of silicon dioxide into the reacting solvent in which the wool fabric is immersed, readjusting pH value of the reactive solution, oscillating for a period of time under constant temperature, taking out the wool fabric, cleaning and drying. The superhydrophilic wool fabric with wash fastness of the present application has the effects of water-absorbing and quick drying, and is fully wash wear. The operation of the method of the present invention is simple. A functionality design can be realized in the microcosmic field. The fabric of the present invention simultaneously has multiple functions such as water- absorbing and quick drying, bacteriostasis, and self-cleaning.
3
BACKGROUND OF THE INVENTION The invention concerns a contact unit for a card-shaped carrier element of electronic components, especially in accordance with PCMCIA standards, comprising a plug-in or insertable card-shaped housing that comprises a base plate and a cover plate that is congruent thereto at least in the transverse direction, between which is formed a slot-like insertion channel that opens on one side of the housing for accommodating a chip-card, and that at the opposing side is provided a plug-in strip, and furthermore comprising arranged parallel to the insertion channel in the housing a printed circuit board that is connected electrically to the plug-in strip and that is provided on its surface with a contact field for contact with the chip-card. Given the increasing miniaturization in the field of computer technology, electronic components are more and more frequently arranged on or in card-shaped carrier elements with a view toward variability and transportability. Frequently encountered are carrier elements in accordance with PCMCIA standards that are cards that comprise a standard-compliant matrix-like connector strip and can accommodate a great variety of electronic components, depending on application. For instance, such cards are employed as memory expansion cards, drive cards, modem cards, etc. The interface to a data processing system (e.g., a notebook computer) is created by means of the plug-in strip, which effects a mechanical and electrical contact with a PCMCIA slot in the data processing system. Widely used are chip-cards that have integrated circuits and comprise flush contact fields arranged for contact with, e.g., correspondingly designed reading units. Known areas of application for this type of chip-cards are currently telephone cards, authorization cards, or what are known as “SmartCards”. Known in the current art are contact units that make it possible to connect a chip-card to a PCMCIA standard interface in a data processing system. The combination of a PCMCIA card and a chip-card contact unit that can be inserted into a corresponding modular insertion slot in a computer and then read is useful in a wide variety of applications (e.g., electronic banking, pay TV, authenticating access authorization to data networks, etc.). The disadvantage is that known chip-card readers of this type comprise an extension in the housing in the form of an enlarged insertion guide for the chip-card that extends beyond the insertion area of the modular insertion slot in the computer and that simultaneously provides a grip for the user. This means the readers are substantially longer than standard PCMCIA cards so that when in the operating position this extension projects out of the insertion slot, e.g., in a notebook computer, so that during mobile operation there is a risk that the contact unit will jam in the slot or might even be bent or damaged. This extension has thus far been considered necessary for safely guiding the chip-card into and out of the slot-type insertion channel without the risk of inserting the card improperly—that is, for introducing, retaining, and removing a chip-card. As the usage of transportable computers (e.g., laptop and notebook computers) continues to increase, there is a technical requirement that a chip-card reader situated in the operating position be completely insertable into the slot in the computer without projecting parts interfering with usage. This becomes important, e.g., when a chip-card must be inserted for personal authorization to use the computer. Although contact elements are known that do not comprise an extension and thus correspond to the PCMCIA standard, these are provided at least partially with closed sides in order to achieve lateral guidance for the chip-card. However, a significant market requirement is that the width of a contact unit also comply exactly with the PCMCIA standard so that even the wall thickness, {fraction (1/10)}mm, for the sides does not deviate substantially from the PCMCIA standard. An additional disadvantage of very thin-walled sides is that the slightest misplacement of the chip-card when it is inserted into the contact unit can damage the card. An additional disadvantage results when the thin sides are deformed and it is then no longer possible to insert the chip-card. The object of the invention is to further develop a contact unit for a card-shaped carrier element in electronic components such that the contact unit can be completely inserted into a PCMCIA slot in a computer without parts projecting therefrom and the object is furthermore also to ensure that proper insertion is still possible and that there is sufficient mechanical stability and simple manufacture. This object is achieved in a contact unit of the type cited in the foregoing in that the insertion channel is continuously open over its entire length in the direction the chip-card is inserted and in that the base plate and cover plate are securely attached to each other solely in the region adjacent to the insertion channel in the direction of insertion. The features in accordance with the invention make it possible to provide a contact unit the length and width of which comply precisely with the PCMCIA standard, e.g., Type II, and which can be inserted in its entirety into the PCMCIA slot of a computer (e.g., a notebook computer) without parts projecting therefrom. The complete insertability precludes any risk of damage, especially during transport, wherein a protective flap can also be provided that closes the PCMCIA slot when the contact unit is inserted. Of course, in this case it is not possible to leave a chip-card in the contact unit since, corresponding to the length of the region adjacent to the insertion channel, it projects from the contact unit when in its inserted position. In a preferred embodiment of the invention, the connection of base plate and cover plate in the region adjacent to the insertion channel in the direction of insertion is also a swivelling axis relative to which the base plate and cover plate can swivel slightly such that the height of the insertion channel can be changed against the effect of a restoring force. The advantage of this is that when inserted into the insertion channel the chip-cards can be retained clamp-like in the channel. It is particularly advantageous when the height of the insertion channel declines as the distance from the connection increases when there is no chip-card inserted therein. When the chip-card is inserted into the insertion channel, the latter expands and the chip-card is held securely in the channel by means of inherent elastic return deformation. At the same time a high degree of form stability in the contact unit and compensation of production tolerances can be achieved in this manner. Furthermore, a particular advantage is that the printed circuit board is connected at its end opposing the plug-in strip to a metal strip that is affixed to the printed circuit board in the housing and that comprises flexibly extending tabs that electrically conductively adjoin the metal cover plate. The metal strip in this manner keeps the printed circuit board level in the housing and also provides a grounded transition to the printed circuit board. With regard to this latter, it is necessary that the metal strip is connected to grounded contact surfaces in the printed circuit board. In order to facilitate simple assembly, in accordance with an additional feature of the invention the metal strip is arranged on a plastic profile that is connected to the cover and that constitutes an upper insertion guide for the chip-card. The plastic profile can be provided on its side facing the insertion channel guides for a chip-card and can be joined to the metal strip, e.g., by clamping, adhesive, or locking means. In accordance with a further advantageous development of the invention, provided in the insertion channel is at least one spring element, the one end of which is securely joined to the cover plate and the other, free end of which can be detachably attached to the base plate. The spring element fulfills a plurality of roles. When no chip-card is inserted, the spring element ensures that the height of the insertion channel remains the same against the action of the restoring force so that the chip-card can be easily introduced. Since the free end of the spring element is detachably attachable to the base plate, the insertion channel is simultaneously protected against outward expansion. This provides the contact unit additional form stability. Introducing the chip-card releases the free end and the spring element is bent in the insertion channel in the direction of the cover plate so that due to this spring-effect the chip-card is subjected to increased pressure which also ensures the contact. Advantageously the spring element is produced integral to the metal strip and when a chip-card is inserted extends to the cover plate through cut-outs in the printed circuit board so that chip-card and metal cover plate are conductively connected to each other, whereby static charging of the chip-card can be prevented. Securing the free end of the spring element on the base plate also makes it possible to achieve a bonding point between cover plate, printed circuit board, and base plate when there is no chip-card inserted. The metal strip and the spring element are cost-effective to produce by means of stamping and bending as strip-type goods and can be joined to the cover plate or to the plastic profile constituting the upper insertion guide in a single step by means of caulking, adhesive, welding, or ultrasound welding. In order to obtain the compression/tension effect with the spring element, it is useful to embody the spring element in an approximate S-shape and to provide at its free end a claw-shaped extension that engages a mating lock element for securing the spring element. In accordance with an additional feature of the invention, it is advantageous to provide the lock element an undercut in which the claw-shaped extension of the spring element is releasably held. In an advantageous embodiment of the invention it is furthermore suggested that the lock element is embodied in a reinforcing plate made of plastic or metal that is joined to the base plate. While a reinforcing plate made of plastic can be joined to the metal base plate by means of injection molding, a metal reinforcing plate can be joined to the base plate by means of welding or adhesive. Advantageously the lock element is employed as a separate component in the reinforcing plate or as a cut-out in the reinforcing plate that is at least single-layer. In the latter case the undercut in the lock element can be produced by punching or stamping a single-layer reinforcing plate or by the offset arrangement of two reinforcing plates, one above the other and provided with openings. If, however, the lock element comprises a separate component, it is useful to prefabricate this component and press it into an opening in the reinforcing plate. In accordance with an additional feature of the invention, the base plate at its end opposing the plug-in strip is provided with a plastic profile that functions as a lower insertion guide in order to ensure that the chip-card can be easily inserted. The plastic profile can be provided guides analogous to those for the upper insertion guide. In an advantageous embodiment of the invention it is furthermore suggested that the base plate and cover plate are each provided at said plug-in strip with plastic holders arranged on the edge for fastening thereto that can be securely joined by means of a plastic bond like adhesive, ultrasound welding, or heat pressing. Base plate and cover plate can be securely joined in this manner. Alternatively, or in addition thereto, in accordance with an additional feature of the invention the base plate and cover plate are congruent and are welded to each other at lateral welded brackets. In this case it is particularly advantageous when the length of the secure joining of base plate and cover plate is approximately 30% of the overall length of the contact unit because this results in high form stability in the contact unit. Finally, it is suggested that an end stop comprising a stop angle is provided for limiting the insertion of the chip-card. Depending on requirements, insertion of the chip-card can also be limited by the lateral welding brackets or by the plastic holders, which are then provided with appropriate rounded stop surfaces. BRIEF DESCRIPTION OF THE DRAWINGS Additional details, features, and advantages of the subject of the invention can be appreciated from the following description of two exemplary embodiments, with reference to the associated drawings, in which: FIG. 1 is a perspective view of a contact unit that does not have a chip-card inserted therein; FIG. 1 a is a perspective view of the contact unit in accordance with FIG. 1 into which a chip-card has been inserted; FIG. 1 b is a perspective view of the contact unit in accordance with FIG. 1 showing swiveling of the base plate and the cover plate relative to one another. FIG. 2 illustrates the individual parts of the contact unit in accordance with FIG. 1 in a perspective view of housing members that have been flipped open and taken apart and their internal composition; FIG. 3 illustrates the individual parts of the contact unit in accordance with FIG. 2 in an intermediate stage of assembly; FIG. 3 a is a perspective exploded view of the attachment of a metal strip to a plastic profile; FIG. 3 b is a perspective view of the attachment of the metal strip in accordance with FIG. 3 a to a printed circuit board; FIG. 4 illustrates a side view of the contact unit in accordance with FIG. 1; FIG. 4 a illustrates a side view of the contact unit in accordance with FIG. 1 a; FIG. 5 illustrates the individual parts of an alternative embodiment of a contact unit in a perspective view of the housing members that have been flipped open and taken apart and their internal composition; FIG. 6 illustrates the individual parts of the contact unit in accordance with FIG. 5 in an intermediate stage of assembly; FIG. 7 shows a side view of the contact unit in accordance with FIG. 5 that does not have a chip-card inserted therein; and FIG. 7 a illustrates a side view in accordance with FIG. 6 into which a chip-card has been inserted. DESCRIPTION OF THE PREFERRED EMBODIMENTS The exemplary embodiment of the invention illustrated in FIG. 1 shows a contact unit 1 designed as a chip-card reader that is provided for contact with a notebook computer by means of a standard PCMCIA interface. The contact unit 1 comprises a two-member external housing 2 having a base plate 3 , a PCMCIA interface field in the form of a plug-in strip 4 with 68 poles at the front end (relative to the direction in which it is inserted into the notebook computer, as indicated by the arrow), an upper and lower insertion guide 5 , 5 a on the opposing end for introducing a chip-card 9 , e.g., in accordance with ISO 78 16, and a cover plate 6 that extends parallel to and at a distance from the base plate 3 and that is rigidly joined to the base plate 3 in the region of the plug-in strip 4 . The parts of the contact unit cited are carried by the interior plastic profile elements made of PCB and illustrated in FIGS. 2 and 3, which furthermore hold a PCMCIA printed circuit board 7 spaced parallel to the base plate 3 in such a manner that formed therebetween is an insertion channel 8 for the ISO 78 16 chip-card 9 that is insertable into the contact unit via an insertion slot 10 between the insertion guides 5 , 5 a . The chip-card 9 can be inserted into and withdrawn from the contact unit 1 in the direction of the double arrow shown in FIG. 1, wherein contact can be created by means of the chip field 11 arranged on the surface of the chip-card 9 and a contact field 11 ′ on the underside of the PCMCIA printed circuit board 7 , which contact makes it possible to process the chip-card via the PCMCIA card when the contact unit 1 is inserted into the notebook and is connected to its PCMCIA interface via the plug-in strip 4 . FIG. 2 illustrates the two individual members of the external housing 1 , i.e., the base plate 3 in a perspective view of the interior and the cover plate 6 , flipped 180°, also in a perspective view of the interior. Base plate 3 and cover plate 6 are separate pieces of sheet that are not joined to each other and that have clips 12 bent inward on the longitudinal sides 13 , 14 and in the back side 15 (relative to direction of insertion), while the front side (relative to direction of insertion) remains free so that the plug-in strip 4 can be arranged there later. In the exemplary embodiment illustrated in FIG. 2, the base plate 3 is provided with a welded reinforcing plate 16 that makes it possible to employ an extraordinarily thin housing sheet of approximately {fraction (2/10)}mm thickness. It should be appreciated that instead of metal, a reinforcing plate 16 made of plastic can be used that can be manufactured, along with other plastic parts described below, in a single process step by means of injection molding. The clips 12 comprise an L shape and it is provided that these be punched from the sheet of the base plate 3 and cover plate 6 , bent upward 90° out of the plane toward the interior and then be bent again 90° inward so that there is a free leg that projects into the subsequent interior of the contact unit 1 parallel to the base plate 3 and cover plate 6 at the clips 12 , which represents a particularly advantageous fastening device for coating the clips 12 , also described below. The number and arrangement of the clips 12 on the base and cover plates 3 , 6 are coordinated to provide a housing that is as torsion-proof as possible, wherein it has proved useful to provide a plurality of clips 12 on the cover plate 6 , while on the base plate 3 , the plastic profile 18 that constitutes the lower insertion guide 5 a is held in place with clips 12 on the side 15 and with hooks 17 . The hooks 17 are likewise punched from the sheet for the base plate 3 and bent upward and inward in an L shape. In principle, instead of using clips 12 and hooks 17 punched out of the material of the base and cover plates, it is also possible to use separate fastening elements that then must be mechanically joined to the housing members. FIG. 2 furthermore illustrates the plastic profiles employed in the interior of the contact unit 1 , which profiles in the preferred embodiment are not however manufactured separately and introduced into the housing but rather are manufactured in connection with the corresponding metal parts of the housing in a single process step in the injection molding process. Provided in the front region of the base plate 3 (relative to the direction of insertion) for holding the plug-in strip 4 are plastic holders 19 , 20 that simultaneously constitute axial stops for limiting the insertion of the chip-card 9 and that comprise corresponding rounded stop surfaces 24 . The plastic holders 19 correspond to correctly shaped holders 25 , 26 on the free ends of a U-shaped plastic frame 27 that belongs to the cover plate 6 and that at its closed side comprises a strip 28 constituting the upper insertion guide 5 and provided with a platform-type tier 21 for attaching a metal strip 22 . The longitudinal legs of the plastic frame 27 comprise a guide that is open toward the interior and that is in the form of a step 29 for engaging and holding the printed circuit board 7 , which when assembled is fixed by the plastic frame 27 , wherein the holders 25 , 26 together with the plastic holders 19 , 20 fix the plug-in strip 4 connected to the printed circuit board 7 . The plastic elements illustrated in FIGS. 2 and 3 are furthermore provided various positioning projections and recesses 30 for positioning purposes. The printed circuit board 7 shown adjacent thereto is arranged on the cover plate 6 , flipped 180°, such that at the front the knobs 31 on the side of the plug-in strip 4 engage in the corresponding recesses on the plastic holders 25 , 26 and opposing grounded contact surfaces 23 in the printed circuit board 7 are pushed flush under the clamp contacts 32 in the metal strip 22 . The base plate 3 is arranged flipped 180° on the cover plate 6 . This means that formed between the base plate 3 and the cover plate 6 with the printed circuit board 7 is the insertion channel 8 that remains free for introducing the chip-card 9 and that makes it possible for the chip field 11 to contact the PCMCIA card through the contact field 11 ′. The base plate 3 and the printed circuit board 7 in FIGS. 2 and 3 are not shown in their assembled positions, but flipped 180° in order to make it possible to see the interior. It shall be appreciated that allocated to the cover plate 6 is the U-shaped plastic frame 27 , which is held to the cover plate 6 by the corresponding clips 12 and upon which the prepared base plate 3 is placed after assembly with the printed circuit board 7 in the manner described. In addition, in contrast to FIG. 2, FIG. 3 illustrates the correct arrangement of the plastic elements on the base plate 3 and cover plate 6 , wherein it can be seen that the clips 12 are no longer visible. This is due to the preferred manufacturing process used during the manufacture of the contact unit 1 in which the exterior housing members in the form of base plate 3 and cover plate 6 are punched as separate pieces of sheet that are not connected to each other, the clips 12 and hooks 17 being punched and bent inward at the same time; in a second process step the base plate 3 is provided with the plastic holders 19 , 20 and the plastic profile 18 and the cover plate 6 is provided with the plastic frame 27 , this being done separately using an injection molding process in the form of a unit. The printed circuit board 7 and its plug-in strip 4 are then flipped 180° and placed onto the cover plate 6 , positioned on the metal strip 22 and the plastic holders 25 , 26 , and in a final process step the housing members pre-assembled in this manner with interior plastic elements are arranged upon each other and joined to each other by means of a plastic joining technique, particularly adhesive or ultrasound welding. FIG. 3 a illustrates the assembly of the metal strip 22 with the upper insertion guide 5 and FIG. 3 b illustrates its [the metal strip's] assembly with the printed circuit board 7 . The clamping contacts 32 in the metal strip 22 are arrested on the grounded contact surfaces 23 on the printed circuit board 7 . Spring elements 33 that are integral to the metal strip 22 engage in the cut-outs 34 of the printed circuit board 7 , as can be seen especially in FIG. 3 b . The metal strip 22 is also provided with bores 35 and grounded contact springs 36 . The bores 35 cooperate with corresponding pins 37 on the tier 21 in the strip 28 , the metal strip 22 and the printed circuit board 7 connected to the metal strip 22 via the clamp contacts 32 being centered on the cover plate 6 . The metal strip 22 is fixed by subsequent ultrasound welding. The functionality of the spring elements 33 integral to the metal strip 22 can be seen in FIGS. 4 and 4 a . FIG. 4 illustrates the contact unit 1 with no chip-card 9 inserted, while as can be seen in FIG. 4 a , the chip-card 9 has been inserted into the insertion channel 8 up to the rounded stop surfaces 24 , the chip field 11 of the chip-card 9 coming to rest at the contact field 11 ′ in the printed circuit board 7 . The spring element 33 is essentially S-shaped and is provided at its free end with a claw-shaped extension 39 that engages under prestress when there is no inserted chip-card 9 a lock element 40 embodied as a recess in the reinforcing plate 16 . As can be seen in FIG. 4 a , the lock element 40 comprises an undercut that ensures that the spring element 33 is arrested. The cover plate 6 and the base plate 3 are connected to each other by the plastic holders 19 , 20 , 25 , 26 such that they are subject to a clamping force. The spring element 33 ensures that the height of the insertion channel 8 does not change, which facilitates simple insertion of the chip-card 9 . When the chip-card 9 is inserted into the insertion channel 8 , the front of the chip-card 9 (relative to direction of insertion) presses the spring element 33 in the direction of the cover plate, the spring element 33 being pressed through the cut-out 34 in the printed circuit board 7 against the metal cover plate 6 . Thus the chip-card 9 can be inserted into the insertion channel 8 up to the rounded stop surfaces 24 and is clamped therein by the internal stress inherent in the base and cover plates 3 , 6 . In addition, the spring element 33 presses on the chip-card 9 so that contact is assured between chip-card 11 and contact field 11 ′. When the chip-card 9 is removed from the insertion channel 8 , the spring element 33 returns to the lock element 40 , this also creating a connection between metal strip 22 respectively to cover plate 6 and base plate 3 . The alternative embodiment of the contact unit 1 illustrated in FIGS. 5 through 7 a comprises on the base plate 3 and cover plate 6 in the region adjoining the insertion channel 8 in the direction of insertion additional welded brackets 41 by means of which the base plate 3 and cover plate 6 are joined together and the clamping internal stress in the contact unit 1 is obtained. In contrast to the embodiment in accordance with FIGS. 2 through 4 a , the metal strip 22 does not comprise the spring element 33 so that when no chip-card 9 is inserted the insertion channel 8 in the contact unit 1 tapers from the welded brackets (which are also the swivelling axis) in the direction of the upper and lower insertion guides 5 , 5 a . When a chip-card 9 is inserted, the insertion channel 8 expands while generating a restoring force, this holding the chip-card 9 in the insertion channel 8 in a clamping manner. The welded brackets 41 on the cover plate 6 are offset for enabling the brackets 41 to be welded without infringing on the width dimensions in the PCMCIA standard. In addition, the plastic holders 19 , 20 , 25 , and 26 can be welded together in a known manner. From FIGS. 2 and 5 it can be seen that the reinforcing plate 16 can be provided with an insulating film or element 42 that is used particularly when the reinforcing plate 16 is made of metal so that short-circuits can be prevented between the contact field 11 ′ on the printed circuit board 7 and the reinforcing plate 16 arranged opposed thereto. In addition, a wear-resistant insulating film can be applied to the underside of the printed circuit board 7 to prevent wear on the chip-card 9 and to simultaneously insulate the conductors and through-contacts on the printed circuit board 7 on the side facing the insertion channel 8 . It can also be seen from FIG. 2 that the lock element 40 can also embody a separate component that is pressed into recesses in the reinforcing plate 16 . This is particularly simple and cost-effective. In order to make it simple to introduce a chip-card 9 into the insertion channel 8 , the lower insertion guide 5 a can in addition be embodied in the form of a lower lip (relative to the upper insertion guide 5 in the direction in which the chip-card 9 is inserted). With the contact unit 1 described in the foregoing a chip-card reader is created that precisely corresponds to PCMCIA dimensions when a chip-card is not inserted and that provides assured contact and sufficient mechanical stability. In addition, security is increased in that the cover plate 6 and base plate 3 are congruent so that when inserted into the PCMCIA slot in a computer the base plate 3 and cover plate 6 are conducted into the lateral guides in the PCMCIA slot. This prevents the cover plate 6 from being forcibly bent upward or downward relative to the base plate 3 in an adjacent PCMCIA slot in the computer. Furthermore, the metal embodiment of the base plate 3 and cover plate 6 provides shielding and a high degree of functional stability and stability in the contact unit 1 , even at high stagnation and ambient temperatures above 100° C. Finally, the contact unit 1 is also distinguished by simple and cost-effective manufacture. The specification incorporates by reference the disclosure of German priority document 298 11 425.9 of Jun. 29, 1998 and European Patent Application priority document PCT/EP99/03560 of May 25, 1999. The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.  1 Contact unit  2 Exterior housing  3 Base plate  4 Plug-in strip  5 Upper insertion guide  5a Lower insertion guide  6 Cover plate  7 PCMCIA printed circuit board  8 Insertion channel  9 Chip-card 10 Insertion slot 11 Chip field   11′ Contact field 12 Clips 13 Longitudinal side 14 Longitudinal side 15 Side 16 Reinforcing plate 17 Hook 18 Plastic profile 19 Plastic holder 20 Plastic holder 21 Platform or tier 22 Metal strip 23 Ground contact surface 24 Stop surfaces 25 Plastic holder 26 Plastic holder 27 Plastic holder 28 Strip 29 Step 30 Positioning projection/recess 31 Knobs 32 Clamp contact 33 Spring element 34 Cut-out 35 Bore 36 Grounded contact spring 37 Pin 38 End stop 39 Extension 40 Lock element 41 Welded bracket 42 Insulating element
A contact unit for a card-shaped carrier element of electronic components is provided. The contact unit includes an insertable card-shaped housing that has a base plate and a cover plate that is congruent to the base plate at least in the transverse direction. Formed between the base plate and the cover plate is a slot-like insertion channel that opens on one side of the housing for accommodating a chip-card. At the opposite side is provided a plug-in strip. Disposed parallel to the insertion channel, in the housing, is a printed circuit board that is electrically connected to the plug-in strip and that is provided on its surface with a contact field for contact with the chip-card. The insertion channel is continuously open on both sides over its entire length in the direction in which the chip-card is inserted. The base plate and the cover plate are securely attached to one another solely in the region adjacent to the insertion channel in the direction of insertion.
7
CROSS REFERENCE TO RELATED APPLICATION [0001] Priority is claimed to U.S. Provisional Patent Application Ser. No. 60/481,957, filed Jan. 27, 2004, the contents and program listing of which are incorporated herein by reference. This application is a continuation-in-part of U.S. patent application Ser. No. 10/997,121, filed Nov. 24, 2004, which has priority to Provisional Application Ser. No. 60/525,905, filed Nov. 26, 2003, the contents of both of which are incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a system and method of collecting, revising, organizing and storing data concerning an online community. [0004] 2. Description of the Related Art [0005] A widely used model for organizing and implementing purchases online is use of a shopping cart analog. Such electronic commerce typically involves users browsing web sites and, when they see items that they want to purchase, adding the items to the shopping cart (phase 1 of purchasing). When they have added all their items, users typically enter a check-out phase (phase 2 of purchasing) that allows the users to confirm the items in their shopping cart and specify or modify shipping and payment information. In another shopping model, online commerce websites have pre-stored purchase and delivery information for some users, and once the users have selected and approved items for purchase, the order is completed. A more recent phenomenon is the usage of online social networking systems that allow people to exist in communities and publish content to the web or associated content with themselves. There have also been approaches that allow groups to browse the web together and shop together by sharing reviews and other preferences. One way to accomplish this includes linking to content in known systems, such as a hyperlink to the associated content of friends, or a user could re-create the content and provide a message saying where the content originated, etc. One deficiency of the known methodology is that user input and linking is required, making it relatively difficult for a user to share and make available shopping or product information. [0006] One known linking methodology applied to creative processes has been developed by Creative Commons (creativecommons.org), which provides licenses for creation of derivative works (new creative works based pre-existing works), which allows users to share their creativity. Although this promotes sharing in the creative process, it suffers the deficiency that it fails to provide a way of sharing in product or service shopping, or in sharing preferences pertaining to media such as music, video, shows, etc. [0007] Accordingly, there exists a need for a system and method of sharing and passing on of content, such as art or music reviews, and product preferences, while giving credit to the original author and providing a reference to the original form created by the author. [0008] A known means for content referencing has been through the use of external or internal hyperlinking. This method suffers a disadvantage of not allowing content to be present with the user or group who is advocating it, and requires clicking a link for access. Accordingly there also exists a need for an automated system of providing users with the ability to incorporate and reference other user or group content into their own content collections. There further is a need for a system providing improved access to incentives for content creators to allow their content to be collected in such a manner. [0009] There also is a need for a system and method of collecting, sharing, and tracking user or group associated activity via a communications network that enables users to easily incorporate other users' content into their own content—whether related to products, services, reviews or any form of content a user may wish to associate with herself or himself. SUMMARY OF THE INVENTION [0010] The present invention alleviates to a great extent the disadvantages of known advertising and content evaluation systems by providing an automated mechanism where brand owners can tap into a network of individuals or groups who are willing to represent their brands via their identities as part of a community. [0011] In some embodiments, the present invention involves using a tool referred to as a GRAB BAG to collect the content or associated content of individuals or groups and associate it with a particular user. In this embodiment, individuals or groups agree to allow such content to be collected in exchange for a service, as part of an online service, or for some reward, monetary or otherwise. Once grabbed, the content can be referenced from the grabbers' content or even purchased via traditional shopping cart functionality, which in one embodiment would have an associated reward for the owner of the original associated content. In one implementation, it also provides a way for the original content owner to track the dissemination of his/her material. [0012] In one aspect of the invention, a framework of collecting and sharing images in an online gallery is provided. In this aspect, users optionally are connected via their real life relationships to one another. For example, a user may browse a friend's (such as for hypothetical example, Mike's) galleries. The user can add to his/her GRAB BAG all the images that Mike has in his gallery. The user can access another friend's (such as for hypothetical example, Melissa's) content and add an image of a mutual friend that the user finds in one of her galleries to the user's GRAB BAG. Once in the GRAB BAG, the user may convert the image to a gallery of his/her own (optionally referencing Melissa and Mike) for people who visit the user's galleries (which may be a different audience) to view. It should be noted that “friend” is used herein to mean any associated individual or group and does not require there to be a personal relationship outside the context of the referencing discussed herein. Alternatively, the user may wish to print these images in his/her GRAB BAG via a partnered picture printing service company. In either case, Mike and Melissa may receive a reward of some kind. In one example, the reward would be a percentage of the image printing profit or the advertisements that are associated with the pages when their pictures are present, although other forms of rewards also may be provided. Mike and Melissa could also take advantage of an interface that informed them about who had collected their content. One benefit to this method is that the content need not be duplicated. It can exist once in storage and be referenced by more than one individual. For example, if there is video that is being referenced on Jack's web page and on Jill's web page, but it is John's original content collected from John's page, the video need only be stored once, even if there are three distinct references to it. [0013] In another embodiment, if Mike is part of a system that allows him to associate his online presence with an advertisement or brand and a user browses his content and views the brand that he/she is supporting, the user may add the brand to his/her GRAB BAG. This implicitly associates the user with the content, in this case a brand. [0014] By providing such a framework, the current invention provides an incentive for users to share and create valuable content to such online communities, provides an storage efficient way for creating rich content collections for a multiplicity of users, and allows an easy mechanism for viewers to incorporate, find, manage, and bookmark content that they like. It also provides an efficient method for spreading content across networked individuals rapidly. This invention is particularly useful in conjunction with a system such as described in U.S. patent application Ser. No. 10/997,121, filed Nov. 24, 2004 and Provisional Application Ser. No. 60/525,905, which are incorporated herein by reference. [0015] Further examples of advantages of the present invention include an easy to use interface and system whereby a user can quickly and efficiently collect and incorporate associated content that they view or browse into their own content displays; a content creator or associated content agent can determine which pieces of content can be collected via such a system, as well as monitor the usages of this content; and users can relatively easily collect content they are browsing for referenced inclusion in their content or for purchase. [0016] In one aspect of the invention, a method of managing content is provided comprising receiving a request in a server system from a viewer to access content associated with a user or group of users, presenting the content to the viewer, receiving a content association request from the viewer relating to requested content, and adding the requested content to content associated with the viewer. The content association request can include a content identifier associated with the requested content, and the server can retrieve the content using the content identifier. The server can also perform a determination procedure to determine whether the viewer is authorized to collect the requested content. Furthermore, the server can determine the viewer's proposed use of the requested content and determine if the proposed use of the requested content complies with one or more previously specified use criteria for the requested content, such as specified by the user or author. The use criteria can be selected from a group consisting of creative common licenses, distribution, modification, and attribution. The content can includes digital content data that optionally includes product purchasing information. A reward can be provided to users whose content is retrieved or whose content leads to a purchase by other users or viewers. In a further aspect of the invention, the viewer is required to pay to retrieve content. In another aspect of the invention, the user can post comments on the content and contribute to the requested content. BRIEF DESCRIPTION OF THE DRAWINGS [0017] These and other features of the invention, its nature, and various advantages will be appreciated from the accompanying drawings, and the following detailed description in which like reference numbers represent like parts throughout: [0018] FIG. 1 is a block diagram of a method and system for collecting, sharing, and tracking content via a communications network, in accordance with a preferred embodiment of the present invention referred to as a GRAB BAG system; [0019] FIG. 2 is a flow chart depicting the high level functionality of the GRAB BAG system via a communications network; [0020] FIG. 3 is a flow chart showing the client-server functionality from when content is GRABBED to how it may be stored in the database; [0021] FIG. 4 is a block diagram of a viewer client for the GRAB BAG system; [0022] FIGS. 5 and 6 show a database schema for a preferred embodiment of the invention (as shown by metails.com and which the attached program listing interacts with); [0023] FIG. 7 is an illustration of an example add to GRAB BAG client display; and, [0024] FIG. 8 is an illustration of an example incorporate GRABBED content client display. DETAILED DESCRIPTION OF THE INVENTION [0025] In the following paragraphs, the present invention will be described in detail by way of example with reference to the accompanying drawings. Throughout this description, the preferred embodiments and examples shown should be considered as exemplars, rather than as limitations on the present invention. It will be apparent that the invention can be embodied in a wide variety of forms, some of which may be quite different from those of the disclosed embodiments. Consequently, the specific structural and functional details disclosed herein are merely representative and do not limit the scope of the invention. As used herein, the “present invention” refers to any one of the embodiments of the invention described herein, and any equivalents. Furthermore, reference to various aspects of the invention throughout this document does not mean that all claimed embodiments or methods must include the referenced aspects. [0026] Generally speaking, a method of collecting, sharing, and tracking user or group associated content is provided in which the method includes the steps of: under control of a client system (“client” as used herein is also referred to as a “viewer”), displaying information identifying individuals or groups of individuals (also referred to as “users”) and their associated content; in response to an action being performed, indicating a desire to collect the content relating to the individual or group of individuals, sending a request to collect the requested content along with an identifier of the content requested; and under control of a server system, receiving the request from the client or viewer, retrieving additional information regarding the associated content, using the identifier in the received request, and adding the associated content to the requestor's associated content. It should be noted that all or a portion of these steps may be practiced in realization of the present invention. [0027] In one embodiment of the above described GRAB BAG framework, individuals or groups (i.e. particular users) can specify who can collect their content and how it can be used. In another embodiment, collected content may be restricted in its use by the collector (or user) as facilitated by the technology (such as by the restrictions of various Creative Commons licenses: distribution [yes/no], modification [yes/no], attribution [yes/no]). In a further embodiment, the authoring individual or group can withdraw all instances or derived instances of content. Alternatively, another embodiment may allow the authoring individual or group to only withdraw the original instance of the content. In another embodiment, a GRAB BAG system allows individuals or groups, whether original or derivative authors, to view and manage the dissemination of their associated content. Instances of this invention could exists within a closed community, such as a social network. The GRAB BAG framework is meant to facilitate the sharing and collection of digital pictures, text, video, music, any other media, or advertisements. [0028] An embodiment of the invention utilizes the GRAB BAG framework as a revenue model and/or to facilitate transactions between agents. In one example, associated content original or derivative authors are rewarded when individuals or groups (other users or viewers) collect their content. In another example, the rewards are privileges offered by a website, such as reward points, gift certificates, or extra quota space. In yet a further example, it allows associated content original or derivative authors to accept rewards (points, money) from requesters in order to allow their content to be collected. In another example, requestors trade content or rewards in order to collect content. Requestors may be required to pay in order to collect content. Such payments may take the form of payment to either the author or derivative author according to the size and type of content they collect (i.e. pay per file size of an image) while the service provider takes a percentage (which may be zero (0)). In a preferred embodiment, requestors are rewarded for collecting content (advertising images) and original authors are rewarded when people print pictures that they have uploaded. This could be extended to a system where requestors are rewarded by the service providing site (i.e. extra quota, gift certificates, reward points). In another aspect of the invention, a method of efficiently storing collected content in which the content is stored as a delta (or change) from its parent (i.e. an image collected an unmodified does not need to be stored twice), creates hierarchical trees of derivative work for efficient storage. A preferred embodiment of the invention also promotes or requires collectors to post comments or contribute to the content in order to collect it, facilitating a forum about the associated content. It should be noted that “content” as used herein can optionally encompass and refer to product descriptions or product purchase pages or links and the rewards associated with content can be granted based on purchases made by other users or viewers who click on or otherwise view the content or associated or linked webpages and purchase products or services. For example, the reward can be a percentage of a purchase price or a referral fee. Likewise, the “content” can optionally encompass and refer to advertisements and rewards based on the content can be based on any model, for example pay-per-click. In another example, the “content” can optionally refer to pay-per-view content or fee-for-view or fee for download content. [0029] Referring to FIG. 1 , there is generally shown a method and system for collecting, sharing, and tracking user or group associated content via a communications network in accordance with the present invention (also referred to as a GRAB BAG system). The GRAB BAG system 1 . 0 includes a plurality of client devices 1 . 1 (such as may be accessed by the “users” or “viewers” discussed herein), each of which is coupled to a network 1 . 2 and, in turn, to a GRAB BAG server system (GBSS) 1 . 3 . Each client device 1 . 1 , of which one is shown in some detail and three others are represented in block form, is typically a personal computer, such as a Windows-based personal computer. It should be understood that client devices may also be laptops, PDA's, workstations, mobile phones, Internet enabled TV, etc. Each client device 1 . 1 preferably has an input device such as a keyboard and/or mouse and a display for communication with a user. The client device 1 . 1 preferably has communications software and a modem (or some other form of Internet connectivity, such as a DSL modem, cable modem, T-1 line, ISDN line, etc.). Communications software may be any software suitable for telecommunications, and is preferably browser software. The communications software is for communication over network 1 . 2 with a GBSS 1 . 3 . Network 1 . 2 may be, for example, the Internet. [0030] The GBSS 1 . 3 is preferably a web application that displays contents authored by agents, where agents are individuals or groups and also optionally may include the users and viewers discussed herein. The GBSS 1 . 3 may be a wholly integrated web application, such as a web log and social networking web site, that allows users to decorate themselves with brands and shares the same web server 1 . 8 , database provider, and server side scripts. It should be understood that the GBSS 1 . 3 may be utilized by third party web applications. Examples of third party web applications include Blogger, social networking systems such as Friendster, instant messaging systems such as AOL Instant Messenger, and community oriented applications such as Ebay, and oPhoto, provided these services are modified to interface with the GBSS 1 . 3 . [0031] The GBSS 1 . 3 typically includes, for example, a web server, which is characteristically a programmed computer, preferably one that supports a HyperText Transfer Protocol (HTTP), that handles document requests and provides other services, returning information to the requester. It should be understood that the web server may communicate by exposing web services which communicate XML, etc. It should be clear that the web server could be replaced by an application that functions as a server, such as a program that listens to a specific port for incoming request. Many suitable software programs for the web server exist, including Apache and “MICROSOFT” Internet Information Services (IIS). GBSS 1 . 3 , in addition to a web server, includes a server side scripting engine 1 . 6 , preferably PHP, available from php.net, connected to the web server for pre-processing an output from the web server before it is returned via the communications network. The server side scripting engine 1 . 6 also allows communication with a database server 1 . 7 , preferably Mysql, available from mysql.com, using the Open Database Connectivity (ODBC) protocol. Other similar server side scripting products could be used, such as Cold Fusion, ASP.NET technology. The database server 1 . 7 is generally configured as an SQL database, and, besides Mysql, other database systems could be used such as those available from Oracle, Informix, “MICROSOFT”, or Sybase. The GBSS 1 . 3 may also be a multi-server system, such as a web farm. The database server 1 . 7 is in communication with a database 1 . 9 in which the database server 1 . 7 stores content. [0032] Referring to FIG. 2 , there is generally shown the high level flow by which a viewer 2 . 1 may add a piece of content to their GRAB BAG store in a GBSS 1 . 3 . It should be noted that “viewer” as used herein is a “user” who is viewing another user's content. At other times or simultaneously a “viewer” can be making his/her own content available to viewing by other viewers. A preferred example of this flow involves a viewer 2 . 1 viewing content in a web browser as illustrated with reference number 205 , the web browser also referred to more generally as a viewer client for Grab Bag system 4 . 1 . The web browser acts as the Viewer Client 4 . 1 , which displays content of a particular user and an option to grab their picture ( 210 ), for example. The user may indicate wanting to add another user's (for example Agent A's) content or associated content to his grab bag ( 215 ). In other words, a request is sent from the viewer's system to the grab bag server system (GBBS 1 . 3 ) ( 220 ). The GBSS 1 . 3 processes the request in any desired fashion, such as first receiving it from the web server, processing the appropriate PHP, accessing the Mysql database when necessary, and entering what is necessary in the database to store the association between the instance of the content where it was grabbed, the original instance, and the new instance where it is being grabbed to. The user's (Agent A's) content or associated content is then made available to the viewer to utilize via the viewer's GRAB BAG ( 225 ). [0033] FIG. 3 is an example of possible process steps relating to the client-server interaction. A user (i.e. viewer 2 . 1 ) activates an action component in the client viewer 4 . 1 to initiate an adding of selected content to the user's GRAB BAG ( 305 ). According to one embodiment, this may be done, for example, by the user selecting a hypertext link such as by clicking or using any other input device, such as a mouse, keyboard, voice recognition software, touch-screen, light pen, etc. The client viewer 4 . 1 sends a request to the GRAB BAG server system 1 . 3 ( 310 ). In one embodiment, the request contains an identifier or plural identifiers indicating the content the user desires to grab and identifying the particular viewer 2 . 1 making the request ( 310 ). After receiving the request, the server system 1 . 3 begins processing it, such as using the server side scripting engine 1 . 6 ( 315 ). In this example, the server side scripting engine 1 . 6 optionally interacts with a database 325 (such as on the database server 1 . 7 ) to retrieve the content ( 320 ). The grabbed content is then stored in the user's (i.e. viewer 2 . 1 ) GRAB BAG. In other words, the grabbed item is added by the server system 1 . 3 into a grab bag storage system (such as in a storage unit such as database system 1 . 9 ) ( 320 ). The grab bag storage system for example includes a data structure, such as for example a table with columns for storing a userID identifying the viewer 2 . 1 grabbing the content, an itemID identifying the content grabbed and an itemType indicating the type of content ( 320 ). The itemType can optionally be the name of a separate table (i.e. a pictures table) ( 320 ). The itemID can be a unique identifier (i.e. uniqueID) for the item in that separate table (i.e. a pictureID) ( 320 ). Other records also can be retained relating to other pertinent information, such as regarding the user (i.e. viewer) who requested (i.e. grabbed) the content, the user whose content was grabbed, date and time information regarding the request, and possibly other information ( 320 ), such as in a fast lookup table. The original creator of the grabbed content also may be recorded ( 320 ). [0034] FIG. 4 depicts the typical components required for a Viewer Client for a GRAB BAG System 4 . 1 . There are displays for two types of information, content 4 . 2 and collect requests 4 . 3 . It should be apparent that these two types of displays may be rendered by the client 4 . 1 in the same display, as a web browser does. For example the displays may be in different parts of the same window, different parts of a display screen, simultaneous, in separate windows etc. In one example, they may be in separate windows such as in a client application that separates advertisement display from content display, such as Kazaa Media Desktop, AOL Instant Messenger, or the iTunes Software Application. An action component 4 . 3 (such as a hyperlink, form submit, button, etc.) is activated by the viewer 4 . 1 to indicate a desire for an agent's content. This is typically assisted via the methods (also commonly known as input techniques or devices) that a web browser supports for interaction, such as keyboard input, mouse input, etc., but extends to other methods of interaction such as the utterance of a sound or the touching of a screen or the sending of an electronic mail message. Finally the GRAB BAG System 4 . 1 requires a method for communication with a server system 4 . 5 , typically this is TCP/IP used by the web browser. [0035] FIGS. 5 and 6 illustrate database schema 500 for a plurality of data objects 505 . The data objects 505 may include objects relating to, for example, blog entries, blogs, class gallery, class cache, class blog entry, class picture, class list item, class list, class blog, electronic mail confirmations, friends, second degree friends, gallery rows, gallery images, galleries, gallery image instances, gallery directories, errors, lists mind, list mind items, reaction blogs, reaction blog entry, reaction gallery, reaction list, reaction list item, reaction picture, reaction user, session browse paths, sessions, user contact settings, user profiles, users, page views, messages, invites, interests, and last viewed friend requests. [0036] Each data object 505 may include a data object name 510 , data object identifier 515 , and data object information 520 . The data object name 510 may be a name assigned by a programmer, administrator or other user of a system for constructing a networking database and system proactively. The data object identifier 515 may be an identifier that is used by the system for retrieving that data object. The data object information 520 may include information relating to that data object 505 . For example, an errors data object 505 may include a data object name 510 titled errors. The data object identifier 515 may be titled errorsID. The data object information 520 may be information relating to errors encountered while the system is being used. For example, the data object information 520 for an errors data object 505 may include an error description, code, location, date, and sessionID. This information assists a programmer, administrator or other user in determining how to correct the error. [0037] FIG. 7 is an exemplary illustration of screenshot 700 showing how content may be GRABBED. The web page 700 may include one or more selectable operations, such for example via tabs 705 as illustrated or any other means. The option selector icons 705 may be selected using, for example, a convention keyboard, mouse, touch-screen, voice recognition software, etc. The web page 700 may also include a web page identifier 710 that identifies the viewer or the viewer's page being viewed. The web page 700 may include a preview pane 720 that presents a preview of an item located in a user's pouch 725 . For example, if an item in at least one of the pouches 725 is selected, that item is displayed in the preview pane 720 . The item may be, for example, an image, text, video, audio etc. The viewer 2 . 1 may examine the item in the preview pane 720 to determine whether to grab that item and add the item to the viewer's content. The item may be grabbed and added to the viewer's content by, for example, clicking and dragging the item to the tab 705 labeled “My Metails” or via any other action sufficient to send a grab request to a server. The viewer may then drop the item into the viewer's content using known or desired techniques. Alternatively, the viewer may select an icon, such as the “Grab Bag® It” icon displayed in a ratings field section (described in further detail below) of the web page 700 . [0038] Each pouch 725 may be, for example, a subset of the user's content. The pouches 725 may hold a predetermined number, for example, eight (8), of items, or may be expandable or contractible to any number of content items. In one embodiment, a pouch is of limited size, and when a predetermined number of items in the pouch has been reached, an additional pouch 725 may be created. The items in each pouch 725 may be displayed as thumbnails. In one embodiment, a particular pouch 725 may be selected using pouch selectors 730 . In one alternative embodiment, a limited number of pouches 725 are displayed on a web page 700 and if a viewer desires to see items in a pouch 725 that is not displayed, the viewer may select another pouch using the pouch selectors 730 . [0039] A message field 735 may also be included in the web page 700 . The message field 735 enables the viewer to post a message to the user whose content is being viewed. The message field 735 may enable the viewer to share the message with only the user, the user and his network or possibly other options. [0040] The web page 700 may also include a ratings field 740 . The ratings field 740 may provide ratings for particular content associated with a user. The ratings shown may be average ratings for a particular item, the viewer's rating for the item, average rating for the user's particular content, such as a gallery of items, the viewer's rating for the gallery, etc. [0041] A connection field 745 may be provided to indicate whether the viewer is logged-in. If the viewer is logged-in, the connection field 745 may include a log-out option. If the viewer is not logged-in, the connection field 745 may include a log-in option. [0042] FIG. 8 is an illustration one example of a web page illustrating how grabbed content optionally may be incorporated after being GRABBED. In this example, illustrated web page 800 is presented to a viewer upon grabbing another user's content and adding that content to the viewer's content. The web page 800 may include one or more matrices 805 that displays items in a content gallery such as via viewable or hearable thumbnails. A gallery title 810 may be used to identify the galleries that are being viewed. Each gallery may include one or more pouches 815 (described above). Modifying functions 820 may be displayed that enable the viewer to edit and/or delete one or more items in the gallery when selected. A “Create New Picture Gallery” option 825 may also be presented. The “Create New Picture Gallery” option 825 enables the viewer to create a new picture gallery with content. The content may include previously grabbed content, newly grabbed content, uploaded content or other content. [0043] Gallery options may also be displayed. The gallery options may include, for example, cancel option 830 and save option 835 . The cancel option 830 enables the viewer to cancel any modifications made to a gallery before the modifications have been saved. The save option 835 enables the viewer to save any modifications made to a gallery. [0044] A gallery tray 840 may also be associated with a gallery. The gallery tray 840 may be used to store items desired to be saved by the viewer but not desired to be available to other users. For example, a viewer may upload a picture to his/her content, however, the viewer does not desire that other users be able to view the picture until a later date. The viewer may simply place the picture in the gallery tray 840 associated with a desired gallery. When the viewer desires the picture be made available to other users for viewing, the viewer may move the picture from the gallery tray 840 to a desired pouch. If, however, the viewer decides that he/she does not wish one or more particular items to be viewed by other users, the viewer may move the particular items to the trash can 845 using known techniques. [0045] Thus, it is seen that a method and system of collecting, sharing, and tracking user or group associated activity via a communications network is provided. One skilled in the art will appreciate that the present invention can be practiced by other than the preferred embodiments which are presented in this description for purposes of illustration and not of limitation, and the present invention is limited only by the claims that follow. It is noted that equivalents for the particular embodiments discussed in this description may practice the invention as well.
A content collection, sharing, and tracking method and system allows individuals or groups to incorporate the content of one another into their own context for creative referenced re-use. Users browse the content of other users and add content to a tool known as a GRAB BAG. Users may be part of affinity groups such as social networks or have common interests such as an interest in a single Internet auction site. The GRAB BAG storage system keeps track subsequent revisions and contexts for the piece of content in all instances where it is grabbed. When users incorporate the content they have grabbed into their own content, it appears with a link to the original author as well as with links to track the dissemination of the original content. The GRAB BAG storage system is created to reference content so that identical items under two different contexts need not be duplicated in full.
6
BACKGROUND OF THE INVENTION 1. Technical Field This invention relates to electrical conduits, and more particularly, to a lock for an electrical conduit. 2. Description of Related Art Most if not all of the municipalities in the continental United States have conduits than contain electrical wires. The electrical wires supply power to streetlights, recreational areas, and other areas or devices that require electricity. The conduits can run for miles underground and have above ground access points at places like light poles and ground boxes. Unfortunately, thieves have discovered that the above ground access points have very little protection and that it is relatively easy to use the above ground access points to steal the electrical wire contained in the conduit. Typically, to gain access to the conduit, thieves first break the ground box lid found on most above ground access points. This allows the thief to gain access to and steal thousands of feet of wire contained within the conduit. Once removed, the wire can be sold as scrap copper to metal recyclers. What is needed is a device or method that will lock or secure existing wires inside an existing conduit and pinch the wires in such a way that is would be impossible or nearly impossible for a would be thief to pull the wires out of the conduit. SUMMARY OF INVENTION The present invention solves the above-described problem by providing a locking conduit lid and method of use that can lock or secure existing wires inside a conduit. The wires are secured in such a way that it would be almost impossible for a would be thief to pull the wires out of the conduit. The locking conduit lid contains a conduit sleeve that securely holds the wires extending from the conduit and prevents them from being pulled from the conduit. The conduit sleeve is designed to slip inside an existing polyvinylchloride (PVC) pipe, rigid metal pipe, or any other pipe or conduit that contains electrical wires. In addition, the conduit sleeve is equipped with a means for securing the conduit sleeve to the existing conduit to prevent the locking conduit lid from being pulled out of the conduit. The locking conduit lid contains a conduit sleeve, locking lid, and locking nut. The conduit sleeve can fit inside an existing conduit and is made of a relatively hard material such as ceramic or metal wherein the material is relatively difficult to saw, cut, drill through, or otherwise compromise the structure such that access can be gained to the interior of the conduit sleeve and the wires within the conduit. The conduit sleeve comprises a first sleeve and a second sleeve wherein the first sleeve and second sleeve can be mated or secured together. Once mated together, they form a conduit sleeve such that the existing wires from the conduit are at least partially contained within the conduit sleeve. In one embodiment, when the conduit sleeve is going to be installed in a new conduit instead of an existing conduit, the conduit sleeve may be a single unit instead of a first and second sleeve that are mated together. The conduit sleeve contains a securing means that secures the conduit sleeve in the conduit and helps prevent the locking conduit lid from being pulled out of the conduit by would be thieves. The conduit sleeve securing means may be tines or spring loaded sharp tines that extent up and away from the conduit sleeve, glue or adhesive that is strong enough to secure the conduit sleeve to the conduit, threads such that the conduit sleeve may be threaded into/onto or screwed into/onto the conduit, or other means to secure the conduit sleeve into the conduit and prevent the locking conduit lid from being pulled out of the conduit by would be thieves. The conduit sleeve contains a means for securing the wires from the conduit inside the conduit sleeve such that the wires cannot be pulled or it is relatively difficult to pull the wires out of the conduit. The means for securing the wires include, but is not limited to tying the wires in a knot, screwing the wires securely to the conduit sleeve or the locking conduit lid, clamping the wires to the conduit sleeve or locking conduit lid, inserting the wires in a recess and securing the wires into the recess with a wire bar, or almost any other means that pinches, restricts or secures the wires to the conduit sleeve and prevents them from being pulled out of the conduit yet still allows electricity to flow through the wires. In addition to the conduit sleeve, the locking conduit lid also contains a locking lid, and a lock nut. The locking lid and lock nut prevent would be thieves from tampering with the conduit sleeve and locking conduit lid. To use the locking conduit lid, the first step is to locate an existing conduit with wires extending from the conduit. Next, the diameter and length of the conduit and conduit access point is determined and the desired diameter and length of the conduit sleeve is calculated based on the diameter and length of the conduit and conduit access point. For example, if the conduit access point has about three feet of exposed conduit, then the length of the conduit sleeve would be at least about three feet. Once the proper diameter and length has been determined, a properly sized first sleeve and second sleeve are joined together to form the conduit sleeve such that the existing wires from the conduit are contained in the middle portion of the conduit sleeve. If the locking conduit lid is being installed on a new conduit, the conduit sleeve may not require the mating of the first and second sleeve. After the conduit sleeve is inserted into the existing conduit and secured in place, the wires from the conduit are secured to the conduit sleeve such that it would be relatively difficult for a would be thief to pull the wires from the conduit sleeve. Once the wires are secured to the conduit sleeve, the locking lid is placed on the conduit sleeve and secured to the conduit sleeve with the lock nut. Because the locking conduit lid is secured relatively deep into the conduit and the wires from the conduit are secured to the locking conduit lid, the wires cannot be pulled or otherwise extracted from or it is relatively difficult to pull or otherwise extract the wires from the conduit, thus preventing wire theft. In addition, the locking conduit lid helps prevent wire theft by preventing or deterring attempts to cut, saw, puncture, or otherwise destroy the conduit because the rigid locking conduit lid extends relatively deep into the conduit and thus deters destruction of the conduit. In addition if the conduit is used to supply electricity to a pole, the locking conduit lid prevents the wire from being pulled out of the conduit if an accident forces the pole away from the conduit. Also, the locking conduit lid provides sealing and containment of the wires extending from the conduit, and provides a limited prevention seal from rodents who might chew or otherwise destroy the wire in the conduit. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of a rigid member of a locking conduit lid in use in accordance with an embodiment of the present invention. FIG. 2 is an exploded diametric view of a conduit sleeve in accordance with an embodiment of the present invention. FIG. 3 is an isometric view of the conduit sleeve in accordance with an embodiment of the present invention. FIG. 4 is a flow diagram depicting the steps used in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized. It is also to be understood that structural, procedural and system changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. For clarity of exposition, like features shown in the accompanying drawings are indicated with like reference numerals and similar features as shown in alternate embodiments in the drawings are indicated with similar reference numerals. Referring to FIG. 1 , shown is locking conduit lid 102 . Locking conduit lid 102 contains conduit sleeve 104 , first wire 112 , second wire 114 , ground wire 116 , locking lid 118 , and locking nut 120 . Conduit sleeve 104 can fit inside conduit 106 . Conduit 106 may be a newly installed conduit or an existing conduit and is a typical conduit as is known in the art. Conduit sleeve 104 is made of a relatively hard material such as ceramic or metal wherein the metal is relatively difficult to saw or drill through, cut, or otherwise compromise the structure such that access can be gained to the interior of conduit sleeve 104 . The length of conduit sleeve 104 depends on the length of conduit 106 that is exposed and is accessible to a would be thief. Conduit sleeve 104 extends a sufficient length inside the exposed portion of conduit 106 such that sawing, drilling, cutting, or otherwise compromising the structure of existing conduit sleeve 104 is relatively difficult and after conduit sleeve 104 has been inserted into conduit 106 , the exposed or vulnerable portion of conduit 106 is protected by conduit sleeve 104 . In one embodiment, the length of conduit sleeve 104 is such that conduit sleeve 104 can be inserted at least about 4 inches into conduit 106 . Conduit sleeve 104 contains first sleeve 108 , and second sleeve 110 . First sleeve 108 and second sleeve 110 can be mated or secured together to form conduit sleeve 104 and are shown in more detail in FIG. 2 . FIG. 2 is an exploded view of conduit sleeve 104 . Conduit sleeve 104 contains first sleeve 108 , first mating member 202 , second sleeve 110 , second mating member 204 , first wire recess 206 a , second wire recess 206 b , ground wire recess 206 c , secure mounting 208 for ground wire 116 , wire bar 210 , upper secure rest 212 for locking lid 118 , lower secure rest 214 for locking lid 118 , attachment means 216 for locking nut 120 , and conduit sleeve securing means 218 . Prior to conduit sleeve 104 being inserted into conduit 106 , first sleeve 108 and second sleeve 110 can be mated or joined together and then taken apart relatively easily. Once first sleeve 108 and second sleeve 110 are joined together to form conduit sleeve 104 and conduit sleeve 104 is inserted into conduit 106 , it is relatively difficult to separate first sleeve 108 and second sleeve 110 . During installation, first sleeve 108 and second sleeve 110 are mated together with the existing wire in the middle of the mated pair and once mated together, first sleeve 108 and second sleeve 110 form a hollow cylinder such that the existing wire contained in conduit 106 can pass through the center of the of conduit sleeve 104 . The existing wire is show in FIGS. 1 and 3 as first wire 112 , second wire 114 , and ground wire 116 . The existing wire runs through conduit 106 and conduit sleeve 104 . First sleeve 108 contains extension 220 . Extension 220 is higher than the top of second sleeve 110 and extension 220 contains first wire recess 206 a , second wire recess 206 b , ground wire recess 206 c , secure mounting 208 for ground wire 116 , wire bar 210 , upper secure rest 212 for locking lid 118 , and attachment means 216 for locking nut 120 . First wire recess 206 a is able to contain at least a portion of first wire 112 . Second wire recess 206 b is able to contain at least a portion of second wire 114 . Ground wire recess 206 c is able to contain at least a portion of ground wire 116 . Wire bar 224 extends over each wire recess 206 a , 206 b , and 206 c and secures the respective wire in each recess. This prevents first wire 112 , second wire 114 , and ground wire 116 from being pulled out of locking conduit lid 102 and if first wire 112 , second wire 114 , and ground wire 116 are pulled with enough force, they will break off at wire holder 206 . It should be obvious to those skilled in the art that other means may be used to prevent first wire 112 , second wire 114 , and ground wire 116 from being pulled out of locking conduit lid 102 . For example, other means for securing first wire 112 , second wire 114 , and ground wire 116 include, but are not limited to tying the wires in a knot, screwing the wires securely to locking conduit lid 102 , clamping the wires, or almost anything other means that pinches, restricts or secures the wires and prevents them from being pulled out of locking conduit lid 102 . Second sleeve 110 contains second mating member 204 and lower secure rest 214 . Second mating member 204 mates with first mating member 202 such that a hollow cylinder is formed wherein the hollow cylinder can surround and contain first wire 112 , second wire 114 , and ground wire 116 from conduit 106 . First mating member 202 and second mating member 204 may have a mating profile such as that shown in FIG. 2 , or any other profile that would allow first sleeve 108 and second sleeve 110 to form a hollow cylinder wherein the hollow cylinder can surround and contain the existing wire from conduit 106 . FIG. 3 shows first sleeve 108 joined to second sleeve 110 forming conduit sleeve 104 and first wire 112 , second wire 114 , and ground wire 116 secured to conduit sleeve 104 . In one embodiment, first sleeve 108 and second sleeve 110 do not have a mating profile but are glued or clamped together. In another embodiment, a slit in conduit sleeve 104 or small slit in sleeve conduit sleeve 104 is used to assist the insertion of the wires and contain the existing wires in conduit 106 . The slit may be used when there is an existing conduit in place. The above described invention is designed to fit inside an existing conduit. If the present invention is to be installed in a new conduit, then there may not be a first sleeve 108 and second sleeve 110 or first sleeve 108 and second sleeve 110 may be pre-joined. Then, if the conduit is new, locking conduit lid 102 is inserted into conduit 106 before first wire 112 , second wire 114 , and ground wire 116 are ran through conduit 106 . After the wires are run through conduit 106 , they are secured to locking conduit lid 102 as described above. After first sleeve 108 and second sleeve 110 are mated together, upper secure rest 212 and lower secure rest 214 support locking lid 118 . FIG. 1 shows first sleeve 108 mated to second sleeve 110 and upper secure rest 212 and lower secure rest 214 supporting locking lid 118 . After supporting locking lid 118 is supported on upper secure rest 212 and lower secure rest 214 , locking nut 120 is inserted through locking lid 118 and into attachment means 216 . Attachment means 216 may be threaded such that locking nut 120 is threaded into attachment means 216 for a secure attachment. Locking nut 120 may be a one way nut such that once locking nut 120 is secured to attachment means 216 it is relatively difficult to remove thus securing locking lid 118 to conduit sleeve 104 and preventing would be thieves from tampering with pinch wire holder 206 . In another embodiment, instead of locking nut 120 , a locking means is used such that only an authorized user can access and use the locking means. For example, the locking means may include but is not limited to a mechanical lock, electro-mechanical lock, combination lock, or some other type of locking means that would prevent access to the means for securing the wires to locking conduit lid 102 . When locking conduit lid 102 is inserted into conduit 106 , conduit sleeve securing means 218 prevents locking conduit lid 102 from being pulled out of conduit 106 by would be thieves. Conduit sleeve securing means 218 may be tines, spring loaded sharp tines that extent up and away from conduit sleeve 104 . In another embodiment, conduit sleeve securing means 218 may be glue or adhesive that is strong enough to secure locking conduit lid 102 to conduit 106 . In yet another embodiment, securing means 218 may be threads such that locking conduit lid 102 may be threaded into/onto or screwed into/onto conduit 106 . If locking conduit lid 102 is to provide an extension of conduit 106 , then locking conduit lid 102 may be threaded or screwed onto the outside of conduit 106 . The extension created by locking conduit lid 102 is from a non-vulnerable location into a vulnerable location and would be used to facilitate easier access to the wire inside conduit 106 for maintenance purposed. By using locking conduit lid 102 as an extension, conduit 106 can remain in the relatively safe non-vulnerable location while locking conduit lid 102 extends into the vulnerable location and provides the necessary protection for the wire inside conduit 106 . It should be obvious to those skilled in the art that other means exist to secure locking conduit lid 102 in conduit 106 and prevent locking conduit lid 102 from being pulled out of conduit 106 by would be thieves. To use locking conduit lid 102 , the first step, as shown in FIG. 4 , is to locate conduit 106 , Step 402 . Conduit 106 may be an existing conduit or a new conduit. Next, the diameter and exposed length of conduit 106 is determined, Step 404 and the desired diameter and length of locking conduit lid 102 is calculated based on the desired level of protection, Step 406 . The desired diameter of locking conduit lid 102 is such that locking conduit lid 102 can be relatively easily secured inside conduit 106 . The desired length of locking conduit lid 102 is such that once locking conduit lid 102 is inserted into conduit 106 , it is relatively difficult to saw, drill, cut, or otherwise compromising the structure of conduit 106 and/or locking conduit lid 102 and access the wires in conduit 106 . Once the proper diameter and length has been determined, a properly sized first sleeve 108 and second sleeve 110 are joined together to form conduit sleeve 104 such that the existing wires from conduit 106 are contained in the middle portion of conduit sleeve 104 , Step 408 . Next, conduit sleeve 104 is inserted into conduit 106 and secured in place, Step 410 . Then, the wires from conduit 106 are secured to conduit sleeve 104 such that it would be relatively difficult for a would be thief to pull the wires from conduit sleeve 104 , Step 412 . Once conduit sleeve 104 is secured into conduit 106 and the wires are secured to conduit sleeve 104 , locking lid is placed on conduit sleeve 104 and secured to conduit sleeve 104 with locking nut 120 , Step 414 . Because locking conduit lid 102 is secured relatively deep into conduit 106 and the wires from conduit 106 are secured to locking conduit lid 102 such that they cannot be pulled from conduit 106 , locking conduit lid 102 helps prevent wire theft by preventing or deterring cutting of conduit. In addition if the conduit is used to supply electricity to a pole, the locking conduit lid prevents the wire from being pulled out of the conduit if an accident forces the pole away from the conduit. Also, the locking conduit lid provides sealing and containment of the wires extending from conduit 106 , and provides a limited prevention seal from rodents who might chew or otherwise destroy the wire in the conduit. It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
A locking conduit lid and method of use that can lock or secure wires inside a conduit such that is would be almost impossible for a would be thief to pull the wires out of the conduit. The locking conduit lid contains a conduit sleeve that is designed to be fixedly attached to the inside of a polyvinylchloride (PVC) pipe, rigid metal pipe, or any other existing pipe or conduit that contains electrical wires. The electrical wires are secured to the conduit sleeve such that they cannot be pulled out of the conduit sleeve. A locking conduit lid prevents access to the wires inside the conduit sleeve thereby preventing theft of the wires.
8
BACKGROUND OF THE INVENTION [0001] The term “waterjet” denotes high-speed water jets generated at high static pressures with special pumps and nozzles. Such waterjets perform a wide range of useful work such as cleaning tanks, ship hulls and various structures and also cutting alloys and composite materials with computer-controlled nozzle movement. Static pressures of water as high as 80,000 pounds per square inch (psi) are generated with special motor-driven or engine-driven piston pumps and special fluid-powered pressure intensifiers, and with nozzles equipped with gem orifices. The term “waterjet technology” describes the various processes and applications of waterjets. The term “abrasive waterjet” describes a particular waterjet technology in which selected industrial abrasive particulates are added into the jet stream with special nozzles to further enhance the capability of waterjets. Very hard and difficult materials are cut or removed with such abrasive waterjets. In fact, it is the only method that can now be used to cut carbon-fiber laminates that are widely used in modern aircrafts. [0002] The pumps and pressure intensifiers known for generating waterjets are positive-displacement piston pumps which have multiple pistons and check valves to build up the potential energy of a fluid. The energy transfer from the piston to the fluid is usually not smooth, due to factors such as fluid compressibility, the finite number of pistons in the pump, and the phase limitations. As a result, there are pressure pulsations in the output fluid. For example, a triplex crankshaft pump has only three cylinders and pistons operating at about 600 rotations per minute (rpm) and a double-acting hydraulic pressure intensifier has only two cylinders and pistons operating at about one stroke per second. These pumps are used to push or build water pressures from atmospheric to 55,000 psi or higher. The output pressure of water at the outlet of each cylinder is not phased properly with the output pressure of other cylinders to cover the entire cycle and to provide smooth pressure output. The rough power output is similar to automobile engines where the power output of a 3-cylinder engine is rougher or not as smooth as the power output of an 8-cylinder engine. Thus, if a waterjet nozzle is placed at the outlet of a triplex pump or a double-acting intensifier, the waterjet will not form a smooth stream. Instead, the waterjet will form a pulsed jet with a stream of water slugs. The water slugs are phased according to the piston motion of the pump. For example, a triplex pump operating at 600 rpm would generate a pulsed waterjet of 3×600=1800 pulses per minute. A double-acting intensifier operating at one stroke per second would produce a pulsed waterjet of 60 pulses per minute. [0003] However, in waterjet applications, nozzles are not positioned next to the pump. Tubes or hoses are used to transport the pressurized water from the pump to a remote or distant nozzle. Inside the tubes or hoses the pressure pulsations in the water is damped and only a portion remain at the nozzle. In many applications, the residue pressure pulsations present no problem but in double-acting intensifiers there may be a problem. Due to the very low stroke rate and the extreme pressures involved, water at the nozzle of an intensifier pump system may have pressure pulsations too high for applications such as abrasive waterjet cutting of composites. An additional pressure attenuator may be required to further damp out the pressure variations. In such applications, the smoothness of cut surface may be related to or a function of the pressure pulsation of the waterjet. [0004] In many waterjet applications, a pulsed waterjet can be more effective than a continuous waterjet when each is at an identical pump power level. One reason is the mitigation of waterjet interference when a waterjet impacts a flat surface. When a continuous waterjet impacts a hard surface, the waterjet rebounds from the surface and collides with the incident waterjet. As a result, a significant portion of the waterjet energy is wasted. In a pulsed waterjet, the water slugs impact the surface individually and the energy of each slug of water has time to dissipate. If the waterjet slugs are phased properly, waterjet interference can be completely avoided. With a pulsed waterjet, the impact pressure on a surface can be greater if the mass of each water slug is greater. Reducing waterjet interference is one reason why waterjetting is widely applied today in industrial cleaning processes, such as by spinning a nozzle assembly at a high speed. Many waterjets generated at known pump pressures are supersonic, and it is difficult to avoid waterjet interference. Rotating a nozzle assembly at a high speed requires a rotating joint with good seals. The durability of such high-pressure seals is a maintenance issue in industrial processes. An impacting power of a waterjet is also reduced when the nozzle is rotating at a high speed. [0005] There are many known investigations using pulsed waterjets for a wide range of jobs. One benefit of a pulsed waterjet is to remove materials, such as concrete, that have significant granular structures of materials. The waterjet pulses can better penetrate into pores of the porous structures, to rupture the structure and wash away the debris. Similar benefits of pulsed waterjet have been reported with coating removal. There are other benefits of using pulsed waterjets. [0006] Even with the benefits of pulsed waterjets, the method is not applied widely today because the pulsed waterjet processes reported in several publications have not been commercialized. One highly publicized known pulsejet technology is not now commercialized, presumably because components involved in that particular pulsejet technology are not matured or there were technical difficulties not overcome. It is difficult to design an on-off valve for use with high-pressure water as the working fluid. To produce a pulsed waterjet at a nozzle is extremely difficult due to many factors. It is difficult to interrupt the flow of water at very high pressures. [0007] Only some known pulsed waterjet processes are applied commercially, including one that uses an ultrasonic transducer placed at the tip of a waterjet nozzle to generate forced pulses at 20,000 cycles per second. Electrical energy is introduced into the nozzle assembly to generate the axial vibrations and forced waterjet pulses. Up to 1 kilowatt of electrical energy may be required to overcome the static water pressure at the nozzle. With this pulsed waterjet process it is possible to remove coatings at static pressures considerably lower than those associated with a conventional continuous waterjet. This 20 kHz pulsed waterjet process is not widely applied because of shortcomings and also the required electricity to power its nozzle. Mixing electricity and water in a handheld piece of field equipment is not a safe practice. [0008] Pulsed waterjets are normally generated with available pumps. Once the pressure pulsations are dampened with tubes and hoses it can be difficult to recreate pressure pulsations at a waterjet nozzle. It is also difficult to interrupt the water flow at very high pressures. Problems, such as water hammer effect and metal fatigue, can occur if the flow interruption is not handled properly. [0009] A process that allows a pulsed waterjet to be generated at a nozzle at a wide range of water pressures is valuable to the entire waterjet technology and would have applications in shipyards and concrete structure repairs and in everyday cleaning applications. It is particularly valuable if the process requires no energy from external or outside sources and requires no use of a heavy component with uncertain durability. This invention can be used to provide a waterjet process that produces a genuine pulsed waterjet by tapping a very small amount of water energy to produce waterjet pulses at a controllable frequency and at a wide range of static pressures. The apparatus and process of this invention will be valuable to waterjet technology and its use in industry. SUMMARY OF THE INVENTION [0010] This invention provides a method for generating a genuine pulsed fluid jet at a wide range of fluid pressures and flowrates without the need for an external power source or input and without the need for bulky, heavy, or unreliable equipment. [0011] This invention can be used to generate a genuine pulsed fluid jet near or at a nozzle, to minimize the chance of pulsation dampening and to put the pulsejet to work. [0012] This invention can incorporate the pulsejet technology into other mechanical and hydraulic systems to do useful work. BRIEF DESCRIPTION OF THE DRAWINGS [0013] This invention is explained in greater detail below in view of exemplary embodiments shown in the drawings, wherein: [0014] FIG. 1 is a cross-sectional view of a pulsejet valve/nozzle, in a closed position, according to one embodiment of this invention; [0015] FIG. 2 is a cross-sectional view of the pulsejet valve/nozzle, as shown in FIG. 1 , but in an open condition; [0016] FIG. 3 is a cross-sectional view of a pulsing valve/nozzle assembly, in a closed condition, according to one embodiment of this invention; [0017] FIG. 4 is a cross-sectional view of a pulsing valve/nozzle assembly, in an open condition, according to another embodiment of this invention; [0018] FIG. 5 is a cross-sectional view of a pulsejet valve/nozzle assembly, in a closed condition, according to another embodiment of this invention; [0019] FIG. 6 is a cross-sectional view, with a valve shuttle rotated 90 degrees, of the valve/nozzle assembly as shown in FIG. 5 , but in an open condition; [0020] FIG. 7 is a cross-sectional view of a valve/nozzle assembly, in a closed condition, according to one embodiment of this invention; [0021] FIG. 8 is a cross-sectional view of a pulsejet generator, in a closed condition, according to one embodiment of this invention; and [0022] FIG. 9 is a cross-sectional view of a pulsejet generator, in an open condition, according to still another embodiment of this invention. DETAILED DESCRIPTION OF THE INVENTION [0023] This invention provides a method for generating pulsed fluid flow without using an external power source. The energy consumed in the process is derived from the potential energy contained in a pressurized fluid from a pressurized source. It is known that a pressurized fluid such as compressed air and pressurized water contains an enormous amount of energy introduced into the fluid during the pumping process. In this invention, a very small amount of fluid energy is taken from the pressurized fluid to generate flow discontinuities in a suitable valve so that the flow discontinuities become fluid jet pulses, particularly if a nozzle is placed downstream from the valve. The amount of energy consumed in generating the flow discontinuities is so relatively small that the fluid jet usefulness is not affected. Also, flow discontinuities do not normally cause a water hammer effect in the fluid system because the flow of fluid is not cut off completely. [0024] In one embodiment of a pulsed fluid jet generator of this invention, such as shown in FIG. 1 , the pulsejet valve/nozzle 100 of this invention comprises a nozzle body 101 having a fluid inlet 102 , a fluid outlet 103 , and a cylindrical cavity 104 in communication with the inlet 102 and the outlet 103 . Inside the cavity 104 , a generally cylindrical valve poppet 105 has a tapered end 106 in contact with an outlet port 107 of the fluid outlet 103 and an other cylindrical end 108 accommodates a compression spring 109 that abuts the valve poppet 105 in one end and abuts a valve plug 110 on the other end. The valve poppet 105 has a central fluid passage 111 . The valve poppet 105 divides the valve cavity 104 into two parts, an upper cavity 112 and a lower cavity 113 . A poppet seal 114 can prevent fluid leakage across the valve poppet 105 although the valve poppet 105 is sized to fit the valve cavity 104 snugly, but is also free to slide up and down. [0025] Still referring to FIG. 1 , in some embodiments, the valve/nozzle assembly 100 of this invention is assembled with the valve poppet 105 in an upright position, relative to the direction shown in FIG. 1 , and the spring 109 is compressed to exert a force on the valve poppet 105 urging it to butt against or abut the outlet port 107 , thus closing the valve/nozzle 100 . If fluid flows into this valve assembly, it will fill the lower cavity 113 but will be stopped by the valve poppet 105 , from being discharged through the outlet 103 . In some embodiments of this invention, the valve poppet 105 has a diameter D 1 and a cross-sectional area A 1 . The tapered end 106 contacts the outlet port 107 to form a contact or a seal circle, or a ring, of a diameter D 2 and of a cross-sectional area A 2 . Thus, in some embodiments, the valve poppet 105 has a donut-shaped cross-sectional area A 1 −A 2 =ΔA exposed to the fluid in the lower cavity 113 . If the fluid is pressurized to a value of Pf psi, then the fluid exerts a fluid-induced force Ff of P×ΔA pounds of force against the valve poppet 105 in lifting it. At the same time, the spring 109 exerts a spring force Fs on the valve poppet 105 to keep it down. If Fs is greater than Ff, then the valve poppet 105 will stay in place and the valve remains closed. On the other hand, if Ff is greater than Fs, then the valve poppet 105 is pushed up by the pressurized fluid, thus opening the outlet port 107 . The fluid will then flow from the inlet 102 through the lower cavity 113 to the outlet 103 . At the same time, the fluid will also flow through the fluid passage 111 of the valve poppet 105 into the upper cavity 112 . As a result, the pressurized fluid will be on both ends of the valve poppet 105 and the poppet lifting force Ff is eliminated or goes to zero. Here, the valve poppet 105 feels only the force from the spring 109 and thus moves down to close the outlet port 107 , thus returning the valve assembly 100 back to its earlier state and completing one cycle of its pulsing action. This cyclic motion can continue automatically as long as the pressurized fluid supply continues. The fluid flow out of the valve assembly 100 will be chopped and if a nozzle 115 is placed at the outlet 103 , a pulsed fluid jet will be formed, such as shown in FIG. 2 . [0026] One example can be used to further explain the valve assembly 100 of this invention. If the valve poppet 105 has a diameter of 0.5 inches, then its cross-sectional area inside the cavity 104 is 0.196 square inches. If the tapered end 106 of the valve poppet 105 contacts the outlet port 107 with a seal ring of 0.312 inches, a cross-sectional area of 0.076 square inches, then the cross-sectional area of the valve poppet 105 exposed to the fluid inside the lower cavity 113 when the valve is closed is ΔA=0.196−0.076=0.120 square inches. If the spring 109 exerts a force of 20 pounds on the valve poppet 105 , then the outlet port 107 will be closed by this force. If a fluid such as water enters into the valve assembly 100 , for example at 100 psi, then the valve will not open because the fluid induced force Ff=100×0.120=12 pounds force, which is smaller than the spring force of 20 pounds. However, if the fluid pressure is increased to 200 psi, the fluid force on the valve poppet 105 will be increased to 24 pounds, which is greater than the spring force 20 pounds, and the valve poppet 105 will move up to open the outlet port 107 . This 200-psi pressurized water will then flow out of the valve assembly 100 but will also flow into the upper cavity 112 to balance the pressure across the valve poppet 105 . The 4 pound force differential is eliminated or goes to zero, and the valve poppet 105 then moves down to close the outlet port 107 . This cyclic motion can continue automatically as long as the force differential is significant and there is no appreciable fluid leakage across the valve poppet 105 with the valve in a closed condition. A pulsed waterjet can be generated at the nozzle 115 . The frequency of this cyclic fluid motion is a function of the flow rate of the fluid and the size of the valve cavity. The fluid pressure determines if the valve will function but will not affect the cyclic frequency. The opening of the nozzle is one parameter that determines the flow rate at a given pressure. Because the spring 109 is compressed by the fluid during each cycle of valve operation, energy is consumed and lost in the form of heat. [0027] The use of the compression spring 109 in the valve assembly 100 of this invention has limitations. Because a spring or bias element can fatigue and fail, the spring can supply only a relatively limited force. A spring of 20 pound compression force is considered to be a relatively strong spring and is classified commonly as a die spring but can only handle fluid of relatively low pressures. At relatively high fluid pressures, the fluid pressure inside the lower cavity 113 usually does not diminish much and the spring 109 may not return the valve poppet 105 to its closed position to complete a clean cycle or a complete cycle. Thus, the valve poppet 105 may get hung up to create a leak or a leaking valve. In some embodiments, eliminating the spring 109 results in a suitable force from the fluid. [0028] An improved pulsing valve/nozzle assembly 200 of this invention is shown in FIG. 3 . The valve assembly 200 comprises a valve body 201 having a fluid inlet 202 , a fluid outlet 203 , an upper cavity 212 and a lower cavity 213 connected by a passage 210 . A valve poppet 205 has a shoulder 206 and a central fluid passage 211 . The valve poppet 205 straddles across the upper cavity 212 and the lower cavity 213 through the passage 210 . The valve poppet 205 has a tapered end 208 situated or positioned in the lower cavity 213 and the shoulder 206 in the upper cavity 212 . There is a seal/bushing 214 around the valve poppet 205 in the upper cavity 212 that fits snugly against a cavity wall and around the valve poppet 205 to prevent fluid from leaking across the shoulder 206 . The seal/bushing 214 and the shoulder 206 divide the cavity to an upper cavity 212 and a lower cavity 216 . The lower cavity 216 has a small bleed hole 217 in communication with the outside environment. The valve poppet 205 is free to slide across the passage 210 for a short distance. The valve poppet 205 has a diameter D 1 and a cross-sectional area A 1 in the lower cavity 213 and a seal ring of diameter D 2 and a cross-sectional area A 2 when the valve poppet 205 is in contact with the outlet port 207 . The valve poppet 205 and the seal/bushing 214 in the upper cavity 212 define a diameter D 3 and a cross-sectional area A 3 . A spacer spring 209 can be inserted into the upper cavity 212 to keep the seal/bushing 214 in place and to urge the valve poppet 205 down, relative to the orientation shown in FIG. 3 when there is no fluid inside the valve/nozzle assembly 200 . In some embodiments of this invention, D 3 is greater than D 2 and D 1 , and is much greater than D 1 −D 2 . In some embodiments of this invention, there can be a seal/bushing 218 and the spring spacer 219 in the lower cavity 213 serving a purpose similar to that of the seal/bushing 214 and the spacer spring 209 in the upper cavity 212 . Any suitable nozzle 215 in the outlet 203 can be used to generate fluid jets. [0029] As shown in FIG. 3 , when a fluid of pressure P enters into the lower cavity 213 , it encounters the surface A 1 −A 2 and quickly exerts a force of Ff=P(A 1 −A 2 ) to lift the valve poppet 205 up from the valve port 207 . Once lifted, the entire cross-sectional area of the valve poppet 205 is exposed to the fluid. Thus a force of Ff=PA 1 is exerted on the valve poppet 205 and pushes it to an uppermost position. Thus, the valve port 207 is wide open and the fluid flows through the outlet 203 and the nozzle 215 . At the same time, the fluid flows into the upper cavity 212 through the fluid passage 211 and encounters the cross-sectional area A 3 and exerts a force of Ff=P·A 3 to push the valve poppet 205 down. Because the lower cavity 216 below the shoulder 206 is exposed to an atmosphere, there is a net downward force of P(A 3 −A 1 ) to push the valve poppet 205 down. This force is very significant if D 1 and D 3 are relatively far apart. Because of this downward force, the valve poppet 205 will move down to close the outlet port 207 and thus complete one cycle of its up-and-down motion. This motion will continue as long as pressurized fluid continues to flow. A pulsed fluid jet can be generated at the nozzle 215 . [0030] Another embodiment of a pulsejet valve/nozzle of this invention is shown in FIG. 4 . In this embodiment, the seal/bushing assemblies are eliminated. The valve poppet 305 sits inside the upper cavity 312 and the passage 310 with a snug fit to minimize fluid leakage. A small fluid leakage rate may not affect the function of this valve/nozzle assembly and can actually lubricate and thus assist the motion of the valve poppet 305 . One advantage of the valve/nozzle assembly 300 is its simple design. In some embodiments, one design requirement is that D 3 be greater than D 1 by a certain margin, which can be a function of the fluid pressure P and the sizing of the outlet port 307 . [0031] Another embodiment of a pulsejet valve/nozzle assembly of this invention is shown in FIG. 5 . The valve/nozzle assembly 400 has an inline arrangement wherein a fluid flows into the valve body 401 from an upper inlet 402 into the upper cavity 412 , through the fluid passage 411 , and into the lower cavity 413 . The valve poppet 405 straddles the upper cavity 412 and the lower cavity 413 through the passage 410 . The valve poppet 405 has a tapered inlet end 409 and a tapered outlet end 408 . The valve poppet 405 has a side inlet port 420 situated or positioned in the upper cavity 412 and the side outlet port 419 situated or positioned in the lower cavity 413 . The inlet port 420 and the outlet port 419 are connected by the passage 411 . The tapered inlet end 409 mates with valve inlet port 414 and the tapered outlet end 408 mates with the valve outlet port 407 . The valve poppet 405 has a shoulder 406 that fits sealably or snugly inside the lower cavity 413 . The valve poppet 405 is free to slide up and down between the inlet port 414 and the outlet port 407 . [0032] Referring to FIG. 6 , when a pressurized fluid enters into the valve/nozzle assembly 400 through the inlet 402 , it pushes down the valve poppet 405 and enters into the upper cavity 412 and into the side ports 420 . The fluid then flows through the passage 411 and enters the lower cavity 413 through the side port 419 . At this moment, the valve poppet 405 is down and the tapered outlet end 408 seals the outlet port 407 with a fluid induced force Ff=PA 1 , where A 1 is a cross-sectional area of the valve poppet 405 in the upper cavity 412 . The fluid of pressure P in the lower cavity 413 quickly sees the cross-sectional area of the poppet shoulder 406 and exerts a lifting force of a magnitude of P(A 3 −A 1 ), where A 1 is the cross-sectional area of the valve poppet 405 inside the lower cavity 413 . This lifting force cancels the downward force P·A 1 in the upper cavity 412 . As a result, the valve poppet 405 moves up and opens the outlet port 407 and closes the inlet port 414 . Simultaneously, the fluid inside the lower cavity 413 flows out of the nozzle 415 . As the fluid pressure inside the lower cavity 413 diminishes, the lifting force on the valve poppet 405 is reduced to a level of less than the downward force inside the upper cavity 412 , and the valve poppet 405 moves down to close the outlet port 407 and thus completes one cycle of the poppet movement. As long as the pressurized fluid flow continues, a pulsed fluid jet will be generated at the nozzle 415 . Fluid flow may be interrupted inside the valve/nozzle assembly 400 but will not be blocked completely. Thus, there will be no water hammer effect in the fluid system. This inline pulsejet valve/nozzle assembly 400 of this invention has one advantage of a relatively slim construction and a simple or logical flow pattern ideally, which is suited for use with handheld tools. [0033] Another embodiment of a pulsejet valve/nozzle assembly 500 is shown in FIG. 7 , and comprises a valve body 501 having an inlet 502 , a cylindrical cavity 504 containing a valve cartridge 510 , and an outlet 503 with a nozzle 514 . The valve cartridge 510 connects the inlet 502 to the outlet 503 in a fluid tight manner. The valve cartridge 510 can have a cylindrical shape and can contain a flow modulating mechanism, such as discussed in this specification. The valve cartridge 510 has an inlet 521 , an inlet cavity 512 , a poppet 505 , an outlet cavity 513 , and an outlet 522 . The valve poppet 505 has an inlet side port 519 , a central fluid passage 511 , an outlet side port 520 , and tapered ends to mate with the inlet 502 and outlet 503 of the valve cartridge 510 . The valve cartridge 510 has a side bleed hole 517 connecting the cavity 516 inside the valve cartridge 510 to an outer atmosphere or the outside. When a pressurized fluid enters into the valve/nozzle assembly 500 of this invention, it flows into the valve cartridge 510 in which its flow is modulated by movement of the valve poppet 505 and the fluid can flow out of the nozzle 514 in the form of a pulsed jet. This cartridge arrangement can simplify the maintenance as the valve poppet 505 and its contact surfaces are subject to wear and the fluid leakage becomes too excessive. It is then the time for maintenance to replace the valve cartridge 510 . This cartridge arrangement can also provide a cartridge having one of various lengths to be used inside the same nozzle body so that various flow modulation frequencies can be used. [0034] In some fluid jet applications, a mass of each fluid jet pulse needs to be substantial so that the pulse frequency can be reduced, which relates to the so-called water cannon technology, particularly when the fluid is water. The water cannon technology is known and characterized by the high power of the fluid pulses that can cause significant damage when impacting a surface. This capability can be useful in many geotechnical applications. This invention can provide the necessary technology to meet the needs of water cannons. [0035] Referring to FIG. 8 , a pulsejet generator 600 of this invention comprises a gas accumulator cylinder 621 connected to one end of a valve inlet head 627 . The other end of the valve inlet head 627 is connected to a valve cylinder 601 . The valve inlet head 627 has an inlet cavity 611 with a tapered inlet port 613 in communication with a valve inlet 602 . The inlet cavity 611 has a tapered inlet port 613 connected to the valve inlet 602 and a central hole 615 that accommodates a cylindrical valve shuttle 605 . The valve shuttle 605 has a tapered inlet end 606 that is mateable with the inlet port 613 . The inlet cavity 611 has a seal 616 around the valve shuttle 605 to minimize fluid leakage. The valve cylinder 601 has a floating piston 617 that straddles around the valve shuttle 605 through a center hole 618 . The piston 617 has an outside diameter seal 619 and an inside diameter seal 620 to isolate or separate the fluids. The valve shuttle 605 has a side inlet port 608 inside the inlet cavity 611 , a central fluid passage 610 , and an outlet side port 609 inside the outlet cavity 612 . The valve shuttle 605 has an upper catch 623 in a gas cavity 604 on top of a piston 617 and a lower catch 624 in the outlet cavity 612 and below the piston 617 . The two catches 623 and 624 on the valve shuttle 605 define a distance that the valve shuttle 605 can travel. The gas cylinder 621 has a gas cavity 622 connected to the gas cavity 604 by the passage 625 drilled through the valve inlet head 627 . When the gas cylinder 621 is filled with a gas such as nitrogen or air to a pressure Pg, the gas will flow into the gas cavity 604 and will push the piston 617 down against the valve shuttle catch 624 and will move the shuttle 605 down to close the outlet port 614 . The outlet port 614 is tapered to mate with the tapered outlet end 607 of the valve shuttle 605 . As a result, the outlet port 614 can be closed by the valve shuttle 605 under a downward force exerted on the valve shuttle 605 in the cavity 611 . The gas pressure Pg can be selected based on characteristics of the system fluid and the intended application. In different embodiments of this invention, Pg is smaller than the pressure of the system fluid entering into the pulsejet generator 600 . [0036] As a system fluid of pressure Pf flows into the inlet cavity 611 through the inlet 602 , the fluid can follow the side inlet port 608 , the passage 610 and the side outlet port 609 of the valve shuttle 605 and can enter into the cavity 612 . Once in the cavity 612 , the fluid encounters the closed outlet port 614 which it cannot open because of the fluid seating force in the cavity 611 . The fluid also encounters the piston 617 and pushes it upward. By design, the gas pressure in the cavity 604 is lower than the fluid pressure in the cavity 612 . Thus, the piston 617 can rise and eventually engage the catch 623 on the valve shuttle 605 . Now, the valve shuttle 605 can rise if the gas pressure in the cavity 604 is lower than the fluid pressure in the cavity 612 . The outlet port 614 can thus open and allow the system fluid to flow out or discharge. Now, the system fluid encounters the entire cross-sectional area of the outlet end 607 and pushes it up to keep the inlet port 613 closed until the fluid loses pressure. The piston 617 can move down with the fluid and engage the lower catch 624 to move the valve shuttle 605 down to the closed outlet port 614 . Thus, the valve shuttle 605 and the piston 617 complete one cycle of their movement. When the flow of pressurized system fluid continues, a pulsed fluid jet can be generated at the nozzle 626 . The cyclic movement of the piston 617 determines the frequency of the pulsejet and the volume of system fluid swept by the piston 617 determines the mass of each pulse. The gas pressure inside the gas cavity 604 can vary during each cycle because the gas is compressing and expanding but remains below that of the system fluid, otherwise the cyclic movement cannot continue. As a result, the pulsejet generated at the nozzle 626 varies in energy content in each slug of fluid, higher at the start of slug and lower at the end. The presence of a gas accumulator allows the use of a large nozzle to generate a pulsejet of high impact energy. If the gas accumulator is replaced with a strong spring, the ability to store energy can be limited and the operation may not be smooth. [0037] In known waterjet operations, the water pressure often exceeds 10,000 psi, which is substantially higher than the gas pressure commonly employed in gas accumulator practices because gas at such high pressure becomes very dangerous and difficult to handle. To accommodate water at very high pressures, the gas accumulator used in the pulsejet generator 600 of this invention can be replaced with a gas pressure intensifier by incorporating a piston-plunger setup into the pulsejet valve/nozzle assembly of this invention. As a result, there is another embodiment of a pulsejet generator 700 of this invention, capable of handling system fluid of very high pressures. With this gas intensifier, a gas can be used to store energy at manageable pressures to accommodate water at pressures above 40,000 psi. Water, due to its non-compressible nature, is easier to handle than a gas at 4,000 psi. [0038] Referring to FIG. 9 , the pulsejet generator 700 of this invention comprises a gas cylinder 726 with a gas chamber 731 , a gas piston 727 housed in the gas chamber 731 with an associated piston seal 728 , a hollow valve cylinder 701 attached to the gas cylinder 726 on one end, a hollow plunger 722 attached to the gas piston 727 on one end which has an end cap 718 at the other end, a valve inlet head 715 situated inside the valve plunger 722 , a fluid supply tube 725 in the center of the gas chamber 732 connecting an outside valve inlet 702 to the valve inlet head 715 through a center hole 729 on the gas piston 727 , a cylindrical valve shuttle 705 straddling across the end cap 718 , and a valve outlet 703 attached to the other end of the valve cylinder 701 . The valve inlet head 715 has an inlet cavity 711 with a tapered inlet port 713 connected to the valve inlet 702 . The inlet cavity 711 has a central hole 716 to accommodate the inlet end 706 of the valve shuttle 705 and a seal 717 around the valve shuttle 705 to prevent fluid leakage. The inlet end 706 is tapered to mate with the inlet port 713 . The plunger end cap 718 has a center hole 719 to accommodate the valve shuttle 705 and has an outside diameter seal 720 and an inside diameter seal 721 to prevent fluid leakage. The plunger end cap 718 defines the outlet cavity 712 and the plunger cavity 730 , which is connected to the atmosphere through a bleed 734 on the hollow plunger 722 and on the gas cylinder 726 . The valve shuttle 705 has a tapered outlet end 707 situated or positioned in the outlet cavity 712 . The inlet end 706 has a side inlet port 708 situated or positioned in inlet cavity 711 , an outlet side port 709 on the outlet end 707 in the outlet cavity 712 , and an internal fluid passage 710 connecting the two side ports. The valve shuttle 705 comprises an upper catch 723 situated or positioned in the plunger cavity 730 and a lower catch 724 situated or positioned in the outlet cavity 712 . The plunger end cap 718 can slide along the valve shuttle 705 between the two catches 723 and 724 . A cushion spring may be placed between the plunger end cap 718 and the lower catch 724 to soften the contact. [0039] Still referring to FIG. 9 , the pulsejet generator 700 can be filled with a gas such as nitrogen or air in the gas chamber 731 to a pressure Pg, which can be determined by the pressure of the system fluid involved. The gas can push down the gas piston 727 and the plunger 722 , and the plunger end cap 718 will then push down the valve shuttle 705 to close the outlet port 714 . The pulsejet generator 700 can now be used to generate pulsed fluid jets. [0040] When a pressurized system fluid, such as water, enters in the pulsejet generator 700 through the inlet 702 at a pressure Pw, it flows into the inlet cavity 711 through the supply tube 725 . In the cavity 711 , it exerts a force on the inlet end 706 of the valve shuttle 705 to push it down while the fluid flows through the valve shuttle 705 into the outlet cavity 712 . In the outlet cavity 712 , water sees or encounters the closed outlet port 714 and cannot open it. Instead, the water pushes the end cap 718 of the plunger 722 against the gas force acting on the piston 727 . If the water force is greater than the gas force, then the plunger end cap 718 rises along the seated valve shuttle 705 . Eventually, the plunger end cap 718 engages the upper catch 723 . At this point, if the water force pushing up the plunger end cap 718 is still greater than the gas force acting-on the piston 727 , then the valve shuttle 705 can be moved or dislodged from the outlet port 714 and water can flow into the valve outlet 703 and discharge at the nozzle 736 . At this time, water in the outlet cavity 712 sees the entire cross-sectional area of the outlet end 709 of the valve shuttle 705 and thus exerts a force pushing it upward to close the inlet port 713 of the valve inlet head 715 until water pressure inside the cavity 712 is reduced to a lower level. Once the outlet port 714 is open, the plunger end cap 718 can move down with the water and eventually engage the lower catch 724 and push down the valve shuttle 705 to close the outlet port 714 . Thus, the valve shuttle 705 and the plunger 722 complete one cycle of their up-and-down movement. If the water supply is continued, the pulsed waterjet can be produced at the nozzle 736 . A time period required to complete this cycle determines a frequency of the pulsed waterjet. The water pressure and the intensification ratio of the intensifier determine the energy content of the waterjet pulses. The intensification ratio is determined by the effective cross-sectional area of the gas piston 727 and the effective cross-sectional area of the plunger end cap 719 . If this ratio is 20 and the gas pressure inside the gas chamber 731 is 2000 psi, the pulsejet generator 700 can handle water at pressures above 40,000 psi. The total volume of the gas chamber 731 can affect the amount of water energy that can be stored during each pulse. Thus, the energy content of each waterjet pulse can also be affected by the gas volume. The larger the gas chamber 731 , the flatter can be the energy profile of a waterjet pulse. Greater energy in waterjet pulses often relates to greater power in doing work. Example 1 [0041] To better illustrate this invention, a pulse valve/nozzle 200 was constructed according to the embodiment shown in FIG. 3 . The valve/nozzle 200 had a rectangular body 201 made of stainless steel with a side fluid inlet 202 of 0.156 inches in diameter, a cylindrical cavity 212 and 213 of 0.500 inches in diameter, and a bottom fluid outlet 203 of 0.156 inches in diameter. Attached to fluid outlet 203 was a nozzle 215 having a replaceable orifice. A valve shuttle 205 with the shoulder 206 was constructed of stainless steel and placed inside the upper cavity 212 with the seal/bushing 214 and 218 . The valve shuttle 205 had a diameter of 0.312 inches and the shoulder 206 had a diameter of 0.498 inches. The seal/bushing 214 and 218 were made of brass disks and polymer packed in a sandwich form and fit the valve shuttle 205 and the cavities 212 and 213 snugly but otherwise the valve shuttle 205 was free to slide. A side bleed hole 0.047 inches in diameter was drilled on the side of valve/nozzle body 201 , as shown in FIG. 3 . The valve/nozzle body 201 was 2 inches wide, 3.7 inches long, and 1 inch thick. The valve shuttle 205 was 2 inches long with the shoulder 206 of 0.1 inches thick and the tapered outlet end 208 of 60 degrees, and had a central fluid passage 211 of 0.125 inches in diameter. The outlet port 207 had a taper of 59 degrees and a contact ring of 0.250 inches in diameter was formed when the valve shuttle 205 made contact with the valve port 207 . Thus, a differential cross-sectional area of the valve shuttle 205 and the contact ring was 0.0764−0.0591=0.0273 square inches, which is the surface that fluid inside cavity 213 encountered while exerting an upward lifting force on the valve shuttle 205 . When 70 psi tap water was introduced into the lower cavity 213 , for example, a lifting force of about 2 pounds was produced. When constructed, the pulsejet valve/nozzle 200 was closed because of the compression spring 209 inside the upper cavity 212 . The spring 209 was relatively light, exerting an estimated force of less than 0.1 pound on the valve shuttle 205 . [0042] The valve/nozzle 200 was tested with 70-psi tap water. When the water was introduced into the inlet 202 , a pulsed waterjet was issued or discharged at the nozzle 215 , immediately. The nozzle 215 was inserted with a sapphire orifice of 0.052 inches in diameter. The oscillation of the valve shuttle 205 inside the valve body 201 could be felt and heard but the waterjet pulses were not clearly visible with naked eyes. The pulses were bunched too closely due to the high pulsating frequency, which was estimated at 100 cycles per second. However, photographing this pulsejet with a digital camera clearly revealed the water pulses. Example 2 [0043] A pulsejet generator was constructed according to the embodiment shown in FIG. 8 . The pulsejet generator 600 was constructed with 1¼-inch Schedule-40 PVC pipe rated for pressures up to 370 psi, and with pipe components such as a tee, an elbow and end caps. A PVC tee was used as the centerpiece of the pulsejet generator 600 . On one end of the tee was the gas accumulator 621 which was made of a 5-inch long section of PVC pipe and a cap and the other end was the valve cylinder 601 made of a 6-inch-long PVC pipe, an end plug, and a cap. The overall length of the assembled accumulator/valve cylinder combination was about 15 inches. A fluid inlet head 627 made of stainless steel was positioned in the center of the tee and had a fluid passage connected to the fluid inlet 602 . The inlet head 627 had a fluid inlet cavity 611 and a tapered inlet port 613 that mated with the tapered inlet end 606 of the valve shuttle 605 . The valve shuttle 605 was made of stainless steel and was 0.500 inches in diameter, 5 inches in length, and was machined to have the upper catch 623 and the lower catch 624 of 0.063 inches in height and 0.010 inches in thickness. The valve shuttle 605 had ends with a 60-degree taper and had the inlet side port 608 and the outlet side port 609 connected by an internal fluid passage 610 . The side ports were 0.125 inches in diameter and the fluid passage 610 was 0.250 inches in diameter. Generator 600 had a gas piston 617 straddling around the valve shuttle 605 between the catch 623 and the catch 624 . The gas piston 617 had an outside diameter of 1.312 inches and a center hole of 0.500 inches in diameter and was fitted with an outside diameter seal 619 and an inside diameter seal 620 around the valve shuttle 605 , and could travel a maximum distance of 3.0 inches between the catch 623 and the catch 624 . The volume of space swept by the gas piston 617 during its maximum travel was 3.3 cubic inches. The gas piston 617 divided the valve cylinder interior space into two parts, an upper gas cavity 604 and a lower outlet cavity 612 . The gas in the accumulator 622 could flow into the gas cavity 604 by the passage 625 drilled through the inlet head 627 . The valve shuttle 605 straddled across three cavities, the inlet cavity 611 , the gas cavity 604 and the outlet cavity 612 . The valve shuttle catch 623 was situated or positioned in the cavity 604 and the catch 624 situated or positioned in the cavity 612 . [0044] Still referring to FIG. 8 , when the accumulator 622 was filled with compressed air to 60 psi, the gas piston 617 was pushed down with the valve shuttle 605 to close the outlet port 614 . The generator 600 was then ready for generating a pulsed fluid jet of choice. In this case, compressed air of 90 psi was selected as the system fluid in order to generate a pulsed air jet for a special application. When the 90-psi compressed air entered into the upper cavity 612 , it saw but could not open the closed outlet port 614 . Instead, the 90-psi air started to push the gas piston 617 upward with a total force of about 100 pounds, which was greater than the downward force of about 69 pounds on the gas piston from the 60-psi air in the accumulator 621 . As a result, the gas piston 617 started to move up while the outlet port 614 remained closed. After traveling for 3 inches, the gas piston 617 made contact with the upper catch 623 and exerted a lifting force on the valve shuttle 605 to open the outlet port 614 and to close the inlet port 613 . At this moment, 90-psi air in the cavity 612 saw the entire cross-sectional area of the valve shuttle 605 , thus exerting a force to keep the inlet port 613 closed. The 90-psi air in the cavity 612 started to flow out of the nozzle under the pushing force of the gas piston 617 . Quickly, the gas piston 617 caught up with the lower catch 624 and the valve shuttle 605 moved down to close the outlet port 614 , thus completing one cycle of the valve operation. This up-and-down movement of the gas piston 617 continued and the pulsed air jet was generated at the nozzle, which had an opening of 0.75 inches. The pulsed air jet was very unique due to the substantial amount of energy it packs. When generated in water, the air jet could propel a small boat such as a kayak or canoe. On the other hand, a continuous stream of compressed air would not be suitable for such use. Likewise, the pulsed air jet or other fluid jet from the generator 600 of this invention will find many other applications. Example 3 [0045] A pulsejet generator 700 was constructed for water applications according to the embodiment shown in FIG. 9 . The generator 700 was made of two attached cylinders, an upper gas cylinder 726 made of carbon steel and a lower water cylinder 701 made of hardened stainless steel. The gas cylinder 726 was 9 inches long and 3.5 inches in diameter and the water cylinder 701 was 5.25 inches long and 2.5 inches in diameter for an assembled overall length of 14.5 inches. The gas cylinder 726 had a gas chamber 731 of 2.5 inches in diameter and housed a gas piston 727 made of aluminum alloy and was fitted with a polymeric outside diameter seal 728 . A hollow plunger 722 made of hardened stainless steel was attached to the gas piston 727 on one end and was fitted with an end cap 718 on the other end. The plunger 722 was housed inside the water cylinder 701 and was free to slide. The plunger end cap 718 was made of hardened stainless steel and was fitted with a polymeric outside diameter seal 720 and a polymeric inside diameter seal 721 around a cylindrical valve shuttle 705 . The valve shuttle 705 was made of hardened stainless steel and was 0.250 inches in diameter, 3.25 inches long, and had tapered ends 706 and 707 of 60 degrees. The valve shuttle 705 also had side ports 708 and 709 of 0.094 inches diameter and an inside fluid passage 710 of 0.125 inches in diameter connecting the two side ports 708 and 709 . The valve shuttle 705 also had machined catches 723 and 724 of 0.063 inches high and 0.010 inches thick. [0046] Still referring to FIG. 9 , the constructed pulsejet generator 700 had a water supply tube 725 placed in the center of gas cylinder 726 connecting the outside water inlet 702 to a valve inlet head 715 situated or positioned inside the hollow plunger 722 . The water tube 725 , made of stainless steel, was 0.250 inches in outside diameter, was 0.094 inches in inside diameter, and was 6.5 inches in length. The valve inlet head 715 , made of stainless steel, was 0.560 inches in outside diameter and 1.0 inch in length, and had a tapered inlet port 713 of 60 degrees, an inlet cavity 711 of 0.312 inches in diameter, and a shuttle opening of 0.250 inches in diameter fitted with a polymeric seal 717 . The valve shuttle 705 straddled across cavities 711 , 730 , and 712 with its inlet side port 708 situated or positioned in the cavity 711 and its outlet port 709 in the cavity 712 . Seals 717 , 720 and 721 kept fluid leakage to a minimum. The cross-sectional area of the gas piston 727 was 4.91 square inches and the cross-sectional area of water tube was 0.049 square inches. Thus, the effective gas surface area on the gas piston 727 was 4.91−0.049=4.857 square inches. The cross-sectional area of plunger end cap 718 was 0.52 square inches. Thus, the intensification ratio of the pressure intensifier was 4.857÷ 0.52=9.34. This intensification ratio indicates that the maximum water pressure the pulsejet generator 700 could accommodate is 9.34×Pg, with Pg being the gas pressure inside the gas chamber 731 . [0047] The pulsejet generator 700 was filled with compressed air to 300 psi. The gas piston 727 was pushed down by the compressed air and the outlet port 714 was closed. Tap water pressurized to 2000 psi from a motorized jet washer was introduced into the pulsejet generator 700 , and a pulsed waterjet issued or discharged immediately at the nozzle 736 , which had a sapphire orifice of 0.052 inches in diameter. The waterjet pulses could be seen with the naked eye and the modulating motion of the valve shuttle inside the generator was felt by hand. The frequency was estimated to be less than 20 cycles per second and the volume of water per pulse was estimated to be less than 0.5 cubic inches. The resultant pulsed waterjet appeared to be quite powerful and compared very favorably against a conventional straight waterjet issued or discharged by the same nozzle in impacting against a concrete block. [0048] While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that this invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of this invention.
An apparatus for generating high-speed pulsed fluid jets. A valve assembly has a valve body with an inlet and an outlet. A valve shuttle is slidably or movably mounted with respect to the valve body. The valve shuttle is positioned within a cavity of the valve body and divides the cavity into an upper or inlet cavity and a lower or outlet cavity. The valve shuttle has a passage in communication with the upper cavity and the lower cavity. In an open condition of the valve assembly, fluid communication is formed between the inlet, the inlet cavity, the passage, the outlet cavity and the outlet.
8
This Application is a continuation of prior application Ser. No. 09/218,503 filed Dec. 22, 1998 (now abandoned). FIELD OF THE INVENTION The present invention relates generally to intravascular stents for implanting into a living body. In particular, the present invention relates to intravascular stents that are expanded by an inflatable balloon catheter and to a method and apparatus for mounting and securing a stent on a balloon catheter. BACKGROUND OF THE INVENTION Intravascular stents having a constricted diameter for delivery through a blood vessel and an expanded diameter for applying a radially outwardly extending force for supporting the blood vessel are known in the art. Selfexpandable articulated stents are described, for example, in U.S. Pat. No. 5,104,404, entitled “Articulated Stent” to Wolff. Balloon expandable articulated stents are commercially available under the trade name Palmaz-Schatz Balloon-Expandable stents from Johnson & Johnson International Systems Co. In conventional stent mounting and securing procedures, the stent is usually first slid over the distal end of a balloon catheter so that the expandable balloon is disposed within the longitudinal bore of the stent. The stent is then crimped or pinched to mount or secure the stent and maintain its position with respect to the expandable balloon as the balloon catheter is advanced to the target area. This crimping is often done utilizing the fingers or a plier-like device to pinch the stent. One shortcoming of this conventional mounting and securing means is that it often produces irregular distortion of the stent which could cause trauma to the lumen being treated. Another shortcoming is that it may weaken a portion or portions of the stent which could result in stent failure. Yet another shortcoming of conventional mounting and securing methods is that they may distort the stent in such a way as to cause the stent to expand in the target area in a non-uniform manner which could result in a portion of the lumen not being properly supported. Yet another shortcoming of conventional mounting and securing methods is irregular distortion of the stent could produce protrusions in the stent which could cause trauma to the patient. Therefore, it would be highly desirable to have a method and an apparatus that permits a stent to be secured over the expandable balloon of a balloon catheter without causing irregular distortion or weakening the stent. OBJECTS AND SUMMARY OF THE INVENTION It is an object of this invention to provide an apparatus for securing a stent on a balloon catheter by substantially uniformly distorting the stent. It is another object of this invention to provide an apparatus for securing a stent on a balloon catheter that reduces the likelihood that the stent will expand in a nonuniform manner. It is yet another object of this invention to provide a method of securing a stent on a balloon catheter that reduces the likelihood that the stent will be weakened by the securing procedure. It is a further object of this invention to provide an apparatus for securing a stent on a balloon catheter, comprising: a) a first clamping portion provided with a first clamping portion recess, said first clamping portion recess sized and adapted to receive a stent crimping sleeve; b) a second clamping portion provided with a second clamping portion recess, said second clamping portion recess sized and adapted to receive a stent crimping sleeve, said first clamping portion recess and said second clamping portion recess defining a longitudinal stent crimping sleeve channel having a variable cross-sectional diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position to selectively impart pressure to a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, said clamping portion recesses sized and adapted so that said longitudinal stent crimping sleeve channel has a substantially circular cross-sectional diameter when said first and said second clamping portions are in said second position; c) a stent crimping sleeve disposed in said crimping sleeve channel, said sleeve having a first end, a second end, an outer surface, and an inner surface defining a longitudinal stent crimping bore therethrough, said longitudinal stent crimping bore having a selectively variable-substantially circular cross-sectional diameter and sized and adapted to receive a balloon catheter with a stent mounted thereon, said stent crimping sleeve further adapted to selectively and substantially uniformly vary said substantially circular cross-sectional diameter of said longitudinal stent crimping bore in response to pressure applied to said external surface of said stent crimping sleeve by said first clamping portion and said second clamping portion when said first clamping portion and said second clamping portion are moved in said second direction. It is still another object of this invention to provide a method of securing an expandable stent having a longitudinal bore on a balloon catheter, comprising the steps of: a) constructing an apparatus comprising: a first clamping portion provided with a first clamping portion recess, said first clamping portion recess sized and adapted to receive a stent crimping sleeve; a second clamping portion provided with a second clamping portion recess, said second clamping portion recess sized and adapted to receive a stent crimping sleeve, said first clamping portion recess and said second clamping portion recess defining a longitudinal stent crimping sleeve channel having a variable cross-sectional diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position to selectively impart pressure to a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, said clamping portion recesses sized and adapted so that said longitudinal stent crimping sleeve channel has a substantially circular cross-sectional diameter when said first and said second clamping portions are in said second position; a stent crimping sleeve having a first end, a second end, an outer surface, and an inner surface defining a longitudinal stent crimping bore therethrough having a selectively variable substantially circular cross-sectional diameter and sized and adapted to receive a balloon catheter with a stent mounted thereon, said stent crimping sleeve further adapted to selectively and substantially uniformly vary said substantially circular cross-sectional diameter of said longitudinal stent crimping bore in response to pressure applied to said external surface of said stent crimping sleeve by said first clamping portion and said second clamping portion; b) disposing said stent crimping sleeve in said stent crimping sleeve channel; c) disposing said stent in said longitudinal stent crimping bore of said stent crimping sleeve; d) disposing said balloon catheter in said longitudinal bore of said stent; and e) moving said first and said second stent clamping portions from said first position to said second position so as to apply pressure to said external surface of said stent crimping sleeve in an amount sufficient to decrease the substantially circular cross-sectional diameter of said longitudinal stent crimping bore in an amount sufficient for said inner surface of said stent crimping sleeve to impart sufficient pressure to said stent to secure said stent to said balloon catheter. It is a further object of this invention to provide an apparatus for securing a stent on a balloon catheter, comprising: a) a first clamping portion having a first clamping portion recess and a second clamping portion having a second clamping portion recess, said first and said second clamping portion recesses defining a longitudinal stent crimping element channel with a variable cross-sectional diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position; b) a plurality of crimping elements disposed within said longitudinal stent crimping element channel defining a stent crimping sleeve channel having a variable cross-sectional diameter, said plurality of crimping elements adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position; and c) a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, having a first end, a second end, an outer wall, and an inner wall defining a longitudinal bore therethrough having a selectively variable substantially circular cross-sectional diameter, said clamping portions said crimping elements, and said sleeve adapted and disposed so that when said first clamping portion, said second clamping portion, and said plurality of crimping elements are disposed in the second position, said crimping elements define a longitudinal stent crimping sleeve channel having a substantially circular crosssectional diameter and said longitudinal stent crimping bore defines a longitudinal bore having a substantially circular cross-sectional diameter. It is a yet another object of this invention to provide an apparatus for securing a stent on a balloon catheter, comprising: a) a first clamping portion and a second clamping portion, said first clamping portion provided with a first surface, a second surface and a third surface defining a first clamping portion recess, said second clamping portion provided with a first surface, a second surface, a third surface, a fourth surface and a fifth surface defining a second clamping portion recess, said first and said second clamping portion recesses defining a longitudinal stent crimping element channel with a variable diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position; b) a first crimping element disposed within said longitudinal stent crimping element channel said first crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a first clamping portion contact surface, and a stent crimping sleeve contact surface; c) a second crimping element disposed within said longitudinal stent crimping channel, said second crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a first clamping portion contact surface, and a stent crimping sleeve contact surface; d) a third crimping element disposed within said longitudinal stent crimping channel, said third crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a second clamping portion contact surface, and a stent crimping sleeve contact surface; e) a fourth crimping element disposed within said longitudinal stent crimping channel, said fourth crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a second clamping portion contact surface, and a stent crimping sleeve contact surface, said crimping elements adapted for movement in a first direction away from each other to a first position and in a second direction towards each other to a second position, said stent crimping sleeve contact surfaces defining a stent crimping sleeve channel having a variable cross-sectional diameter that is substantially circular—when said plurality of crimping elements are disposed in said second position; and f) a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, said sleeve having a first end, a second end, an outer wall, and an inner wall defining a longitudinal bore therethrough having a selectively variable substantially circular crosssectional diameter, said clamping portions, said crimping elements, and said sleeve adapted and disposed so that when said first clamping portion and said second clamping portion are in the second position, said crimping sleeve contact surfaces define a stent crimping sleeve channel having a substantially circular cross-sectional diameter and said longitudinal bore defines a longitudinal bore having a substantially circular cross-sectional diameter. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view of a stent placed on a balloon catheter before the stent has been secured to the balloon; FIG. 2 is a side view of the stent of FIG. 1 after the stent has been secured to the balloon utilizing conventional securing methods; FIG. 3 is a cross-sectional end view of a stent securing apparatus constructed in accordance with this invention with the clamping portions disposed in a first or non-securing position; FIG. 4 is a cross-sectional end view of a stent securing apparatus constructed in accordance with this invention with the clamping portions disposed in a second or securing position; FIG. 5 is a cross-sectional side view of a stent crimping sleeve constructed in accordance with the invention; FIG. 6 is an end view of the stent crimping sleeve shown in FIG. 5; FIG. 7 is a cross-sectional side view of the stent crimping sleeve of FIGS. 5 and 6 with the balloon catheter and stent of FIG. 1 disposed within it prior to the stent being secured to the balloon; FIG. 8 is an end view of FIG. 7; FIG. 9 shows the stent crimping sleeve shown in FIGS. 5 and 6 disposed between the first and second clamping portions with the first and second clamping portions disposed in a first or non-securing position; FIG. 10 shows the stent crimping sleeve shown on FIGS. 5 and 6 disposed between the first and second clamping portions with the first and second clamping portions moved to a second or securing position; FIG. 11 shows the stent of FIG. 1 secured to the balloon catheter after being secured in accordance with the invention; FIG. 12 shows an alternative embodiment of the invention having a first clamping portion and a second clamping portion disposed in a first position; FIG. 13 shows the clamping portions shown in FIG. 12 with a plurality of crimping elements disposed between the clamping portions; FIG. 14 shows the clamping portions and crimping elements of FIG. 13 disposed in a second position; FIG. 15 shows FIG. 13 with a stent crimping sleeve disposed between the crimping elements with the clamping portions and the crimping elements disposed in a first or non-securing position; FIG. 16 shows the embodiment shown in FIG. 15 with the clamping portions and the crimping elements disposed in a second or securing position; FIG. 17 is a cross-sectional side view of an alternative embodiment of the invention which utilizes a catheter protector and a catheter protector and stent positioners; FIG. 18A is an end view of the second catheter protector and stent positioner shown in FIG. 17; FIG. 18B is an end view of the first catheter protector shown in FIG. 17; and FIG. 19 is an enlarged detailed view of a portion of FIG. 17 . DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a conventional balloon catheter 1 and shows a catheter 2 , a balloon 3 , and a stent 4 mounted on the balloon 3 prior to the stent 4 being secured on the balloon 3 . FIG. 2 shows the stent of FIG. 1 after it has been secured to the balloon by conventional methods, e.g., by pinching between the fingers or by crimping with a conventional plier-like device. As shown in FIG. 2, the ends of the stent protrude and there is some irregular distortion of the stent between the two ends of the stent. FIG. 3 shows a stent securing apparatus 5 constructed in accordance with the invention. FIG. 3 shows a first clamping portion 6 having a first clamping portion recess 7 and a second clamping portion 8 having a second clamping portion recess 9 . The first clamping portion recess 7 and the second clamping portion recess 9 define a longitudinal stent crimping sleeve channel 10 with a selectively variable cross-sectional diameter. FIG. 3 shows the first clamping portion 6 and the second clamping portion 8 disposed in a first or non-securing position which provides a first clearance D 1 between the first clamping portion 6 and the second clamping portion 8 that is adequate for inserting an uncompressed stent crimping sleeve into the stent crimping sleeve channel 10 . FIG. 4 shows the first clamping portion 6 and the second clamping portion 8 of FIG. 3 moved to a second or securing position with a second clearance D 2 between the first clamping portion 6 and the second clamping portion 8 that is less than that D 1 . Thus, when disposed in the second or securing position, the first clamping portion 6 and the second clamping portion 8 are closer to each other than they are when disposed in the first position and, as shown in FIGS. 3 and 4, the crimping sleeve channel 10 has a smaller diameter. As also shown in FIG. 4, when the first clamping portion 6 and the second clamping portion 8 are in the second position, the crimping sleeve channel 10 has a substantially circular crosssectional diameter. The first clamping portion 6 and the second clamping portion 8 may be arranged in a variety of ways well known to those skilled in the art which permits selective movement of the first clamping portion 6 and second clamping portion 8 from the first position to the second position, i.e., toward and away from each other. In the embodiment shown, a channel 11 aligns the first clamping portion 6 and second clamping portion 8 and external pressure, e.g., finger pressure may be utilized to move the first clamping portion 6 and 8 from the first position to the second position. In another embodiment, pneumatic pressure or an electrical motor is utilized to move the clamping portions 6 and 8 . In an especially preferred embodiment, a pressure gauge and pressure regulator are utilized to control the amount of pressure applied. In still another embodiment, the first and second clamping portions 6 and 8 are mounted on a plier like hinged device. FIG. 5 is a cross-sectional side view of a stent crimping sleeve 12 having an outer surface 13 and an inner surface 14 defining a longitudinal stent crimping bore 15 . FIG. 6 is an end view of FIG. 5 . The stent crimping bore 15 has a selectively variable substantially circular crosssectional diameter that changes in response to external pressure applied to the external surface 13 of the stent crimping sleeve 12 . The material comprising the stent crimping sleeve 12 is selected from a material which will substantially uniformly vary and maintain the substantially circular cross-sectional diameter of the longitudinal stent crimping bore 15 in response to pressure applied to the outer surface 13 of the stent crimping sleeve 12 . In a preferred embodiment, polyurethane is utilized. FIG. 7 shows the stent 4 , balloon 3 , and catheter 2 of FIG. 1 disposed within the longitudinal stent crimping bore 15 of the stent crimping sleeve 12 shown in FIG. 5 prior to the stent 4 being crimped and secured to the balloon 3 . FIG. 8 is an end view of FIG. 7 . FIG. 9 shows the stent crimping sleeve 12 of FIGS. 5 and 6 disposed in the stent crimping sleeve channel 10 between the first stent clamping portion 6 and second stent clamping portion 8 of the stent securing apparatus 5 . As shown in FIG. 9, the first stent clamping portion 6 and second stent clamping portion 8 are disposed in a first position which provides adequate clearance in the stent crimping sleeve channel 10 for the stent crimping sleeve 12 to be easily inserted or removed from the stent crimping sleeve channel 10 . Longitudinal bore 15 has a substantially circular cross-sectional diameter D 1 . FIG. 10 differs from FIG. 9 in that the first stent clamping portion 6 and the second stent clamping portion 8 have been moved to a second position. The first clamping portion recess 7 and the second clamping portion recess are sized and cooperatively adapted so that when disposed in the second position the first and second clamping portions 6 and 8 define a channel 10 having a substantially circular cross-sectional diameter. As shown in FIG. 10, in response to the pressure applied by the first and second clamping portions 6 and 8 on the external wall 13 of the stent crimping sleeve 12 , the stent crimping sleeve 12 is compressed. This causes the diameter of the longitudinal stent crimping bore 15 to be reduced substantially uniformly to a substantially circular crosssectional diameter D 2 which is less than the uncompressed diameter D 1 shown in FIG. 9 . In response to the external pressure-applied to the outer surface 13 , the inner surface 14 of the stent crimping bore 15 applies a substantially uniform pressure to the stent 4 in an amount sufficient so as to substantially uniformly crimp the stent 4 and secure it on the balloon 3 with minimal irregular distortion of the stent 4 because the longitudinal bore 15 maintains its substantially circular cross-sectional diameter when the stent crimping sleeve 12 is compressed and the diameter of the stent crimping bore 15 is reduced. FIG. 11 is a side view of the stent shown in FIG. 1 after it has been secured in accordance with the invention and removed from the stent securing apparatus 5 and shows that the stent 4 has been substantially uniformly crimped and secured on the balloon 3 with minimal irregular distortion. FIGS. 12 to 16 show an alternative embodiment of the invention that utilizes a plurality of crimping elements disposed between the clamping portions to apply pressure to a stent crimping sleeve. FIG. 12 shows a first clamping portion 16 and a second clamping portion 18 . First clamping portion 16 is provided with a first surface 19 , a second surface 20 , and a third surface 21 defining a first clamping portion recess 66 . Second clamping portion 18 is provided with a first surface 22 , a second surface 23 , a third surface 24 , a fourth surface 25 and a fifth surface 26 defining a second clamping portion recess 67 . The surfaces 19 , 20 , 21 , comprising the first clamping portion recess 66 and the surfaces 22 , 23 , 24 , 25 , and 26 comprising the second clamping portion recess 67 define a longitudinal stent crimping element channel 27 with a selectively variable cross-sectional diameter. As shown in FIG. 13, disposed within the longitudinal stent crimping element channel 27 is a first crimping element 29 , a second crimping element 30 , a third crimping element 31 and a fourth crimping element 32 . First crimping element 29 is provided with a first crimping element contact surface 33 , a second crimping element contact surface 35 , a first clamping portion contact surface 34 and a stent crimping sleeve contact surface 36 . Second crimping element 30 comprises a first crimping element contact surface 37 , a second crimping element contact surface 39 , a first clamping portion contact surface 38 and a stent crimping sleeve contact surface 40 . Third crimping element 31 is provided with a first crimping element contact surface 41 , a second crimping element contact surface 43 , a second clamping portion contact surface 42 and a stent crimping sleeve contact surface 44 . Fourth crimping element 32 is provided with a first crimping element contact surface 45 , a second crimping element contact surface 47 , a second clamping portion contact surface 46 , and a stent crimping sleeve contact surface 48 . The stent crimping sleeve contact surfaces 36 , 40 , 44 , and 48 define a stent crimping sleeve channel 10 , having a selectively variable crosssectional diameter. FIG. 13 shows the first clamping portion 16 , the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 disposed in a first or non-securing position, which provides a cross-sectional diameter No. of the stent crimping sleeve channel 101 that is adequate for inserting an uncompressed stent crimping sleeve 12 into the stent crimping sleeve channel 101 . As the first clamping portion 16 and the second clamping portion 18 are moved to the second position, surface 19 impinge on surface 34 , surface 21 impinges upon surface 38 , surface 23 impinges upon surface 46 and surface 25 impinges upon surface 42 moving the crimping elements 29 , 30 , 31 , and 32 to a second or securing position. FIG. 14 shows the first clamping portion 16 , the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 disposed in a second position the stent crimping sleeve surfaces 36 , 40 , 44 , and 48 define a crimping sleeve channel 10 ′ having a substantially circular cross-sectional diameter D 2 that is smaller than diameter No. shown in FIG. 13 . The first clamping portion 16 and second clamping portion 18 may be arranged in a variety of ways well skilled to those skilled in the art which permits selective movement of the first clamping portion 16 and second clamping portion 18 in a first direction away from each other to a first position and in a second direction toward each other to a second position. FIGS. 15 and 16 show a stent crimping sleeve 12 (previously discussed) disposed in the longitudinal stent crimping sleeve channel 10 ′. (The stent and balloon catheter have been omitted for clarity.) As shown in FIG. 15, when the first clamping portion 16 and the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 are disposed in the first position, some portions of crimping element contact surfaces 36 , 40 , 44 , and 48 may not be in contact with some portion of the outer surface 13 of the stent crimping sleeve 12 because when the first clamping portion 16 , the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 are in the first position, surfaces 36 , 40 , 44 , and 48 do not define a stent crimping sleeve channel 10 , having a substantially circular crosssectional diameter. Thus, when the first and second clamping portions and the crimping elements are in the first or non-securing position, gaps 68 may exist between the outer surface 13 of the stent crimping sleeve 12 and crimping element contact surfaces 36 , 40 , 44 , and 48 . As shown in FIG. 16, however, when first clamping portion 16 , second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second or securing position, substantially all of crimping element contact surfaces 36 , 40 , 44 , and 48 are in contact with the external surface 13 of the crimping sleeve 12 because surfaces 36 , 40 , 44 , and 48 are sized and adapted to define a stent crimping sleeve channel 10 ′ having a substantially circular cross-sectional diameter when the first clamping portion 16 , the second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second position. As shown in FIG. 15, when the first clamping portion 16 , the second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the first or non-securing position, the stent crimping bore 15 has a substantially circular cross-sectional diameter of D 1 . As shown in FIG. 16, when the first clamping portion 16 , the second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second or securing position, the stent crimping bore 15 has a substantially circular cross-sectional diameter D 2 that is smaller than D 1 . Because the stent crimping bore 15 maintains its substantially circular cross-sectional diameter when first clamping portion 16 , second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second position, the inner surface 14 of the stent crimping sleeve 12 applies substantially uniform pressure to the stent 4 to be crimped mounted on the balloon catheter 1 disposed within the longitudinal stent crimping bore 15 and substantially uniformly crimp and secure the stent 4 to the balloon catheter on which it is mounted with minimal irregular distortion of the stent 4 . FIGS. 17 to 19 show an alternative embodiment of the invention in which a first catheter protector 60 and a second catheter protector and stent positioner 61 is utilized to protect the catheter shaft and also to limit the movement of the stent along the longitudinal axis of the catheter resulting in more precise placement on the catheter. FIG. 17 is a cross-sectional side view and shows a balloon catheter 1 , a stent 4 , a guide-wire 65 , a first catheter protector 60 and a second catheter protector and stent positioner 61 . FIG. 18A is an end view of the second catheter-protector and positioner 61 shown in FIG. 17 and FIG. 18B is an end view of the first catheter protector 60 shown in FIG. 17 . As shown in FIG. 18A, the second catheter protector and stent positioner 61 is circular in cross-section and comprises an outer ring 62 of compressible material and an inner ring 63 of substantially non-compressible material. The inner ring 63 is provided with an inner ring aperture 64 having a substantially circular cross-sectional diameter. As shown in FIG. 18B, the first catheter protector 60 is circular in cross-section and comprises an outer ring 62 ′ of compressible material and an inner ring 63 ′ of substantially non-compressible material. The inner ring 63 ′ is provided with an inner ring aperture 64 ′ having a substantially circular cross-sectional diameter. In a preferred embodiment, the substantially compressible material is polyurethane and the substantially non-compressible material is metal. FIG. 19 is an enlarged view of the second catheter protector and stent positioner 61 and the first catheter protector 60 of FIG. 17 . As shown, the inner ring aperture 64 of the substantially non-compressible inner ring 63 of the second catheter protector and positioner 61 is sized sufficiently large so as to permit the catheter 2 to enter into the inner ring aperture 64 and is sized sufficiently small so as to prevent the stent 4 from entering into the inner ring aperture 64 . Thus, the inner ring aperture 64 is sized sufficiently small to prevent entrance of the uncrimped stent 4 and is sized sufficiently large to permit entrance of the balloon portion 3 of the catheter 2 into the inner ring aperture 64 . Because the inner ring aperture 64 is substantially non-compressible it protects the portions of the catheter 2 and guide-wire 65 disposed within the inner ring aperture 64 of the inner ring 63 during the securing procedure. The substantially non-compressible inner ring 63 also acts as a stop to positively position the stent 4 on the catheter 2 . In an especially preferred embodiment, the balloon portion of the catheter has an external diameter of about 0.9 to about 1.2 mm, the inner ring aperture 64 of the second catheter protector and stent positioner 61 has a diameter of about 1.4 mm, the unexpanded and uncrimped stent has an external diameter of about 1.7 to about 1.75 mm and the crimped stent has a diameter of about 1.0 to about 1.1 mm. As shown in FIGS. 17, 18 A, 18 B, and 19 , the first catheter protector 60 has an inner ring aperture 64 ′ that is larger than the inner ring aperture 64 of the second catheter protector and stent positioner 61 . The inner ring aperture 64 ′ is sized large enough to permit the passage of an uncrimped stent through the inner ring aperture 64 ′ and into the longitudinal stent crimping bore of the stent crimping sleeve. In an especially preferred embodiment a diameter of about 1.9 mm to about 2.0 mm is utilized. In operation, the uncrimped stent is advanced through the inner ring aperture 64 ′ of the first catheter protector 60 and into the longitudinal stent crimping bore until the stent contacts the second catheter protector and stent positioner 61 . Because the second catheter protector and stent positioner 61 has an inner ring aperture 64 that is smaller than the diameter of an uncrimped stent and greater than the diameter of the catheter, the catheter positioner and stent positioner 61 serves both to position the stent and to protect the distal end of the catheter. The catheter is then introduced into the longitudinal bore of the stent and the stent is crimped onto the balloon portion of catheter. After the stent has been crimped on the balloon portion of the catheter, the catheter with the stent crimped on it is withdrawn by pulling the catheter through the inner ring aperture 64 ′ of the first catheter protector 60 .
Apparatus and method for securing a stent to a balloon catheter. A first clamping portion and a second clamping portion are arranged for movement toward and away from each other and are provided with recesses defining a channel to receive a stent crimping sleeve having a longitudinal bore. The stent is slid into the longitudinal bore of the stent crimping sleeve and the balloon catheter is then slid into the longitudinal bore of the stent. The first and second clamping portions are moved towards each other and apply pressure to the external surface of the stent crimping sleeve causing the internal diameter of the longitudinal bore to get smaller and apply pressure to the external surface of the stent and crimp the stent to the balloon.
0
BACKGROUND OF THE INVENTION The invention relates generally to the field of disposal of highly radioactive materials, and, more particularly, to a method and apparatus for reducing the volume of radioactive rectangular tubular fuel channels stored under water. In one type of boiling water nuclear reactor (BWR), there is a fuel assembly consisting of fuel rods surrounded by a fuel channel. The channel is a 5.278 inch square tube, approximately fourteen feet long, with open ends and made of zircalloy. The channels typically have a wall thickness of 0.080, 0.100 or 0.120 inch. There are a large number of these fuel assemblies in a BWR reactor, and one-third of these assemblies are normally replaced each year. Even though the fuel channels are normally reused after the fuel rods are removed, for various reasons it has been determined that in some cases, they cannot be resued, but must be replaced, thereby requiring these highly radioactive fuel channels to be disposed of in a safe and economical manner. These used fuel channels are highly radioactive for two reasons. First, the zircalloy metal itself has become somewhat radioactive during operation of the nuclear reactor, and second, there is formed on the outside of the channel a crust or crud which itself is also highly radioactive. The present method of disposing of such radioactive fuel channels is to place them in a special heavy metal shipping cask, and transport them to one of the five federal disposal grounds in the country where they are then buried. However, the rental for these casks is quite expensive, and it would be highly desirable to reduce the effective volume of these tubular fuel channels thereby to increase the number of channels which can be shipped in each cask. There are presently hundreds of these fuel channels stored in water-filled fuel pools at numerous BWR-nuclear power plants. Due to the radiation levels of these fuel channels, they must be handled under water, thus posing one problem. Another problem is that the handling operation must result in as little debris as possible, since such debris is radioactive and will contaminate the pool water. One suggestion has been to crush the fuel channels in order to reduce their volume, but this procedure would result in a great deal of debris in the form of flaked-off radioactive crust dislodged from the channel during the crushing operation. In addition, the volume reduction would not be optimum using this method of compaction. SUMMARY OF THE INVENTION Therefore, the broad object of this invention is to provide a method and apparatus for disposing of these fuel channels, which are stored under water, by minimizing the effective volume of each fuel channel, with a minimum of radioactive debris, such that each shipping cask can accommodate a much larger number of fuel channels than would otherwise be possible. A more specific object of this invention is to cut under water a radioactive rectangular tube into four side plates which are then nested or stacked as they are placed in a shipping cask which is also under water. Another object of the invention is to provide an apparatus into which a rectangular fuel channel may be placed under water, such apparatus being provided with four roller cutters which travel along the four longitudinal edges or corners of the fuel channel to cut the fuel channel simultaneously and efficiently into four side plates which are then placed in a shipping cask, thereby greatly increasing the total number of fuel channels which may be accommodated by each shipping cask. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a schematic illustration of the method of this invention; FIG. 2 illustrates the environment in which the preferred apparatus of the invention is used; FIG. 3 is a front elevation of the apparatus of the invention; FIG. 4 is a side sectional view of the apparatus of FIG. 3; FIG. 5 is a sectional view taken along line "5--5" of FIG. 3; FIG. 6 is a sectional view taken along line "6--6" of FIG. 3; FIG. 7 is a vertical section of the cutter head assembly taken along line "7--7" of FIG. 8; FIG. 8 is a section taken along line "8--8" of FIG. 7; FIG. 9 is a section taken along line "9--9" of FIG. 7; FIG. 10 is a section taken along line "10--10" of FIG. 7; and FIG. 11 is a section taken along line "11--11" of FIG. 7. DESCRIPTION OF THE PREFERRED EMBODIMENT Reference numeral 10 designates a spent highly radioactive fuel channel 10, typically made of zircalloy which has become highly radioactive, and reference numeral 12 designates a radioactive crust or crud which is formed on the channel during its use in a nuclear reactor. The illustrated channel is an approximately five inch square tube which is approximately fourteen feet long with open ends. The thickness of the walls of the channel is typically in the range of 0.080 to 0.12 inch. FIG. 1 illustrates the method of the invention. The spent radioactive fuel channel is stored in a pool 14 of water. In order to ship such fuel channels to the federal burial grounds within the country, the channels must be stored in a radioactive-shielded shipping cask 16. In accordance with this invention, in order to reduce the volume of the fuel channel for shipping, the channel is cut along its four longitudinal corners 18, 20, 22 and 24 to sever the channel into four rectangular side plates 26, 28, 30 and 32 which may then be nested to form a stack having a volume approximately ten times less than that of the fuel channel 10. In practice, after the fuel channel is severed into the side plates, the side plates are removed from the cutting apparatus 34 by suitable mechanical manipulator means controlled by an operator above the pool and stacked in a suitable disposal basket 36. Several side plates are stacked in each disposal basket, and then several disposal baskets are placed in the shipping cask 16. Since available shipping casks are of various heights, the fuel channel 10 may be cut into shorter lengths to accommodate the dimensions of the cask. Since the upper end of the fuel channel may have some projecting members which prevents tight nesting, this upper end may also be transversely severed and handled as a separate radioactive element. As will be explained in more detail in connection with the description of the preferred apparatus of the invention, the severing operation is accomplished by roller cutter blades, thereby reducing to a minimum the production of metal chips and any radioactive debris caused by flaking off of the radioactive crust during the cutting operation. Any chips or radioactive debris is collected by suitable filtering means for subsequent disposal. FIG. 2 schematically illustrates the preferred apparatus of the invention as applied to the disposal of spent fuel channels which are stored under water in a pool. A fuel channel 10 is shown already inserted in the corner cutter apparatus 34 which is supported by cables 38 and 40 from a bracket 42 attached to the edge 44 of the pool 14. A hydraulic cylinder and piston actuator 46 is fixed to the lower end of the outside of the apparatus 34 and actuates the fuel channel cutter assembly via a pulley and cable arrangement 48 which will be described in more detail below. The actuator 46 is connected via a pair of hydraulic lines 50 and 52 to a hydraulic power supply 54 whose operation is controlled by a cutter control console 56. Of course both the power supply and the cutter control console are located at the top of the pool. The support cables 38 and 40 maintain the cutter apparatus 34 in a vertical orientation. In order to prevent the pool water from being contaminated by metal chips or radioactive debris which may be flaked off of the fuel channel 10 during the cutting operation, a filtering system is provided to remove this debris from the apparatus 34. To achieve filtering, the water is pumped from the lower end of the apparatus 34 via a conduit or hose 60, and intermediate filter assembly 62, a suction pump 64 and a final filter 66 from which the filtered water is discharged back into the pool. As shown in FIG. 3, note that both the hydraulic lines 50, 52 and the filter hose 60 are strapped to the support cables 38 and 40. Any radioactive debris is trapped in the filters 62 and 66 for subsequent disposal. FIGS. 4-7 illustrate the cutter apparatus 34 used in this invention. The apparatus consists of an outer cylindrical tubular housing 70 which is suspended by cables 38 and 40 fixed to the support bar and bracket 42 which in turn is hooked to the pool's top edge. Mounted on the outside of the housing 70 at the lower end thereof are the piston and cylinder actuator 46 and the cable and pulley assembly 48. Mounted for longitudinal movement within the outer housing 70 is a cutter assembly 72 having four roller cutter blades 74 in engagement with the four longitudinal corners or seams, respectively, of the fuel channel 10. The cutter assembly 72 is mounted on a carrier assembly 78 which is supported within the inside walls of the outer housing 70 by four guide assemblies 80 which are driven in a reciprocating manner along the length of the fuel channel 10. In FIGS. 4-7, the cutter assembly 72 is shown in its upwardmost position generally opposite an upper mandrel assembly 82 which is disposed within the inside corners of the fuel channel 10 to act as a backing member for the cutter blades 74. Mandrel assembly 82 is fixed to cylindrical support member 86 extending the length of the fuel channel. As indicated, a duplicate mandrel assembly 82 is affixed to the lower end of support member 86. FIGS. 8-12 are sectional views showing the details of the cutter assembly 72. As shown in FIG. 8, the channel 10 may be supported on top of the mandrel assembly 82 by means of one or more inwardly extending straps 84 which are an integral part of a particular fuel channel to which this invention is addressed. (In such fuel channels, the upper end thereof may be transversely severed from the remainder of the channel in order to permit tighter nesting of the severed side plates.) It is seen that the cutter assembly 72 consists of four sets of three rollers which engage respective corners of the fuel channels. Two of the rollers 90 and 92 in each set are guide rollers, whereas the third roller 94 is a cutter roller having a cutter blade 96. These rollers are all mounted for rotation on stainless steel ball bearings, such as ball bearing 98. Each of the rollers 90, 92 and 94 has a concave recess 100 which mates with the corresponding slightly rounded corner 102 of the fuel channel 10. Thereby, all three rollers, including the cutting roller 94, act as guide rollers to keep the cutter assembly positioned relative to the fuel channel 10 so that the cutter blades 96 bisect the corner angles of the fuel channel 10, thereby assuring maximum nesting and compaction of the four side plates after they are severed. The cutter roller 94 is mounted for rotation on a shaft 104 which is journaled in a member 106. The upper guide roller 90 is mounted for rotation on a shaft 108 which is journaled in the member 110 such that the member 106 carrying the cutter roller 94 is pivotable about the shaft 108. The member 106 is welded to a cam 112 which is spring-biased outwardly by a spring 114. The lower end of a cutter adjusting screw 116 engages the inclined surface of the cam 112, and an adjusting knob 118 is fixed to the upper end of the adjusting screw 116. By moving the adjusting screw downwardly, the cutter blade 94 is moved inwardly to increase the depth of cut in the walls of the fuel channel 10. In operation, the cutter assembly starts in its upwardmost position, and the cutter rollers 94 are adjusted for the desired depth for the first downward cutting stroke. Upon return of the cutter assembly to its upper position and before it begins its next downward stroke, the adjusting knob 118 is turned to move the cutter blade inwardly to increase the depth of cut for the next downward stroke. All four cutter blades 94 may be simultaneously so adjusted at the top of each stroke until the four side plates are completely severed. It is noted that the mandrel assembly 82 is slightly rounded at the extremities thereof to mate with the curved corners of the fuel channel, and that each projection of the mandrel assembly has a small notch therein to accommodate the cutting blade 96 on the cutter roller 94. The cutter assembly 72 and carrier assembly 78 are supported within the outer housing 70 by means of the four guide assemblies 80, each of which has an upper double guide roller 120 and a lower double guide roller 122 which engage the inner wall of the housing 70. Referring to FIGS. 7 and 8, two of the guide assemblies 80 are affixed to and driven by the cable and pulley assembly 48. More specifically, one of the guide assemblies 80 is fixed at its upper end to a cable 126 which passes over an idler pulley 128, and is fixed at its lower end to another cable 130. In like manner, the diametrically opposite guide assembly 80 of FIG. 3 is fixed at its upper end to a cable 132 passing over a second idler pulley 134, and the lower end thereof is fixed to another cable 136 corresponding to the cable 130. The cable and pulley assembly 48 consists of a series of pulleys located at fixed points on the housing and on a horizontal bar attached to the end of the piston rod 47. This arrangement of pulleys results in a four-to-one mechanical advantage between the travel of the cutter head 72 and the travel of the piston rod 47. In other words for every inch of extension of the piston rod 47 the cutter head 72 will travel four inches. There are four groupings of cable and pulley assemblies but it will be necessary to describe only one as all four operate essentially the same. Reference is made to the right-hand power pulley assembly of FIGS. 3, 4, 5 and 6. Cable 130 is fixedly attached at 138 to the middle portion of casing 70 (FIG. 3). From there the cable runs down to pulley 140 mounted on the end of piston rod 47. The cable then runs up to pulley 142 and back down again to pulley 144 lying adjacent to pulley 140. From there the cable 130 runs up to pulley 146 then down to 148 and into the interior of casing 70. The cable 130 then runs up the inside of the casing to the lower portion of guide assembly 80 and is fixed at this point. The operation of the illustrated preferred apparatus of the invention may be summarized as follows. A plurality of spent, highly radioactive fuel channels 10 are stored under water in a pool. The corner cutter apparatus 34 is suspended in a vertical orientation under water from the edge of the pool. A human operator, using suitable mechanical manipulators, places a fuel channel 10 in the apparatus 34 so that the mandrel assembly 82 is inside of the channel. A channel hold down plate 83 is affixed to the upper mandrel assembly 82 by suitable bolts 85. The four roller blades 94 are adjusted by the adjusting screw 116 to the desired depth of cut for the first stroke of the cutting mechanism 72. The hydraulic power supply 54 is operative via the cutter controls console 56 to activate the piston and cylinder arrangement 46 to initiate a downward stroke of the cutter assembly. The pulley and cable arrangement 48, having a four-to-one mechanical advantage relative to the piston stroke, pulls the cutter assembly down to its lowermost position, thereby making a first cut through the longitudinal corners or seams of the fuel channel. The hydraulic power supply then returns the cutter assembly to its upwardmost position, where the adjusting screws are rotated wither individually or simultaneously to move the roller cutters inwardly for the next downward cutting stroke. This operation is continued until the four side plates are severed from the fuel channel. (The fuel channel may also be cut transversely into varying lengths to remove projections thereof which would prevent nesting and to accommodate the height of the ultimate storage casks.) The side plates are then removed by a mechanical manipulator, and several of the plates are then stacked or nested in a disposal basket 36, several of which are then stacked in the shipping cask 16. All of the above operations take place under water. Furthermore, there is provided a filtering system (62, 64 and 66) which removes from the housing assembly 34 and possible metal cutter slivers or radioactive debris produced during the cutting operation by the flaking off of radioactive crust on the exterior surface of the fuel channel. The filtered, uncontaminated water is then returned to the pool. The operation of the preferred apparatus of the invention thereby provides the means by which highly radioactive BWR fuel channels can be safely and economically shipped from the owner's storage pool for ultimate disposal with minimum infringement on pool space and without degradation of storage pool water.
Irradiated tubular rectangular fuel channels from a nuclear reactor are temporarily stored under water. In order to dispose of these highly radioactive channels and to ship them to permanent burial grounds, the channels must be placed in specially designed shipping casks under water. In order to reduce the volume of the channel so as to economize on the use of the casks, the channels are cut along their longitudinal edges to form four plates which are then nested before being placed in the storage casks, thereby greatly increasing the number of channels which may be stored in each cask. The cutting is done under water by an apparatus having four roller cutters which are positioned along the outside of the four edges or corners of a channel and are moved longitudinally down the channel edges in a reciprocating motion until the four side plates of the channel are severed.
6
FIELD OF THE INVENTION The present invention relates to a method and an apparatus for the use of carbon-isotope monoxide in labeling synthesis. More specifically, the invention relates to a method and apparatus for producing an [ 11 C]carbon monoxide enriched gas mixture from an initial [ 11 C]carbon dioxide gas mixture, and using the produced gas mixture in labeling synthesis by photo-initiated carbonylation. Radiolabeled acids are provided using alkyl or aryl iodides as precursors, as well as sulfoxides and triethylamine. BACKGROUND OF THE INVENTION Tracers labeled with short-lived positron emitting radionuclides (e.g. 11 C, t 1/2 =20.3 min) are frequently used in various non-invasive in vivo studies in combination with positron emission tomography (PET). Because of the radioactivity, the short half-lives and the submicromolar amounts of the labeled substances, extraordinary synthetic procedures are required for the production of these tracers. An important part of the elaboration of these procedures is development and handling of new 11 C-labelled precursors. This is important not only for labeling new types of compounds, but also for increasing the possibility of labeling a given compound in different positions. During the last two decades carbonylation chemistry using carbon monoxide has developed significantly. The recent development of methods such as palladium-catalyzed carbonylative coupling reactions has provided a mild and efficient tool for the transformation of carbon monoxide into different carbonyl compounds. Carbonylation reactions using [ 11 C]carbon monoxide has a primary value for PET-tracer synthesis since biologically active substances often contain carbonyl groups or functionalities that can be derived from a carbonyl group. The syntheses are tolerant to most functional groups, which means that complex building blocks can be assembled in the carbonylation step to yield the target compound. This is particularly valuable in PET-tracer synthesis where the unlabelled substrates should be combined with the labeled precursor as late as possible in the reaction sequence, in order to decrease synthesis-time and thus optimize the uncorrected radiochemical yield. When compounds are labeled with 11 C, it is usually important to maximize specific radioactivity. In order to achieve this, the isotopic dilution and the synthesis time must be minimized. Isotopic dilution from atmospheric carbon dioxide may be substantial when [ 11 C]carbon dioxide is used in a labeling reaction. Due to the low reactivity and atmospheric concentration of carbon monoxide (0.1 ppm vs. 3.4×10 4 ppm for CO 2 ), this problem is reduced with reactions using [ 11 C]carbon monoxide. The synthesis of [ 11 C]carbon monoxide from [ 11 C]carbon dioxide using a heated column containing reducing agents such as zinc, charcoal or molybdenum has been described previously in several publications. Although [ 11 C]carbon monoxide was one of the first C-labelled compounds to be applied in tracer experiments in human, it has until recently not found any practical use in the production of PET-tracers. One reason for this is the low solubility and relative slow reaction rate of [ 11 C]carbon monoxide which causes low trapping efficiency in reaction media. The general procedure using precursors such as [ 11 C]methyl iodide, [ 11 C]hydrogen cyanide or [ 11 C]carbon dioxide is to transfer the radioactivity in a gas-phase, and trap the radioactivity by leading the gas stream through a reaction medium. Until recently this has been the only accessible procedure to handle [ 11 C]carbon monoxide in labeling synthesis. With this approach, the main part of the labeling syntheses with [ 11 C]carbon monoxide can be expected to give a very low yield or fail completely. There are only a few examples of practically valuable 11 C-labelling syntheses using high pressure techniques (>300 bar). In principal, high pressures can be utilized for increasing reaction rates and minimizing the amounts of reagents. One problem with this approach is how to confine the labeled precursor in a small high-pressure reactor. Another problem is the construction of the reactor. If a common column type of reactor is used (i.e. a cylinder with tubing attached to each end), the gas-phase will actually become efficiently excluded from the liquid phase at pressurization. The reason is that the gas-phase, in contracted form, will escape into the attached tubing and away from the bulk amount of the liquid reagent. The cold-trap technique is widely used in the handling of 11 C-labelled precursors, particularly in the case of [ 11 C]carbon dioxide. The procedure has, however, only been performed in one single step and the labeled compound was always released in a continuous gas-stream simultaneous with the heating of the cold-trap. Furthermore, the volume of the material used to trap the labeled compound has been relative large in relation to the system to which the labeled compound has been transferred. Thus, the option of using this technique for radical concentration of the labeled compound and miniaturization of synthesis systems has not been explored. This is especially noteworthy in view of the fact that the amount of a 11 C-labelled compound usually is in the range 20-60 nmol. Recent technical development for the production and use of [ 11 C]carbon monoxide has made this compound useful in labeling synthesis. WO 02/102711 describes a system and a method for the production and use of a carbon-isotope monoxide enriched gas-mixture from an initial carbon-isotope dioxide gas mixture. [ 11 C]carbon monoxide may be obtained in high radiochemical yield from cyclotron produced [ 11 C]carbon dioxide and can be used to yield target compounds with high specific radioactivity. This reactor overcomes the difficulties listed above and is useful in synthesis of 11 C-labelled compounds using [ 11 C]carbon monoxide in palladium or selenium mediated reaction. With such method, a broad array of carbonyl compounds can be labeled (Kilhlberg, T.; Långström, B. J., Org. Chem. 1999, 9201-9205). The use of transition metal mediated reactions is, however, restricted by problems related to the competing β-hydride elimination reaction, which excludes or at least severely restricts utilization of organic electrophiles having hydrogen in β-position. Thus, a limitation of the transition metal mediated reactions is that most alkyl halides could not be used as substrates due to the β-hydride elimination reaction. One way to circumvent this problem is to use free-radical chemistry based on light irradiation of alkyl halides. We earlier succeeded in using free-radical chemistry for the carbonylation of alkyl iodides using amines to yield labeled amides. However, the attempt to yield labeled esters and acids in an analogous way (using water as a reactant instead of amines) is challenged by dissimilar solubility of water and alkyl or aryl iodides in solvents due to very different polarities of the reactants. Another problem of this approach is the low reactivity of water in these reaction conditions (typically the yields of esters and acids compared to those of amides are lower by 10 to 100 times). Therefore, there is a need for a method in order to use photo-induced free radical carbonylation to overcome the problems of weakly reacting water and dissimilar solubility of water and alkyl or aryl iodides and provide target structures with high yield to further increase the utility of [ 11 C]carbon monoxide in preparing useful PET tracers. Discussion or citation of a reference herein shall not be construed as an admission that such reference is prior art to the present invention. SUMMARY OF THE INVENTION The present invention provides a method for labeling synthesis, comprising: (a) providing a UV reactor assembly comprising a high pressure reaction chamber with a gas inlet and a liquid inlet, a UV spot light source with a light guide, wherein the light guide is used to provide photo irradiation of a reaction mixture through a window in the reaction chamber, (b) dissolving triethylamine (TEA) and a sulfoxide in a solvent, (c) adding an alkyl or aryl iodide to the solution of step (b) to give a reagent volume to be labeled, (d) introducing a carbon-isotope monoxide enriched gas-mixture into the reaction chamber of the UV reactor assembly via the gas inlet, (e) introducing at high-pressure said reagent volume into the reaction chamber via the liquid inlet, (f) turning on the UV spot light source and waiting a predetermined time while the labeling synthesis occur, and (g) collecting labeled acid from the reaction chamber. The present invention also provides a system for labeling synthesis, comprising: a UV reactor assembly comprising a high pressure reaction chamber with a gas inlet and a liquid inlet, a UV spot light source with a light guide, wherein a light guide is used to provide photo irradiation of the reaction mixture through a window in the reaction chamber thereof, wherein the photo irradiation from the light source, which stands at the distance from the reaction chamber, is delivered through the window of the reaction chamber. The present invention further provides a method for the synthesis of labeled acids, using photo-initiated carbonylation with [ 11 C]carbon monoxide using alkyl or aryl iodides, TEA and a sulfoxide, preferably dimethysulfoxide (DMSO). In another embodiment, the invention also provides [ 11 C]-labeled acids, and pharmaceutically acceptable salts and solvates thereof. In yet another embodiment, the invention provides kits for use as PET tracers comprising effective amount of [ 11 C]-labeled acids, or pharmaceutically acceptable salts and solvates thereof. In still another embodiment, the invention provides a method for conducting PET of a subject comprising administering to the subject a kit of the instant invention and measuring distribution within the subject of the [ 11 C]-labeled acids by PET. Other features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating preferred embodiments of the invention are 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. BRIEF DESCRIPTION OF THE FIGURES FIG. 1 shows a flow chart over the method according to the invention FIG. 2 is a schematic view of a carbon-isotope monoxide production and labeling-system according to the invention. FIG. 3 is the cross-sectional view of the reaction chamber. FIG. 4 is a view of the UV spot light source. FIG. 5 shows how the reaction chamber, magnetic stirrer, and the UV spot light source are arranged into the UV reactor assembly. FIGS. 6 a and 6 b show alternative embodiments of a reaction chamber according to the invention. DETAILED DESCRIPTION OF THE INVENTION The main advantage of the present invention is to overcome the limitations of transition metal-mediated reaction and provide a simple approach to synthesize 11 C-labeled acids under very mild conditions using alkyl/aryl iodides as precursors. The levels of specific radioactivity are high compared with alternative methods such as the use of Grignard reactions for preparation of [carbonyl- 11 C]esters and acids. Iodides used in this invention have a formula RI, where R is linear or cyclic alkyl or substituted alkyl, aryl or substituted aryl, and may contain fluoro, ester and carboxyl groups, which are separated by at least one carbon atom from the carbon atom bearing the iodide atom. Sulfoxides are defined as compounds having the structure R′ 2 S═O, wherein R′ is a lower (less than 10 carbons) alkyl or aryl. Examples of sulfoxides include DMSO and diphenylsulfoxide (Ph 2 S═O). The resultant labeled acids have a formula wherein R is defined as above. They and their pharmaceutically acceptable salts and/or solvates thereof provide valuable PET tracers in various PET studies. It is to be clear that the present invention includes pharmaceutically acceptable salts and solvates of labeled compounds of the instant invention, and mixtures comprising two or more of such labeled compounds, pharmaceutically acceptable salts of the labeled compounds and pharmaceutically acceptable solvates of labeled compounds. The term “pharmaceutically acceptable” means compatible with the treatment of animals, in particular, humans. The term “pharmaceutically acceptable salt” refers to salt forms that are pharmacologically suitable for or compatible with the treatment of patients. If the inventive compound is a base, the desired pharmaceutically acceptable salt may be prepared by an suitable method available in the art, for example, treatment of the free base with an inorganic acid, such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid and the like, or with an organic acid, such as acetic acid, maleic acid, succinic acid, mandelic acid, fumaric acid, malonic acid, pyruvic acid, oxalic acid, glycolic acid, salicylic acid, a pyranosidyl acid, such as glucuronic acid or galacturonic acid, an α-hydroxy acid, such as citric acid or tartaric acid, an amino acid, such as aspartic acid or glutamic acid, an aromatic acid, such as benzoic acid or cinnamic acid, a sulfonic acid, such as p-toluenesulfonic acid or ethanesulfonic acid, or the like. If the inventive compound is an acid, the desired pharmaceutically acceptable salt may be prepared by any suitable method, for example, treatment of the free acid with an inorganic or organic base, such as an amine (primary, secondary or tertiary), an alkali metal hydroxide or alkaline earth metal hydroxide, or the like. Illustrative examples of the suitable salts include organic salts derived from amino acids, such as glycine and arginine, ammonia, primary, secondary, and tertiary amines, and cyclic amines, such as piperidine, morpholine and piperazine, and inorganic salts derived from sodium, calcium, potassium, magnesium, manganese, iron, copper, zinc, aluminum and lithium. The term “solvate” as used herein means a compound of the invention, wherein molecules of a suitable solvent are incorporated in the crystal lattice. A suitable solvent is physiologically tolerable at the dosage administered. Examples of suitable solvents are ethanol, water and the like. When water is the solvent, the molecule is referred to as a “hydrate”. General reaction scheme for the synthesis of labeled acids are as illustrated below: wherein R and sulfoxide are as defined above. * indicates the 11 C-labeled position. The radiolabelled compounds, or pharmaceutically acceptable salts and solvates thereof, of the invention are suitably formulated into pharmaceutical or radiopharmaceutical compositions for administration to human subjects in a biologically compatible form suitable for administration in vivo. Accordingly, in another aspect, the present invention provides a pharmaceutical composition comprising a radiolabelled compound or pharmaceutically acceptable salts and solvates thereof, of the invention in admixture with a suitable diluent or carrier. The term an “effective amount” as used herein is that amount sufficient to effect desired results, including clinical results, and, as such, an “effective amount” depends upon the context in which it is being applied. The term “subject” as used herein includes all members of the animal kingdom including human. The subject is preferably a human. In preferred embodiment of the present invention, it provides kits for use as PET tracers comprising an effective amount of carbon isotope-labeled esters and acids, or pharmaceutically acceptable salts and solvates thereof. Such kits are designed to give sterile products suitable for human administration, e.g. direct injection into the bloodstream. Suitable kits comprise containers (e.g. septum-sealed vials) containing the adrenergic interfering agent and precursor of the adrenergic imaging agent. The kits may optionally further comprise additional components such as radioprotectant, antimicrobial preservative, pH-adjusting agent or filler. By the term “radioprotectant” is meant a compound which inhibits degradation reactions, such as redox processes, by trapping highly-reactive free radicals, such as oxygen-containing free radicals arising from the radiolysis of water. The radioprotectants of the present invention are suitably chosen from: ascorbic acid, para-aminobenzoic acid (i.e. 4-aminobenzoic acid), gentisic acid (i.e. 2,5-dihydroxybenzoic acid) and salts thereof. By the term “antimicrobial preservative” is meant an agent which inhibits the growth of potentially harmful micro-organisms such as bacteria, yeasts or moulds. The antimicrobial preservative may also exhibit some bactericidal properties, depending on the dose. The main role of the antimicrobial preservative(s) of the present invention is to inhibit the growth of any such micro-organism in the pharmaceutical composition post-reconstitution, i.e. in the radioactive diagnostic product itself. The antimicrobial preservative may, however, also optionally be used to inhibit the growth of potentially harmful micro-organisms in one or more components of the kit of the present invention prior to reconstitution. Suitable antimicrobial preservatives include: the parabens, i.e., ethyl, propyl or butyl paraben or mixtures thereof; benzyl alcohol; phenol; cresol; cetrimide and thiomersal. Preferred antimicrobial preservative(s) are the parabens. The term “pH-adjusting agent” means a compound or mixture of compounds useful to ensure that the pH of the reconstituted kit is within acceptable limits (approximately pH 4.0 to 10.5) for human administration. Suitable such ph-adjusting agents include pharmaceutically acceptable buffers, such as tricine, phosphate or TRIS [i.e. tris(hydroxymethyl)aminomethane], and pharmaceutically acceptable bases such as sodium carbonate, sodium bicarbonate or mixtures thereof. When the ligand conjugate is employed in acid salt form, the pH-adjusting agent may optionally be provided in a separate vial or container, so that the user of the kit can adjust the pH as part of a multi-step procedure. By the term “filler” is meant a pharmaceutically acceptable bulking agent which may facilitate material handling during production and lyophilisation. Suitable fillers include inorganic salts such as sodium chloride, and water soluble sugars or sugar alcohols such as sucrose, maltose, mannitol or trehalose. The present invention also includes a method for conducting positron emission tomography of a subject comprising administering to the subject an effective amount of a radiolabelled compound, or pharmaceutically acceptable salts and solvates thereof, of the instant invention and measuring the distribution within the subject of the compound by PET. In a preferred embodiment, the invention provides a method for conducting PET of a subject comprising administering to the subject a kit of the instant invention and measuring distribution within the subject of the [ 11 C]-labeled esters or acids by PET. In accordance with the methods of the invention, the radiolabeled compounds of the invention may be administered to a patient in a variety of forms depending on the selected route of administration, as will be understood by those skilled in the art. The compositions of the invention are preferably administered by intravenous administration, and the radiopharmaceutical compositions formulated accordingly, for example together with any physiologically and radiologically tolerable vehicle appropriate for administering the compound systemically. In a preferred embodiment of the instant invention, it provides a method and system is that nearly quantitative conversion of carbon-isotope monoxide into labeled products can be accomplished. There are several other advantages with the present method and system. The high-pressure technique makes it possible to use low boiling solvents such as diethyl ether at high temperatures (e.g. 200° C.). The use of a closed system consisting of materials that prevents gas diffusion, increases the stability of sensitive compounds and could be advantageous also with respect to Good Manufacturing Practice (GMP). Still other advantages are achieved in that the resulting labeled compound is highly concentrated, and that the miniaturization of the synthesis system facilitates automation, rapid synthesis and purification, and optimization of specific radioactivity through minimization of isotopic dilution. Most important is the opening of completely new synthesis possibilities, as exemplified by the present invention. Embodiments of the invention will now be described with reference to the figures. The term carbon-isotope that is used throughout this application preferably refers to 11 C, but it should be understood that C may be substituted by other carbon-isotopes, such as 13 C and 14 C, if desired. FIG. 1 shows a flow chart over the method according to the invention, which firstly comprises production of a carbon-isotope monoxide enriched gas-mixture and secondly a labeling synthesis procedure. More in detail the production part of the method comprises the steps of: Providing carbon-isotope dioxide in a suitable carrier gas of a type that will be described in detail below. Converting carbon-isotope dioxide to carbon-isotope monoxide by introducing said gas mixture in a reactor device which will be described in detail below. Removing traces of carbon-isotope dioxide by flooding the converted gas-mixture through a carbon dioxide removal device wherein carbon-isotope dioxide is trapped but not carbon-isotope monoxide nor the carrier gas. The carbon dioxide removal device will be described in detail below. Trapping carbon-isotope monoxide in a carbon monoxide trapping device, wherein carbon-isotope monoxide is trapped but not said carrier gas. The carbon monoxide trapping device will be described in detail below. Releasing said trapped carbon-isotope monoxide from said trapping device, whereby a volume of carbon-isotope monoxide enriched gas-mixture is achieved. The production step may further comprise a step of changing carrier gas for the initial carbon-isotope dioxide gas mixture if the initial carbon-isotope dioxide gas mixture is comprised of carbon-isotope dioxide and a first carrier gas not suitable as carrier gas for carbon monoxide due to similar molecular properties or the like, such as nitrogen. More in detail the step of providing carbon-isotope dioxide in a suitable second carrier gas such as He, Ar, comprises the steps of: Flooding the initial carbon-isotope dioxide gas mixture through a carbon dioxide trapping device, wherein carbon-isotope dioxide is trapped but not said first carrier gas. The carbon dioxide trapping device will be described in detail below. Flushing said carbon dioxide trapping device with said suitable second carrier gas to remove the remainders of said first carrier gas. Releasing said trapped carbon-isotope dioxide in said suitable second carrier gas. The labeling synthesis step that may follow the production step utilizes the produced carbon-isotope dioxide enriched gas-mixture as labeling reactant. More in detail the step of labeling synthesis comprises the steps of: Providing a UV reactor assembly comprising a UV spot light source and a high pressure reaction chamber having a liquid reagent inlet and a labeling reactant inlet in a bottom surface thereof. In a preferred embodiment, the UV reactor assembly further comprises a magnetic stirrer and a magnetic stirring bar. In another preferred embodiment, the UV reactor assembly further comprises a protective housing and a bench where the reaction chamber, UV spot light guide and the magnetic stirrer can be mounted. The UV reactor assembly and the reaction chamber will be described in detail below. Providing a reagent volume that is to be labeled. The reagent volume can be prepared in following steps: 1. Dissolve TEA and a sulfoxide in a solvent; 2. Add alkyl or aryl iodide to the solution of step 1 to form a reagent volume as late as possible before being introduced into the high pressure reaction chamber. Definition and examples of sulfoxides are provided above. In a preferred embodiment, a sulfoxide is a DMSO. Solvent can be any organic solvent or water. Introducing the carbon-isotope monoxide enriched gas-mixture into the reaction chamber via the labeling reactant inlet. Introducing, at high pressure, said liquid reagent into the reaction chamber via the liquid reagent inlet. Turning on the UV spot light source and waiting a predetermined time while the labeling synthesis occurs. Collecting the solution of labeled acid from the reaction chamber. The step of waiting a predetermined time may further comprise adjusting the temperature of the reaction chamber such that the labeling synthesis is enhanced. FIG. 2 schematically shows a [ 11 C]carbon dioxide production and labeling-system according to the present invention. The system is comprised of three main blocks, each handling one of the three main steps of the method of production and labeling: Block A is used to perform a change of carrier gas for an initial carbon-isotope dioxide gas mixture, if the initial carbon-isotope dioxide gas mixture is comprised of carbon-isotope dioxide and a first carrier gas not suitable as carrier gas for carbon monoxide. Block B is used to perform the conversion from carbon-isotope dioxide to carbon-isotope monoxide, and purify and concentrate the converted carbon-isotope monoxide gas mixture. Block C is used to perform the carbon-isotope monoxide labeling synthesis. Block A is normally needed due to the fact that carbon-isotope dioxide usually is produced using the 14N(p,α) 11 C reaction in a target gas containing nitrogen and 0.1% oxygen, bombarded with 17 MeV protons, whereby the initial carbon-isotope dioxide gas mixture comprises nitrogen as carrier gas. However, compared with carbon monoxide, nitrogen show certain similarities in molecular properties that makes it difficult to separate them from each other, e.g. in a trapping device or the like, whereby it is difficult to increase the concentration of carbon-isotope monoxide in such a gas mixture. Suitable carrier gases may instead be helium, argon or the like. Block A can also used to change the pressure of the carrier gas (e.g. from 1 to 4 bar), in case the external system does not tolerate the gas pressure needed in block B and C. In an alternative embodiment the initial carbon-isotope dioxide gas mixture is comprised of carbon-isotope dioxide and a first carrier gas that is well suited as carrier gas for carbon monoxide, whereby the block A may be simplified or even excluded. According to a preferred embodiment ( FIG. 2 ), block A is comprised of a first valve V 1 , a carbon dioxide trapping device 8 , and a second valve V 2 . The first valve V 1 has a carbon dioxide inlet 10 connected to a source of initial carbon-isotope dioxide gas mixture 12 , a carrier gas inlet 14 connected to a source of suitable carrier gas 16 , such as helium, argon and the like. The first valve V 1 further has a first outlet 18 connected to a first inlet 20 of the second valve V 2 , and a second outlet 22 connected to the carbon dioxide trapping device 8 . The valve V 1 may be operated in two modes A, B, in mode A the carbon dioxide inlet 10 is connected to the first outlet 18 and the carrier gas inlet 14 is connected to the second outlet 22 , and in mode B the carbon dioxide inlet 10 is connected to the second outlet 22 and the carrier gas inlet 14 is connected to the first outlet 18 . In addition to the first inlet 20 , the second valve V 2 has a second inlet 24 connected to the carbon dioxide trapping device 8 . The second valve V 2 further has a waste outlet 26 , and a product outlet 28 connected to a product inlet 30 of block B. The valve V 2 may be operated in two modes A, B, in mode A the first inlet 20 is connected to the waste outlet 26 and the second inlet 24 is connected to the product outlet 28 , and in mode B the first inlet 20 is connected to the product outlet 28 and the second inlet 24 is connected to the waste outlet 26 . The carbon dioxide trapping device 8 is a device wherein carbon dioxide is trapped but not said first carrier gas, which trapped carbon dioxide thereafter may be released in a controlled manner. This may preferably be achieved by using a cold trap, such as a column containing a material which in a cold state, (e.g. −196° C. as in liquid nitrogen or −186° C. as in liquid argon) selectively trap carbon dioxide and in a warm state (e.g. +50° C.) releases the trapped carbon dioxide. (In this text the expression “cold trap” is not restricted to the use of cryogenics. Thus, materials that trap the topical compound at room temperature and release it at a higher temperature are included). One suitable material is porapac Q®. The trapping behavior of a porapac-column is related to dipole-dipole interactions or possibly Van der Waal interaktions. The said column 8 is preferably formed such that the volume of the trapping material is to be large enough to efficiently trap (>95%) the carbon-isotope dioxide, and small enough not to prolong the transfer of trapped carbon dioxide to block B. In the case of porapac Q® and a flow of 100 ml nitrogen/min, the volume should be 50-150 μl. The cooling and heating of the carbon dioxide trapping device 8 may further be arranged such that it is performed as an automated process, e.g. by automatically lowering the column into liquid nitrogen and moving it from there into a heating arrangement. According to the preferred embodiment of FIG. 2 block B is comprised of a reactor device 32 in which carbon-isotope dioxide is converted to carbon-isotope monoxide, a carbon dioxide removal device 34 , a check-valve 36 , and a carbon monoxide trapping device 38 , which all are connected in a line. In the preferred embodiment the reactor device 32 is a reactor furnace comprising a material that when heated to the right temperature interval converts carbon-isotope dioxide to carbon-isotope monoxide. A broad range of different materials with the ability to convert carbon dioxide into carbon monoxide may be used, e.g. zinc or molybdenum or any other element or compound with similar reductive properties. If the reactor device 32 is a zinc furnace it should be heated to 400° C., and it is important that the temperature is regulated with high precision. The melting point of zinc is 420° C. and the zinc-furnace quickly loses it ability to transform carbon dioxide into carbon monoxide when the temperature reaches over 410° C., probably due to changed surface properties. The material should be efficient in relation to its amount to ensure that a small amount can be used, which will minimize the time needed to transfer radioactivity from the carbon dioxide trapping device 8 to the subsequent carbon monoxide trapping device 38 . The amount of material in the furnace should be large enough to ensure a practical life-time for the furnace (at least several days). In the case of zinc granulates, the volume should be 100-1000 μl. The carbon dioxide removal device 34 is used to remove traces of carbon-isotope dioxide from the gas mixture exiting the reactor device 32 . In the carbon dioxide removal device 34 , carbon-isotope dioxide is trapped but not carbon-isotope monoxide nor the carrier gas. The carbon dioxide removal device 34 may be comprised of a column containing Ascarite® (i.e. sodium hydroxide on silica). Carbon-isotope dioxide that has not reacted in the reactor device 32 is trapped in this column (it reacts with sodium hydroxide and turns into sodium carbonate), while carbon-isotope monoxide passes through. The radioactivity in the carbon dioxide removal device 34 is monitored as a high value indicates that the reactor device 32 is not functioning properly. Like the carbon dioxide trapping device 8 , the carbon monoxide trapping device 38 , has a trapping and a releasing state. In the trapping state carbon-isotope monoxide is selectively trapped but not said carrier gas, and in the releasing state said trapped carbon-isotope monoxide is released in a controlled manner. This may preferably be achieved by using a cold trap, such as a column containing silica which selectively trap carbon monoxide in a cold state below −100° C., e.g. −196° C. as in liquid nitrogen or −186° C. as in liquid argon, and releases the trapped carbon monoxide in a warm state (e.g. +50° C.). Like the porapac-column, the trapping behavior of the silica-column is related to dipole-dipole interactions or possibly Van der Waal interactions. The ability of the silica-column to trap carbon-isotope monoxide is reduced if the helium, carrying the radioactivity, contains nitrogen. A rationale is that since the physical properties of nitrogen are similar to carbon monoxide, nitrogen competes with carbon monoxide for the trapping sites on the silica. According to the preferred embodiment of FIG. 2 , block C is comprised of a first and a second reaction chamber valve V 3 and V 4 , a reagent valve V 5 , an injection loop 70 and a solvent valve V 6 , and the UV reactor assembly 51 which comprises a UV lamp 91 , a concave mirror 92 and a reaction chamber 50 . The first reaction chamber valve V 3 has a gas mixture inlet 40 connected to the carbon monoxide trapping device 38 , a stop position 42 , a collection outlet 44 , a waste outlet 46 , and a reaction chamber connection port 48 connected to a gas inlet 52 of the reaction chamber 50 . The first reaction chamber valve V 3 has four modes of operation A to D. The reaction chamber connection port 48 is: in mode A connected to the gas mixture inlet 40 , in mode B connected to the stop position 42 , in mode C connected to the collection outlet 44 , and in mode D connected to the waste outlet 46 . FIG. 3 shows the reaction chamber 50 (micro-autoclave) which has a gas inlet 52 and a liquid inlet 54 , which are arranged such that they terminate at the bottom surface of the chamber. Gas inlet 52 may also be used as product outlet after the labeling is finished. During operation the carbon-isotope monoxide enriched gas mixture is introduced into the reaction chamber 50 through the gas inlet 52 , where after the liquid reagent at high pressure enters the reaction chamber 50 through the liquid inlet 54 . FIGS. 6 a and 6 b shows schematic views of two preferred reaction chambers 50 in cross section. FIG. 6 a is a cylindrical chamber which is fairly easy to produce, whereas the spherical chamber of FIG. 6 b is the most preferred embodiment, as the surface area to volume-ratio of the chamber is further minimized. A minimal surface area to volume-ratio optimizes the recovery of labeled product and minimizes possible reactions with the surface material. Due to the “diving-bell construction” of the reaction chamber 50 , both the gas inlet 52 and the liquid inlet 54 becomes liquid-filled and the reaction chamber 50 is filled from the bottom upwards. The gas-volume containing the carbon-isotope monoxide is thus trapped and given efficient contact with the reaction mixture. Since the final pressure of the liquid is approximately 80 times higher than the original gas pressure, the final gas volume will be less than 2% of the liquid volume according to the general gas-law. Thus, a pseudo one-phase system will result. In the instant application, the term “pseudo one-phase system” means a closed volume with a small surface area to volume-ratio containing >96% liquid and <4% gas at pressures exceeding 200 bar. In most syntheses the transfer of carbon monoxide from the gas-phase to the liquid phase will probably not be the rate limiting step. After the labeling is finished the labeled volume is nearly quantitatively transferred from the reaction chamber by the internal pressure via the gas inlet/product outlet 52 and the first reaction chamber valve V 3 in position C. In a specific embodiment, FIG. 3 shows a reaction chamber made from stainless steel (Valco™) column end fitting 101 . It is equipped with sapphire window 102 , which is a hard material transparent to short wavelength UV radiation. The window is pressed between two Teflon washers 103 inside the drilled column end fitting to make the reactor tight at high pressures. Temperature measurement can be accomplished with the thermocouple 104 attached by solder drop 105 to the outer side of the reactor. A magnet stirrer (not shown) drives small Teflon coated magnet stirring bar 106 placed inside the reaction chamber. The magnetic stirrer can be attached against the bottom of the reaction chamber. Distance between the magnet stirrer and the reactor should be minimal. FIG. 4 shows a commercial UV spot light source 110 (for example, Hamamatsu Lightningcure™ LC5), which is an example of UV spot light sources that can be used in the instant invention. Light source 110 has necessary means of operating and controlling the photo irradiation that is produced, of the light source is available from the manufacturer (Hamamatsu Photonics K. K. Thus intensity and time duration of the photo irradiation are easily adjusted by an operator. Light source 110 may be externally controlled by a computer, providing a possibility for automating the reactor assembly. The photo irradiation is delivered to the reaction vessel through a flexible light guide, which is an accessory of Hamamatsu Lightningcure™ LC5. Thus light source 110 may be placed at the distance from the reaction chamber providing the possibility to save precious space inside a sheltered hot-cell, where the radiolabeling syntheses are carried out. Light source 110 complies with the existing industrial safety standards. Further, optional accessories (e.g. changeable lamps, optical filters) are provided which may be advantageously used for adjusting the properties of the photo irradiation. FIG. 5 shows the reaction chamber 50 situated a magnetic stirrer 201 , with gas inlet/product outlet 52 and liquid inlet 54 facing the magnetic stirrer 201 . Top of the reaction chamber 50 is connected through the flexible light guide 202 to the UV spot light source (not shown). Referring back to FIG. 2 , the second reaction chamber valve V 4 has a reaction chamber connection port 56 , a waste outlet 58 , and a reagent inlet 60 . The second reaction chamber valve V 4 has two modes of operation A and B. The reaction chamber connection port 56 is: in mode A connected to the waste outlet 58 , and in mode B it is connected to the reagent inlet 60 . The reagent valve V 5 , has a reagent outlet 62 connected to the reagent inlet 60 of the second reaction chamber valve V 4 , an injection loop inlet 64 and outlet 66 between which the injection loop 70 is connected, a waste outlet 68 , a reagent inlet 71 connected to a reagent source, and a solvent inlet 72 . The reagent valve V 5 , has two modes of operation A and B. In mode A the reagent inlet 71 is connected to the injection loop inlet 64 , and the injection loop outlet 66 is connected to the waste outlet 68 , whereby a reagent may be fed into the injection loop 70 . In mode B the solvent inlet 72 is connected to the injection loop inlet 64 , and the injection loop outlet 66 is connected to the reagent outlet 62 , whereby reagent stored in the injection loop 70 may be forced via the second reaction chamber valve V 4 into the reaction chamber 50 if a high pressure is applied on the solvent inlet 72 . The solvent valve V 6 , has a solvent outlet 74 connected to the solvent inlet 72 of the reagent valve V 5 , a stop position 76 , a waste outlet 78 , and a solvent inlet 80 connected to a solvent supplying HPLC-pump (High Performance Liquid Chromatography) or any liquid-pump capable of pumping organic solvents at 0-10 ml/min at pressures up to 400 bar (not shown). The solvent valve V 6 , has two modes of operation A and B. In mode A the solvent outlet 74 is connected to the stop position 76 , and the solvent inlet 80 is connected to the waste outlet 78 . In mode B the solvent outlet 74 is connected to the solvent inlet 80 , whereby solvent may be pumped into the system at high pressure by the HPLC-pump. Except for the small volume of silica in the carbon monoxide trapping devise 38 , an important difference in comparison to the carbon dioxide trapping device 8 , as well as to all related prior art, is the procedure used for releasing the carbon monoxide. After the trapping of carbon monoxide on carbon monoxide trapping devise 8 , valve V 3 is changed from position A to B to stop the flow from the carbon monoxide trapping devise 38 and increase the gas-pressure on the carbon monoxide trapping devise 38 to the set feeding gas pressure (3-5 bar). The carbon monoxide trapping devise 38 is then heated to release the carbon monoxide from the silica surface while not significantly expanding the volume of carbon monoxide in the carrier gas. Valve V 4 is changed from position A to B and valve V 3 is then changed from position B to A. At this instance the carbon monoxide is rapidly and almost quantitatively transferred in a well-defined micro-plug into the reaction chamber 50 . Micro-plug is defined as a gas volume less than 10% of the volume of the reaction chamber 50 , containing the topical substance (e.g. 1-20 μL). This unique method for efficient mass-transfer to a small reaction chamber 50 , having a closed outlet, has the following prerequisites: A micro-column 38 defined as follows should be used. The volume of the trapping material (e.g. silica) should be large enough to efficiently trap (>95%) the carbon-isotope monoxide, and small enough (<1% of the volume of a subsequent reaction chamber 50 ) to allow maximal concentration of the carbon-isotope monoxide. In the case of silica and a reaction chamber 50 volume of 200 μl, the silica volume should be 0.1-2 μl. The dead volumes of the tubing and valve(s) connecting the silica column and the reaction chamber 50 should be minimal (<10% of the micro-autoclave volume). The pressure of the carrier gas should be 3-5 times higher than the pressure in the reaction chamber 50 before transfer (1 atm.). In one specific preferred embodiment specifications, materials and components are chosen as follows. High pressure valves from Valco®, Reodyne® or Cheminert® are used. Stainless steel tubing with o.d. 1/16″ is used except for the connections to the porapac-column 8, the silica-column 38 and the reaction chamber 50 where stainless steel tubing with o.d. 1/32″ are used in order to facilitate the translation movement. The connections between V 1 , V 2 and V 3 should have an inner diameter of 0.2-1 mm. The requirement is that the inner diameter should be large enough not to obstruct the possibility to achieve the optimal flow of He (2-50 ml/min) through the system, and small enough not to prolong the time needed to transfer the radioactivity from the porapac-column 8 to the silica-column 38. The dead volume of the connection between V 3 and the autoclave should be minimized (<10% of the autoclave volume). The inner diameter (0.05-0.1 mm) of the connection must be large enough to allow optimal He flow (2-50 ml/min). The dead volume of the connection between V 4 and V 5 should be less than 10% of the autoclave volume. The porapac-column 8 preferably is comprised of a stainless steel tube (o.d.=⅛″, i.d.=2 mm, l=20 mm) filled with Porapac Q® and fitted with stainless steel screens. The silica-column 38 preferably is comprised of a stainless steel tube (o.d= 1/16″, i.d.=0.1 mm) with a cavity (d=1 mm, h=1 mm, V=0.8 μl) in the end. The cavity is filled with silica powder (100/80 mesh) of GC-stationary phase type. The end of the column is fitted against a stainless steel screen. It should be noted that a broad range of different materials could be used in the trapping devices. If a GC-material is chosen, the criterions should be good retardation and good peak-shape for carbon dioxide and carbon monoxide respectively. The latter will ensure optimal recovery of the radioactivity. Below a detailed description is given of a method of producing carbon-isotope using an exemplary system as described above. Preparations of the system are performed by the steps 1 to 5: 1. V 1 in position A, V 2 in position A, V 3 in position A, V 4 in position A, helium flow on with a max pressure of 5 bar. With this setting, the helium flow goes through the porapac column, the zinc furnace, the silica column, the reaction chamber 50 and out through V 4 . The system is conditioned, the reaction chamber 50 is rid of solvent and it can be checked that helium can be flowed through the system with at least 10 ml/min. UV lamp 91 is turned on. 2. The zinc-furnace is turned on and set at 400° C. 3. The porapac and silica-columns are cooled with liquid nitrogen. At −196° C., the porapac and silica-column efficiently traps carbon-isotope dioxide and carbon-isotope monoxide respectively. 4. V 5 in position A (load). The injection loop (250 μl), attached to V 5 , is loaded with the reaction mixture. 5. The HPLC-pump is attached to a flask with freshly distilled THF (or other high quality solvent) and primed. V 6 in position A. Production of carbon-isotope dioxide may be performed by the steps 6 to 7: 6. Carbon-isotope dioxide is produced using the 14N(p,α) 11 C reaction in a target gas containing nitrogen (AGA, Nitrogen 6.0) and 0.1% oxygen (AGA. Oxygen 4.8), bombarded with 17 MeV protons. 7. The carbon-isotope dioxide is transferred to the apparatus using nitrogen with a flow of 100 ml/min. Synthesis of carbon-isotope may thereafter be performed by the steps 8 to 16 8. V 1 in position B and V 2 in position B. The nitrogen flow containing the carbon-isotope dioxide is now directed through the porapac-column (cooled to −196° C.) and out through a waste line. The radioactivity trapped in the porapac-column is monitored. 9. When the radioactivity has peaked, V 1 is changed to position A. Now a helium flow is directed through the porapac-column and out through the waste line. By this operation the tubings and the porapac-column are rid of nitrogen. 10. V 2 in position A and the porapac-column is warmed to about 50° C. The radioactivity is now released from the porapac-column and transferred with a helium flow of 10 ml/min into the zinc-furnace where it is transformed into carbon-isotope monoxide. 11. Before reaching the silica-column (cooled to −196° C.), the gas flow passes the ascarite-column. The carbon-isotope monoxide is now trapped on the silica-column. The radioactivity in the silica-column is monitored and when the value has peaked, V 3 is set to position B and then V 4 is set to position B. 12. The silica-column is heated to approximately 50° C., which releases the carbon-isotope monoxide. V 3 is set to position A and the carbon-isotope monoxide is transferred to the reaction chamber 50 within 15 s. 13. V 3 is set to position B, V 5 is set to position B, the HPLC-pump is turned on (flow 7 ml/min) and V 6 is set to position B. Using the pressurised THF (or other solvent), the reaction mixture is transferred to the reaction chamber 50 . When the HPLC-pump has reached its set pressure limit (e.g 40 Mpa), it is automatically turned off and then V 6 is set to position A. 14. UV spot light source 110 , magnetic stirrer 201 and magnet stirring bar 106 in reaction chamber 50 are turned on. 15. After a sufficient reaction-time (usually 5 min), V 3 is set to position C and the content of the reaction chamber 50 is transferred to a collection vial. 16. The reaction chamber 50 can be rinsed by the following procedure: V 3 is set to position B, the HPLC-pump is turned on, V 6 is set to position B and when maximal pressure is reached V 6 is set to position A and V 3 is set to position 3 thereby transferring the rinse volume to the collection vial. With the recently developed fully automated version of the reaction chamber 50 system according to the invention, the value of [ 11 C]carbon monoxide as a precursor for 11 C-labelled tracers has become comparable with [ 11 C]methyl iodide. Currently, [ 11 C]methyl iodide is the most frequently used 11 C-precursor due to ease in production and handling and since groups suitable for labeling with [ 11 C]methyl iodide (e.g. hetero atom bound methyl groups) are common among biologically active substances. Carbonyl groups, which can be conveniently labeled with [ 11 C]carbon monoxide, are also common among biologically active substances. In many cases, due to metabolic events in vivo, a carbonyl group may even be more advantageous than a methyl group as labeling position. The use of [ 11 C]carbon monoxide for production of PET-tracers may thus become an interesting complement to [ 11 C]methyl iodide. Furthermore, through the use of similar technology, this method will be applicable for synthesis of 13 C and 14 C substituted compounds. EXAMPLES The invention is further described in the following examples which are in no way intended to limit the scope of the invention. Example 1 Precursors and Resultant Products Precursors that were used to label acids are shown in List. 1. List 1. Iodides Used as Precursors in the Synthesis of Labeled Acids The following experiments illustrate the present invention. Radical carboxylation using submicromolar amounts of [ 11 C]carbon monoxide is performed yielding labeled with the acids shown in Table 1 as target compounds. TABLE 1 Radiochemical yields for 11 C-labelled acids 11 CO Isolated Base conv. Yield b Yield Labelled compound a Solvents (mmol) (%) (%) (%) DMSO TEA 25 N/A 34 DMSO TEA 82 64 50 DMSO DMSO/THF (1:9) TEA TEA 81 74 69 67 59 58 C 16 H 33 [ 11 C]O 2 H DMSO/THF (2:3) TEA 86 67 N/A a The position of 11 C label is denoted by * and 13 C substitution by †. b Decay-corrected radiochemical yield determined by LC. Example 2 Experimental Setup [ 11 C]Carbon dioxide production was performed using a Scanditronix MC-17 cyclotron at Uppsala Imanet. The 14 N(p,α) 11 C reaction was employed in a gas target containing nitrogen (Nitrogen 6.0) and 0.1% oxygen (Oxygen 4.8), that was bombarded with 17 MeV protons. [ 11 C]Carbon monoxide was obtained by reduction of [ 11 C]carbon dioxide as described previously (Kihlberg, T.; Långström, B. Method and apparatus for production and use of [ 11 C]carbon monoxide in labeling synthesis. Swedish Pending Patent Application No. 0102174-0). Liquid chromatographic analysis (LC) was performed with a gradient pump and a variable wavelength UV-detector in series with a β + -flow detector. An automated synthesis apparatus, Synthia (Bjurling, P.; Reineck, R.; Westerberg, G.; Gee, A. D.; Sutcliffe, J.; Långström, B. In Proceedings of the VIth workshop on targetry and target chemistry ; TRIUMF: Vancouver, Canada, 1995; pp 282-284) was used for LC purification of the labelled products. Radioactivity was measured in an ion chamber. Xenon-mercury lamp was used as a photo-irradiation source. In the analysis of the 11 C-labeled compounds, isotopically unchanged reference substances were used for comparison in all the LC runs. NMR spectra were recorded at 400 MHz for 1 H and at 100 MHz for 13 C, at 25° C. Chemical shifts were referenced to TMS via the solvent signals. LC-MS analysis was performed with electrospray ionization. Solvents: THF was distilled under nitrogen from sodiuni/benzophenone; all other solvents were commercial grade, The solvents were purged with helium. Alkyl iodides were commercially available or otherwise prepared from commercial allyl bromides by the Finkelstein reaction. Example 3 Preparation of [carboxyl- 11 C] Acids General procedure. Triethylamine (25 μL) was placed in a capped vial (1 mL, flushed beforehand with nitrogen to remove oxygen) and dissolved in DMSO (500 μL). An alkyl or aryl iodide (0.1 mol) was added to the solution ca. 7 min before the start of the synthesis. The resulting mixture was pressurized (over 40 MPa) into the micro-autoclave (270 μL), pre-charged with [ 11 C]carbon monoxide (10 −8 -10 −9 mol) mixed with He. The mixture was irradiated with a UV source for 6 min with stirring at 35° C. The crude reaction mixture was then transferred from the autoclave to a capped vial, held under reduced pressure. After measurement of the radioactivity the vial was purged with nitrogen and the radioactivity was measured again. The crude product was diluted with acetonitrile or methanol (0.6 mL) and injected on the semi-preparative LC. Analytical LC and LC-MS were used to assess the identity and radiochemical purity of the collected fraction. Specific Embodiments Citation of References The present invention is not to be limited in scope by specific embodiments described herein. Indeed, various modifications of the inventions in addition to those described herein will become apparent to these skilled in the art from the foregoing description and accompanying figures. Such modifications are intended to fall within the scope of the appended claims. Various publications and patent applications are cited herein, the disclosures of which are incorporated by reference in their entireties.
Methods and reagents for photo-initiated carbonylation with carbon-isotope labeled carbon monoxide using alkyl/aryl iodides with sulfoxides and triethylamine are provided. The resultant carbon-isotope labeled acids, and pharmaceutical acceptable salts and solvates are useful as radiopharmaceuticals, especially for use in Positron Emission Tomography (PET). Associated kits and method for PET studies are also provided.
2
BACKGROUND OF THE INVENTION This invention relates to electrically conducting polymers, and is particularly directed to such polymers obtained from mono- or difunctional phenylacetylene-substitued Schiff's base monomers. For many years synthetic organic polymers have attracted attention in a variety of electrical and electronic applications because of their outstanding insulator properties. However, since the discovery of the conducting properties of polyacetylene in the mid-seventies, replacement of metallic conductors with conductive polymers has been an important goal in chemically oriented research. During the past decade research efforts have intensified in obtaining improved, electroconductive, themosetting polymers useful, for example, in applications such as low-cost photovoltaic cells, moldable electrodes for use in light-weight batteries, composites, electromagnetic shielding devices, and the like. The term "conductive polymer" is typicaly used to describe three distinct categories of polymeric materials. In the first category there are metal or graphite-filled polymers where conductivity is due solely to the filler. While most often these polymers exhibit high conductivity, a major drawback lies in the relatively large amount of filler which is needed, often changing the base polymer properties. The second category includes "doped" polymer systems. These systems will typically consist of unsaturated polymers which contain no conductive filler but are treated to contain amounts of selected oxidizing or reducing agents. Although highly conductive polymers can be prepared by this means, most of the polymers will suffer from a loss of conductivity on simple exposure to normal atmospheric conditions or mild heat. Many of these polymers are difficult to prepare and isolate, and cannot be processed by ordinary polymer techniques. The third category of conductive polymers includes polymers which are conductive in the pristine state. In this category, conductivity is due to the molecular configuration of the thermally post-cured polymer. Conductive polymers within this category are known in the prior art. See, for example, U.S. Pat. No. 4,178,430 to Bilow, and U.S. Pat. Nos. 4,283,557 and 4,336,362 to Walton. The monomeric precursors of these conductive polymers are ordinarily solids at room temperature. On heating, the monomers pass through a measurable temperature range in which they are in a viscous liquid or thermoplastic state. Within this range, prior to the onset of curing and the development of conductivity, these materials can be readily processed, in bulk, from the melt. The "processing window" of a conductive monomer herein is the temperature range between the endothermic minimum (where melting is just completed) and the temperature where polymerization just begins and is measured using a Differential Scanning Calorimeter (DSC) technique. This processing window where the monomer is in a liquid or thermoplastic state is a characterizing property of individual monomers and varies greatly with the monomer structure. In general, monomers having an unsymmetrical structure are likely to have a desirable wide processing window as compared to processing windows exhibited by symmetrical monomers. Largely because of the noted deficiencies of the filled and doped polymers, interest in new intrinsically conductive or semi-conductive polymers remains high. SUMMARY OF THE INVENTION The present invention provides a new class of mono- or difunctional phenylacetylene-substituted Schiff's base monomers which melt on heating, go through a thermoplastic, viscous liquid state, and thereafter on continued heating at high temperatures become thermoset, electrically conducting polymers. The invention further provides monomeric precursors of conducting polymers where most members of the class will slowly cure to set when held at temperatures above the melting point and cure more rapidly at temperatures greater than 200° C. or more. It further provides an opportunity to produce cured polymeric molded articles possessing a bulk electroconductivity (σ) of a least 10 -2 S/cm. The molecular formula of the novel monomers of the invention are: ##STR1## where B is ##STR2## and R is CH 2 , C(CH 3 ) 2 , CHOH, ##STR3## C(CF 3 ) 2 , SO 2 , S, CH 2 CH 2 , HC═CH, O, ##STR4## n=0 or 1; and ##STR5## where G is C.tbd.CH, H, ##STR6## and ##STR7## where A is ##STR8## where G' is C.tbd.CH, H, and ##STR9## The mono- or difunctional phenylacetylene-substituted Schiff's base monomers of Structure I above are prepared by first catalytically reacting phenylacetylene with a suitable bromobenzaldehyde to yield a corresponding phenylethynylbenzaldehyde intermediate. Another intermediate, phenylethynylaniline is prepared by catalytically reacting an aminophenylacetylene with bromobenzene. Other means for preparing these intermediates are known and may be used. For example, phenylethynylaniline may be prepared starting with a nitrobromobenzene which is reacted with phenylacetylene. The resulting nitro compound is later reduced to the amine. Either of the two intermediates is thereafter further reacted with compounds such as, for example, phenylene diamine, methylene dianiline, oxydianiline, aminophenyl sulfone, terephthalaldehyde, and isophthalaldehyde, where the aldehyde and amine groups are reacted to provide the acetylene-substituted Schiff's base monomers of the invention. Monomers of structures (II) above require different intermediates, e.g. intermediates prepared from a palladium catalyzed coupling reaction of the appropriate bromobenzaldehyde with ethynylbenzaldehyde or the reaction of ethynylaniline with an appropriate bromoaniline. Subsequent reaction of the dialdehyde intermediate with aniline, ethynylaniline or phenylethynylaniline or reaction of the diamine intermediate with benzaldehyde, ethynylbenzaldehyde or phenylethynylbenzaldehyde yields the desired difunctional phenylacetylene substituted Schiff's base monomers. Additionally, the reaction of these phenylethynylbenzaldehyde intermediates with aniline or ethynylanilines or the reaction of phenylethynylaniline with benzaldehyde or ethynylbenaldehyde will result in the formation of the monofunctional phenylacetylene substituted structures represented in (III) above. Reaction of the two intermediates, i.e., phenylethynylbenzaldehyde and phenylethynylaniline, with one another yields a corresponding phenylethynyl monomer containing the Schiff's base functionality. DESCRIPTION OF PREFERRED EMBODIMENTS With respect to the coupling reaction of the bromobenzaldehyde and the phenylacetylene as well as the reaction of bromobenzene and aminophenylacetylene, the reaction is run preferably in triethylamine which serves as a solvent and scavenger for the hydrogen bromide generated during the ethynylation reaction. Other useful amines which can be used in place of triethylamine are, for example, diethylamine, butylamines (mono, di and trisubstituted), pyridine, and the like. A co-solvent such as toluene, xylene, dimethylformamide, and dimethylacetamide can also be used to improve the solubility of the starting materials. The reaction requires the presence of a catalytic amount of a palladium catalytic species which, for example, may be palladium acetate, palladium chloride, etc. Optionally, to hasten the coupling reaction a co-catalyst may also be used. Suitable co-catalysts include cuprous salts, for example, cuprous chloride, cuprous bromide, and cuprous iodide which is preferred. Use of palladium catalysts to promote coupling reactions of aromatic halides with acetylene compounds is described in the literature, for example, Richard F. Heck, Palladium Reagents in Organic Syntheses, Academic Press, New York 1985, Chapter 6, Section 6.8.1. Additionally, to improve the utility of the palladium catalyst, a solubilizing phosphine ligand is often used. Examples of such phosphine ligands include triorthotoluylphosphine and triphenylphosphine which is preferred because of its availability and cost. The reaction is run in an inert atmosphere at atmospheric pressure at a temperature of 75°-85° C. for about 6-18 hours. The reaction is monitored by gas-liquid chromatography tracking the disappearance of starting material and/or appearance of product. The reaction conditions for providing Schiff's bases are well known and no special precautions are needed herein. The monomeric compounds of the invention are solid, non-conductors. Heating melts the monomers to yield a thermoplastic, tacky, viscous liquid mass. Most of the monomers of the invention will start to melt at temperatures between 140°-160° C. It is in this state that the monomers are molded or conveniently processed to produce the desired end-products. To provide the thermoset electrically conducting polymer, thermal post-curing in the range of 300°-800° C. for about 10 to 100 hours is required. The monomers herein also may be solution polymerized and the polymer thereafter subjected to thermal post-curing to develop electroconductivity. In addition to providing homopolymers by heating of the monomeric precursors, it is also within the scope of the invention to provide electrically conducting copolymers where mixtures of two or more monomers of the invention are well mixed in their viscous liquid state. Copolymers may also be prepared from mixtures using monomers of the invention and monomer(s) selected from the classes of maleimide and bis-maleimide monomers as well as other compatible monofunctional acetylenic monomers which produce heat stable polymers. The monomers of the invention may constitute a minor or major portion of the "mixed" copolymer. The Schiff's base monomers herein as well as described mixtures can also find use in bonding articles by placing the monomer in contact between the articles to be bonded and exposing the composite to heat or heat and pressure, sufficient to polymerize the monomer. Likewise, one or more layers of woven fabric can be impregnated with a monomer (or monomer blend) of the invention to provide a high temperature stable composite thereof. The woven fabric can be made from, for example, glass, graphite or high temperature stable polyamide fibers. The invention is further illustrated in connection with the following examples. EXAMPLE I Preparation of 4-Phenylethynylbenzaldehyde A multinecked, round bottom flask fitted with a mechanical stirrer, reflux condenser and thermometer was flushed and maintained under a positive pressure of nitrogen. The flask was charged with 25 g (0.135 mol) of 4-bromobenzaldehyde, 250 ml of dried, degassed triethylamine, 15.2 g (0.148 mol) of phenylacetylene, 0.108 g (0.152 mmol) of bis(triphenylphosphine)palladium II chloride, 0.50 g (1.90 mmol) of triphenylphosphine and 0.5 g (0.262 mmol) of cuprous iodide. The mixture was brought to reflux temperature and maintained at that temperature overnight. The following morning gas chromatography indicated no presence of 4-bromobenzaldehyde. The reaction mixture was cooled to room temperature. To separate the product from the triethylamine hydrobromide by-product, 500 ml of ether was added to the flask and the mixture was stirred for 1 hour. The triethylamine hydrobromide was separated by filtration and the filtrate was concentrated on a rotary evaporator yielding a crystalline solid in the mother liquor. The mixture was chilled overnight in the refrigerator and subsequent filtration yielded 23.3 g (0.113 mol, 84% yield) of product as off-white platelets. Analysis: IR (KBr pellet), 2225 cm -1 (C.tbd.C, weak) 1710 cm -1 (C═O). 1 HMR (CDCl 3 ), δ10.0 (s, 1H, CHO), 6.8-8.3 (m, 9H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 95.5° C., minimum 98.8° C. (endothermic transition, 146 J/g). EXAMPLE 2 Preparation of 3-Phenylethynylbenzaldehyde A multinecked flask as described in Example I was charged with 100 g (0.54 mol) of 3-bromobenzaldehyde, 400 ml of dried, degassed triethylamine, 55.2 g (0.54 mol) of phenylacetylene, 0.43 g (0.61 mol) of bis(triphenylphosphine)palladium II chloride, 1.99 g (7.58 mmol) of triphenylphosphine and 0.10 g (0.52 mmol) of cuprous iodide. The mixture was brought to mild reflux and maintained at that temperature overnight. The following morning gas chromatography indicated only a trace presence of 3-bromobenzaldehyde. The reaction mixture was cooled to room temperature and 250 ml of ether was added. The mixture was allowed to stir for 1 hour and then filtered to remove the triethylamine hydrobromide by-product. The filtrate was concentrated on the rotary evaporator to a yellow solid to which 100 ml of petroleum ether was added. On filtration, 101.2 g (0.49 mol, 91% yield) of the product was obtained as a yellow crystalline solid. Analysis: IR (KBr pellet), 2225 cm -1 (C.tbd.C, weak) 1700 cm -1 (CαO). 1 HMR (CDCl 3 ) δ9.2 (s, 1H, CHO), 6.4-7.3 (m, 9H, Ar-H)ppm. DSC (10° C./min, N 2 ) onset 44.6° C., minimum 48.0° C. (endothermic transition 95 J/g. EXAMPLE 3 Preparation of 3(3-Formylphenyl)ethynylbenzaldehyde A multinecked flask as described in Example I was charged with 35 g (0.27 mol) of 3-ethynylbenzaldehyde, 300 ml of dried, degassed triethylamine, 49.7 g (0.27 mol) of 3-bromobenzaldehyde, 0.21 g (0.30 mmol) of bis(triphenylphosphine)palladium II chloride, 1.0 g (3.8 mmol) of triphenylphosphine, and 0.05 g (0.262 mmol) of cuprous iodide. The system is brought to mild reflux and maintained at that temperature overnight. The following morning gas chromatography indicated only a trace of each reactant. The mixture was cooled to room temperature and filtered. The funnel cake, a physical mixture of triethylamine hydrobromide and product, was washed with water to dissolve the hydrobromide salt. The insoluble product was filtered and dried overnight on the funnel, 55.5 g of the product was obtained (0.23 mol, 85% yield). Analysis: IR (KBr pellet), 1700 cm -1 (C═O). 1 HMR (CDCl 3 ) δ9.8 (s, 2H, CHO), 7.0-8.2 (m, 8H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 101° C., minimum 106.4° C. (endothermic transition 95 J/g). EXAMPLE 4 Preparation of 3-Phenylethynylaniline A multinecked flask as described in Example I was charged with 50 g (0.427 mol) of 3-aminophenylacetylene, 300 ml of dried, degassed triethylamine, 67 g (0.427 mol) of bromobenzene, 0.34 g (0.48 mmol) of bis(triphenylphosphine)palladium II chloride, and 0.05 g (0.262 mmol) of cuprous iodide. The system is brought to mild reflux and maintained at that temperature overnight. The following morning gas chromatography indicated only a trace presence of 3-aminophenylacetylene. The system was cooled to room temperature and 200 ml of a 1:1 mixture of tetrahydrofuran and ether was added to the reaction mixture and allowed to stir for 1 hour. The triethylamine hydrobromide by-product was removed by filtration. Concentration of the filtrate yielded the product as a dark oil which solidified on standing. Yield of product was 65%, based on amount of triethylamine hydrobromide isolated. Analysis: IR (neat), 3460 and 3380 cm -1 (NH 2 ), 2210 cm -1 (C.tbd.C). 1 HMR (CDCl 3 ) δ6.2-8.0 (m, 9H, Ar-H), 3.5 (s broad, 2H, NH 2 ) ppm. EXAMPLE 5 Preparation of Schiff's Base from 3-phenylethynylbenzaldehyde and 1, 4-Phenylenediamine A multinecked round bottom flask fitted with a mechanical stirrer, reflux condenser, thermometer and a positive pressure of argon was charged with 19 g (0.092 mol) of 3 phenylethynlbenzaldehyde and 200 ml of ethanol. The mixture was heated to 40° C. and 4.6 g (0.042 mol) of 1, 4-phenylenediamine was added portion-wise. After the addition was completed, the mixture was allowed to cool to room temperature and was stirred overnight. The product, a dark yellow solid, was recovered by filtration: 20 g (0.033 mol, 97% yield). Recrystallization of the compound from heptane/benzene (3:1) yielded gold-colored crystals. Analysis: IR (KBr pellet) 1620 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH=N), 7.8-8.2 (m, 22H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 182.2° C., minimum 185.7° C. (endothermic transition, 125 J/g), onset 289.8° C., maximum 314.7° C. (exothermic transition, 446 J/g), Processing Window 89° C. EXAMPLE 6 Preparation of Schiff's Base from 4-Phenylethynylbenzaldehyde and 1, 4-Phenylenediamine This compound was prepared using a procedure similar to that described in Example 5. The reaction was carried out using 6.5 g (0.315 mol) of 4-phenylethynylbenzaldehyde, 100 ml of ethanol, and 1.6 g (0.015 mol) of 1, 4-phenylenediamine. The crystalline product was isolated in a 87% yield (6.5 g, 0.013 mol). Analysis: IR (KBr pellet) 1620 cm -1 (CH═N). DSC (10° C./mm, N 2 ) onset 271.7° C., minimum 277.3° C. (endothermic transition 89 J/g), onset 312.8° C., maximum 326.3° C. (exothermic transition 446 J/g), Processing Window 7° C. EXAMPLE 7 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 1,3-Phenylenediamine Using a procedure similar to that described in Example 5, the reaction was carried out using 5.2 g (0.025 mol) of 3-phenylethynylbenzaldehyde, 50 ml of ethanol and 1.3 g (0.12 mol) of 1,3-phenylenediamine. The crystalline product was isolated in a 91% yield (5.3 g, 0.011 mol). Analysis: IR (KBr pellet) 1620 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.45 (s, 2H, CH═N), 6.9-8.2 (m, 22H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 112.6° C., minimum 125.6° C. (endothermic transition 72 J/g), onset 285.5° C., maximum 308.8° C. (exothermic transition 515 J/g), Processing Window 139° C. EXAMPLE 8 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 4, 4'-Methylenedianiline. A multi-necked flask as described in Example 5 was charged with 6.5 g (0.0315 mol) of 3-phenylethynylbenzaldehyde and 125 ml of ethanol. To this mixture was added, portionwise, 3.0 g (0.150 mol) of 4,4'-methylenedianiline. The resultant mixture was then heated to 60° C. for 15 minutes, cooled to room temperature and allowed to stir overnight. The product, an off-white solid, 8.5 g (0.0147 mol, 98% yield) was isolated by filtration. The compound can be recrystallized by boiling in heptane and adding just enough toluene to effect solution. Analysis: IR (KBr pellet) 1630 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.35 (s, 2H, CH═N), 6.6-8.0 (m, 26H, Ar-H), 3.9 (s, 2H, CH 2 ) ppm. DSC (10° C./min, N 2 ), onset 172.8° C., minimum 176.7° C. (endothermic transition 99 J/g), onset 281.9° C., maximum 315.2° C. (exothermic transition 471 J/g), Processing Window 78° C. EXAMPLE 9 Preparation of Schiff's Base from 3-Phenylethynylaniline and Terephthalaldehyde A multinecked flask as described in Example 5 was charged with 3.0 g (0.022 mol) of terephthalaldehyde and 50 ml of ethanol. To this mixture is added 8.9 g (0.046 mol) of 3-phenylethynylaniline in 50 ml of ethanol. The resultant mixture is stirred overnight at room temperature. The product, a yellow solid, was isolated by filtration; 10.0 g (0.021 mol, 95% yield). The product is recrystallized from isobutyl alcohol. Analysis: (KBr pellet) 1625 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH═N), 7.1-8.1 (m, 22H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 161.9° C., minimum 168.8° C. (endothermic transition 94 J/g), onset 272.8° C., maximum 298.1° C. (exothermic transition 456 J/g), Processing Window 81° C. EXAMPLE 10 Preparation of Schiff's Base from 3-Phenylethynylaniline and Isophthalaldehyde This compound was prepared using a procedure similar to that of Example 9. The reaction was carried out using 3 g (0.022 mol) of isophthalaldehyde, a total of 100 ml of ethanol, and 8.9 g (0.046 mol) of 3-phenylethynylaniline. The product, a yellow solid, was isolated by filtration; 9.8 g (0.02 mol, 91% yield). Analysis: IR (KBr pellet) 1625 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH═N), 6.8-8.2 (m, 22H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 105.2° C., minimum 120.1° C. (endothermic transition 39 J/g), onset 269.5° C., maximum 302.6° C. (exothermic transition 330 J/g), Processing Window 124° C. EXAMPLE 11 Preparation of Schiff's Base from 3-phenylethynylaniline and 3(3-Formylphenyl)ethynylbenzaldehyde A multinecked flask as described in Example 5 was charged with 10.1 g (0.525 mol) of 3-phenylethynylaniline and 50 ml of ethanol. The system was heated to 50° C. at which point 5.8 g (0.0248 mol) of 3(3-formylphenyl)ethynylbenzaldehyde in 50 ml of ethanol was added to the reaction mixture. The temperature of the mixture was maintained at 50° C. for 30 minutes. The mixture was then cooled to room temperature and stirred overnight. The product, a tan solid, was isolated by filtration: 13.0 g (0.022 mol, 89% yield). Analysis: IR (KBr pellet) 1625 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.5 (s, 2H, CH═N), 6.8-8.2 (m, 26H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 159.1° C., minimum 168.4° C. (endothermic transition 80 J/g), onset 266.3° C., maximum 307.1° C. (exothermic transition 527 J/g), Processing Window 66° C. EXAMPLE 12 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 3-Phenylethynylaniline This compound was prepared using a procedure similar to that used in the preparation of the monomer of Example 9. The reaction was carried out using 4.7 g (0.022 mol) of 3-phenylethynylbenzaldehyde, 100 ml of ethanol and 4.4 g (0.023 mol) of 3-phenylethynylaniline. The product was isolated by filtration: 7.5 g (0.021 mol, 95% yield). The product was recrystallized from isopropyl alcohol/water (7:3). Analysis: (KBr pellet) 1635 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.45 (s, 1H, CH═N), 7.0-8.2 (m, 18H, Ar-H) ppm. DSC (10° C./min, N 2 ) onset 111.8° C., minimum 123.6° C. (endothermic transition 78 J/g), onset 286° C., maximum 310.9° C. (exothermic transition 567 J/g), Processing Window 141° C. EXAMPLE 13 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and Aniline A multinecked flask as described in Example 5 was charged with 5.4 g of 3-phenylethynylbenzaldehyde, 50 ml of ethanol and 2.3 g (0.025 mol) of aniline. The solution was heated to 55° C. and held at that temperature for 5 minutes. The solution was cooled to room temperature, stirred overnight, and then concentrated on a rotary evaporator to a yellow oil which solidified on standing to give 6.9 g of product (0.024 mol, 96% yield), as a tan solid. The compound was recrystallized from petroleum ether. Analysis: IR (KBr pellet) 1630 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.45 (s, 1H, CH═N), 6.9-8.1 (m, 14H, Ar-H) ppm. DSC (10° C./min. N 2 ) onset 55.1° C., minimum 59.1° C. (endothermic transition 79 J/g), onset 296.8° C., maximum 324.2° C. (ethothermic transition 577 J/g), Processing Window 223° C. EXAMPLE 14 Preparation of Schiff's Base from 3-phenylethynylbenzaldehyde and 3-Aminophenylacetylene This compound was prepared using a procedure similar to that used in the preparation of the monomer of Example 13. The reaction was carried out using 5.0 g (0.024 mol) of 3-phenylethynylbenzaldehyde, 50 ml of ethanol, and 3.0 g (0.025 mol) of 3-aminophenylacetylene. The product was isolated as a red oil which solidified on standing: 6.8 g (0.022 mol, 92% yield). Analysis: IR (KBr pellet) 3295 cm -1 (C.tbd.CH), 1630 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.3 (s, 1H, CH═N), 6.6-8.1 (m, 13H, Ar-H), 3.1 (s, 1H, C.tbd.CH) ppm. DSC (10° C./min, N 2 ) onset 215.9° C., maximum 245.2° C. (exothermic transition 753 J/g), Processing Window 160° C. EXAMPLE 15 Preparation of Schiff's Base from 3-Aminophenylacetylene and 3(3-Formylphenyl)ethynylbenzaldehyde. Using a procedure similar to that described in Example 5, 10.8 g (0.044 mol) of 3(3-formylphenyl)ethynylbenzaldehyde was reacted with 11.2 g (0.096 mol) of 3-aminophenylacetylene in 150 ml of ethanol. The product precipitated as an off-white solid, 15.8 g (0.036 mol, 82% yield). This monomer was used without further purification. Analysis: IR (KBr pellet), 3280 cm -1 (C.tbd.CH), 1635 cm -1 (CH═N). 1 HMR (CDCl 3 ) δ8.35 (s, 2H, CH═N), 6.9-8.1 (m, 16H, Ar-H), and 3.10 (s, 2H, C.tbd.CH) ppm. DSC (10° C./min. N 2 ) onset 100.7° C., minimum 110.6° C. (endothermic transition, 83.9 J/g), onset 206.5° C., maximum 229.9° C. hermic transition, 526 J/g), Processing Window 54° C. EXAMPLE 16 Preparation of Schiff's Base from 4-Phenylethynylbenzaldehyde and 3-Phenylethynylaniline This monomer was prepared using a procedure similar to that described in Example 5. The reaction was carried out using 4.8 g (0.025 mol) of 3-phenylethynylaniline, 75 ml of ethanol and 5.2 g (0.025 mol) of 4-phenylethynylbenzaldehyde. The product which initially oils out solidified on standing to yield 8.1 g (0.022 mol; 89% yield). This monomer was purified by dissolving the crude product in hot isopropyl alcohol, filtering, and concentrating the filtrate. Analysis: IR (KBr pellet), 1630 cm -1 (CH═N) 1 HMR (CDCl 3 ) δ8.44 (s, 1H, CH═N), 7.20-8.00 (m, 18H, Ar-H) ppm. DSC (10° C./min. N 2 ) onset 133.8° C., minimum 140.4° C. (endothermic transition, 74.5 J/g), onset 268.3° C., maximum 302.0° C. (exothermic transition, 519 J/g), Processing Window 95° C. EXAMPLE 17 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 4,4'-Oxydianiline Using a procedure similar to that described in Example 5, 3.2 g (0.016 mol) of 4,4'-oxydianiline was reacted with 6.6 g (0.032 mol) of 3-phenylethynylbenzaldehyde in 75 ml of ethanol. The product precipitated as an off-white solid and was filtered and dried (8.6 g, 0.015 mol, 94% yield). This monomer was purified by recrystallization from isopropyl alcohol/toluene. Analysis: IR (KBr pellet), 1630 cm -1 (CH═N), 1250 cm -1 (Ar-O-Ar). 1 HMR (CDC 3 ) δ8.45 (s, 2H, CH═N), 6.90-8.20 (m, 26H, Ar-H) ppm. DSC (10° C./min. N 2 ) onset 143.4° C., minimum 146.5° C. (endothermic transition, 97.1 J/g), onset 298.1° C., maximum 327.6° C. (exothermic transition, 467 J/g), Processing Window 134° C. EXAMPLE 18 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 4-Aminophenylsulfide Using a procedure similar to that described in Example 5, 3.4 g (0.016 mol) of 4-aminophenylsulfide was reacted with 6.6 g (0.032 mol) of 3-phenylethynylbenzaldehyde in 75 ml of ethanol. The product precipitates as a yellow solid which was recrystallized from heptane/toluene (8.9 g, 0.015 mol, 94% yield). Analysis: IR (KBr Pellet), 1630 cm -1 (CH═N). 1 HMR (THF-d 8 ) δ8.60 (s, 2H, CH═N), 7.10-8.30 (m, 26H, Ar-'uns/H/ ). DSC (10° C./min. N 2 ) onset 170.3° C., minimum 175.6° C. (endothermic transition, 107 J/g), onset 291.2° C., maximum 313.7° C. (exothermic transition, 445 J/g), Processing Window 104°C. EXAMPLE 19 Preparation of Schiff's Base from 3-Phenylethynylbenzaldehyde and 3-Aminophenylsulfone Using a procedure similar to that described in Example 5, 3.7 g (0.015 mol) of 3-aminophenylsulfone was reacted with 6.2 g (0.03 mol) of 3-phenylethynylbenzaldehyde in 75 ml of ethanol. The product, which initially oiled out of solution, was dissolved in hot ethanol which on cooling yielded off-white crystals, 8.0 g (0.013 mol, 85% yield). Analysis: IR (KBr pellet), 1635 cm -1 (CH═N), 1305 and 1150 cm -1 (SO 2 ). DSC (10° C./min. N.sub. 2) onset 129.5° C., minimum 139.0C. (endothermic transition, 79 J/g), onset 272.2° C., maximum 305.8° C. (exothermic transition, 419 J/g), Processing Window 116° C. EXAMPLE 20 Blend of Schiff's Base Monomer from Example 5 with the Schiff's Base Monomer from Example 8 (1:1) To 0.6445 g of molten Schiff's base monomer from Example 5 was dissolved 0.6445 g of Schiff's base monomer from Example 8. Upon complete dissolution the material was allowed to cool to a hard glass-like solid. The sample remained completely homogeneous. EXAMPLE 21 Blend of Schiff's Base Monomer from Example 9 with the Schiff's Base Monomer from Example 8 (3:1) To 0.9668 g of molten Schiff's base monomer from Example 9 was dissolved 0.3223 g of Schiff's base monomer from Example 8. Upon complete dissolution the material was allowed to cool to a hard glass-like solid. The sample remained completely homogeneous. EXAMPLE 22 Representative Schiff's base monomers of the invention were evaluated for thermal and oxidative stability employing a thermogravimetric analysis technique (TGA). All of the monomers undergo polymerization to a highly crosslinked polymer during the TGA procedure. Thermal-oxidative stability is an important property of these polymeric compounds particularly because high temperature post-cure for extended periods is needed to obtain conductivity in the thermoset polymers. Dynamic TGA's were run on the Schiff's base monomers at 10° C./min under compressed air using a DuPont 1090 Thermal Analyzer System with a DuPont 951 module. Thermal stability in the absence of oxygen was also determined in a similar manner. Results showing the temperature at which decomposition begins and the percent residue of the sample after exposure to 800° C. in a nitrogen atmosphere are summarized in Table I below. TABLE I______________________________________Monomer Decomposition % ResidueExample No. Onset (°C.) at 800° C.______________________________________5 527.5 73.86 521.8 79.97 509.6 75.28 522.8 72.99 522.6 76.310 515.9 76.711 522.1 65.512 299.4 65.213 270.1 27.114 510.5 --*15 543.4 --*16 345 (500) 52.517 510 55.518 500 57.219 470 --*______________________________________ *not determined EXAMPLE 23 In this example the electroconductivity of typical post-cured Schiff's base monomers of the invention was evaluated. Thermal polymerization of the disubstituted acetylene monomers was carried out in bulk from the melt by placing 1.0 to 1.5 g of monomer in a aluminum circular mold (1.0" diam.) and heating in an air circulating oven (Blue M) at 233° C. for 6 days. At this temperature, each monomer polymerized to a glossy surfaced, hard black solid within 5 hours. Weight loss data for representative samples after 6 days was recorded and is given in Table II below: TABLE II______________________________________Monomer ofExample No. Weight loss (%)______________________________________5 3.677 3.008 1.079 2.8710 0.9211 1.0112 8.9313 65.15 0.13 (gain)______________________________________ The initially cured samples were then subjected to thermal post-cure under a nitrogen atmosphere in order to develop electroconductivity. Two post-cure methods were used (described below as Method A and Method B). Both methods yield substantially equivalent conductivity measurements. Method A--In this method, portions of the solid pellet of polymer which results from the initial cure weighing between 50-90 mg are broken off and placed in the furnace of the thermogravmetric analyser for post-cure treatment. The sample is heated under nitrogen at a rate of 10° C./min from room temperature to a temperature of 800° C., and then rapidly cooled to room temperature. Method B--In this method, the entire solid pellet of polymer which results from the initial cure is post-cured by heating under nitrogen in a programmable oven for 50 hours at 300° C., then heated at a rate of 0.5° C./min to a temperature of 600° C., and held at 600° C. for 50 hours. The oven temperature setting is then returned to room temperature. Electrical conductivity evaluations were carried out on the post-cured samples at room temperature using an in-line four point probe. Bulk resistivity and bulk conductivity were calculated according to the following formula: ##EQU1## where S=probe spacings in cm V=voltage drop in volts A=applied current in amps and σ=1/ρ Table 3 shows the bulk electrical conductivity for representative samples post-cured by Method A. Table 4 shows conductivity measurements for representative samples post-cured by Method B. Both tables also show the % weight loss of the samples during these post-cure conditions. TABLE 3______________________________________(Method A)Monomer ConductivityExample No. (S/cm) Wt. loss (%)______________________________________5 1.23 × 10.sup.-1 21.27 4.75 × 10.sup.-2 22.08 5.91 × 10.sup.-2 25.99 5.33 × 10.sup.-2 20.910 6.37 × 10.sup.-2 21.312 5.22 × 10.sup.-2 19.416 8.03 × 10.sup.-2 17.617 7.83 × 10.sup.-2 25.518 7.46 × 10.sup.-2 24.619 9.91 × 10.sup.-2 21.420 1.40 × 10.sup.-2 27.721 7.46 × 10.sup.-2 24.6______________________________________ TABLE 4______________________________________(Method B)Monomer ConductivityExample No. (S/cm) Wt. loss (%)______________________________________5 4.23 × 10.sup.-2 12.27 3.13 × 10.sup.-2 15.69 3.40 × 10.sup.-2 14.810 4.35 × 10.sup.-2 14.411 3.64 × 10.sup.-2 12.115 4.75 × 10.sup.-2 9.1______________________________________ Now that the preferred embodiments of the present invention have been described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is to be limited only by the appended claims, and not by the foregoing disclosure.
Novel mono- or difunctional phenylacetylene-substituted Schiff's base monomers useful in the preparation of electrically conducting polymers is disclosed. On heating, these monomers melt to a viscous liquid state, and on continued heating above about 300° C. polymerize to form an electrically insulating thermoset polymer. On further post-cure heat treatment, the polymer becomes electroconductive showing a bulk conductivity of at least 10 -2 S/cm.
2
BACKGROUND OF THE INVENTION In the papermaking drying process, it has always been important to maximize heat transfer through the dryer drum to the paper web. In recent years, this heat transfer has been enhanced by mounting a plurality of longitudinal bars circumferentially around the inner surface of the steam heated dryer drums to interrupt the condensate which otherwise tends to rim around the inner surface in a substantially uniformly thick layer which effectivelly retards heat transfer from the steam to the paper web on the dryer's outer surface. When the condensate layer is interrupted, turbulence is generated in the layer which imporves the heat transfer through the condensate layer. Such interruption of condensate flow around the inner dryer surface is referred to as "spoiling " in the papermaking industry, and the bars mounted within the dryer to accomplish this are called spooiler bars. Barnscheidt et al and Kraus U.S. Pat. Nos. 3,217,426 and 3,808,700, respectively, teach the use and advantages of spoiler bars and the manner in which they can be mounted within a dryer drum utilizing outwardly biased rings and screws. Appel et al further advanced the art by teaching a unique manner of circumferentially spacing the bars to optimize the turbulence of the condensate to enhance heat transfer. More recently, the concepts of attaching spoiler bars magnetically (U.S. Pat. No. 4,195,417); with pins disposed in smooth holes, sometimes with magnetic assistance, (U.S. Pat. No. 4,267,644); and by a combination of pins disposed in smooth holes and springs biasing the bars against the dryer wall (U.S. Pat. No. 4,282,656) have been disclosed. SUMMARY OF THE INVENTION In this invention, the spoiler bars are assemblies comprising non-magnetic flux conducting base and backing plates and magnetic flux conducting rails which enclose one or more magnets. The magnets themselves are relatively small and, in the preferred embodiments, a plurality of them are grouped together in columns extending longitudinally in the spoiler bar assembly. Since a dryer roll drum, or shell, is a steam heated pressure vessel, it is important for safety reasons that its structural integrity be maintained. As shown in some of the patents mentioned above, early methods of mounting spoiler bars utilized holes formed in the dryer drum to position and secure the spoiler bars. However, holes inherently decrease the strength of the drum which means either the drum has a smaller safety factor, or the drum wall must be thicker to compensate for the holes. Thicker drum walls retard the heat transfer process. When spoiler bars are held in place magnetically, there are no holes needed in the drum wall, and, therefore, its strength is not compromised. However, it is also very important to maintain the spoiler bars in their carefully determined, circumferentially spaced positions to realize their advantages in improving heat transfer by breaking up the condensate layer. When the spoiler bars consist solely of metal magnets, such as Alnico V, for example, they have a tendency to shift their position during operation due to the inability of a "U" shaped magnet to develop and maintain sufficient magnetic force against the drum wall over an extended period of time at the steam temperatures (i.e. about 250° F.-400° F.) typically found in dryer drums, or a combination of these factors. Further, a bar shaped magnet has significantly less adherent force than a "U" shaped magnet. By making the magnetic assemblies in the form of rectangular prisms, the flux density can be maximized by proper selection of the cross-sectional area and aspect ratio of the magnetic material and proper selection of the material and thickness of the magnetic flux conducting side rails. For convenience of manufacture and assembly, the magnets preferably comprise a plurality of magnetic segments within each spoiler bar assembly. Thus, the pole faces of the individual segments are arrayed contiguously to the rails of the assembly which thereby efficiently converts the rails into magnetic poles. The rails preferably have smaller, or equal sized, areas contacting the inner surface of the dryer drum which optimizes the adherent unit force of the rails against the dryer drum, as long as the rails are not saturated with magnetic flux, to provide superior mounting of the spoiler bar assemblies. Such improved adherence is of great importance since the controlled interruption of the condensate is a function of the precise spacing of the spoiler bars around the inner circumference of the dryer drum which must be maintained to achieve optimum heat transfer. Further, if the spoiler bars shift their position, the dryer may become unbalanced which would result in serious operational problems and inefficiencies. In using non-magnetic flux conducting backing and base plates, and magnetic flux conducting rails, there is a minimum of flux loss and maximum flux is channeled from the magnet to the dryer drum for improved adherence. Ceramic magnets are preferred because of their high normal and intrinsic coercive force values and the stability of their magnetic strength at the elevated temperatures of the dryer drums. Surrounding the ceramic magnet with backing plates, base plates and rails increases the structural strength of the spoiler bars and protects the ceramic magnet from being damaged by being mishandled during installation and by loose scale in the dryer drum during operation. Accordingly, it is an object of this invention to provide an improved magnetic spoiler bar capable of maintaining its position within a steam heated dryer drum in operation indefinitely without shifting position. Another object of this invention is to provide a spoiler bar assembly which is comprised of magnetic flux conducting rails, and non-magnetic flux conducting backing and base plates which together form a rigid, deformation resistant structure holding a magnet whereby the magnetic flux is directed through the rails into the dryer drum on which the assembly is mounted. Still another object of this invention is to provide a magnetic spoiler bar assembly wherein the magnet is in the shape of a rectangular prism, and the magnetic flux paths are short and efficiently channeled into the dryer drum. A feature and advantage of this invention is the provision of a spoiler bar assembly having high structural strength and which utilizes a ceramic magnet. These and other objects, features and advantages of this invention will become more readily apparent to those skilled in the art upon reading the following description of the preferred embodiments in conjunction with the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an end view of a dryer drum with its head removed exposing the axially extending, circumferentially arrayed spoiler bar assemblies. FIG. 2 shows a spoiler bar assembly wherein the magnet orientation is vertically arrayed. FIG. 3 illustrates the magnet in the assembly shown in FIG. 2 as comprising a plurality of aligned magnetic segments. FIG. 4 shows a spoiler bar assembly wherein the magnet is horizontally arrayed. FIG. 5 shows how the magnet in the spoiler bar in FIG. 4 can comprise a plurality of aligned magnetic segments. FIG. 6 shows a spoiler bar assembly similar to that shown in FIG. 4, but which incorporates a pair of horizontally arrayed magnets. FIG. 7 shows how the magnets in the spoiler bar assembly in FIG. 6 can comprise two rows of aligned magnetic segments. FIG. 8 shows a spoiler bar assembly wherein a plurality of rails are interposed between the magnetic segments which are axially aligned within the assembly. FIG. 9 shows a pair of adjacent magnetic segments in the spoiler bar assembly in FIG. 8. FIG. 10 shows a spoiler bar assembly similar to that shown in FIG. 6 except the poles of the magnet on the right side is reversed. FIG. 11 shows a spoiler bar assembly similar to that shown in FIG. 7 except that the poles of the magnet, or column of magnetic segments, is reversed. FIG. 12 shows a spoiler bar assembly similar to that shown in FIG. 8 except that the poles of the ends of adjacent magnets facing each other are alike. FIG. 13 shows two adjacent magnets, and their poles, in the spoiler bar assembly in FIG. 12. DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 1, a plurality of longitudinally extending, parallel spoiler bars 14 are disposed circumferentially about the inner surface of dryer drum 10 which rotates about its longitudinal axis 12 in the direction of arrow 16. In modern papermaking machines, the paper web traveling through the dryer section can easily attain speeds of 3,000 fpm, and higher. This corresponds to a rotational speed on a 6 ft. diameter drum of about 160 rpm. At these speeds, any weakness in the means attaching or securing the spoiler bars to the inner surface of the dryer drum can permit the spoiler bars to shift their positions and move to the detriment of the operation and efficiency of the dryer drum. In addition, the moving layer of liquid condensate from the condensing steam within the dryer drum will exacerbate any impairment of the spoiler bar mounting system and their tendency to move, thus accelerating the onset of a potentially destructive situation. In the following descriptions of the various configurations of the assemblies, and magnetic segments which are mounted in the assemblies, corresponding parts in each embodiment will be numbered with the two digit numerals used in FIGS. 1 and 2, but prefaced by a different hundred series. Thus, the backing plate 20 in FIG. 2 is designated as backing plate 120 in FIG. 4, and so forth. In FIG. 2, a spoiler bar assembly 14 has a pair of horizontally spaced, parallel side rails 17, 19 which extend downwardly from an upper backing plate 20. A magnet 28 is disposed within the rail and backing plate structural assembly with axially extending spaces 30, 32 between it and the respective side rails. The magnet is disposed with its north/south poles (N/S) vertical so the magnetic flux field M, shown by the double headed arrow 34, also travels vertically through the magnet. The lower end surfaces 22, 24 of the side rails and the lower pole face (extending from edge 26) of the magnet are curved slightly to conform to the radius of curvature of the dryer drum on which the spoiler bars are mounted. This is shown exaggerated in FIG. 2 (and FIGS. 3, 4, 6, 8, 10 and 12) for purposes of illustration. When mounted in the dryer drum, the upper surface of the magnet is in direct contact with the lower surface of backing plate 20, as shown at 31. In the embodiment shown in FIG. 2, side rails 17, 19 and backing plate 20 are all constructed of a magnetic flux field conducting material, such as mild steel. The side rails and backing plate are preferably formed from a single piece of metal, or attached to one another, such as by welding. The magnetic flux field flows from the magnet into the backing plate and through the side rails into the iron dryer drum. With the lower face of the magnet forming the north pole N, the magnetic flux field flows vertically up through the top plate and down the side rails to make the lower faces 22, 24 of the rails the south pole S. Thus, the magnet is held in place by the magnetic flux field conducting backing plate 20 and side rails 17, 19 which are not themselves magnets. Since the preferred material for the magnet is a ceramic, which can be chipped or cracked relatively easily, the metal side rails and backing plate further function as a structural enclosure to protect the magnet from damage. In FIG. 3, the magnet is shown as comprising a plurality of magnetic segments 28, 28a, b, c, d, e, f, g and h. These segments are axially aligned and arrayed so their poles N, S, are disposed on their lower and upper faces, respectively. The individual magnetic segments are aligned with their top edges 33, 33a, b, c, d, e, f and g in a horizontal plane along their top surfaces. Since the lower faces of the segments cannot be seen in the figure, the N is shown on the bottom of the front side of segment 28 with the understanding that the north pole N is on the diametrically opposed (i.e. bottom) face from the top face 48 on which the south pole S is located. By providing the magnet in the form of a plurality of magnetic segments, the spoiler bar assemblies 14 can be made in convenient lengths, such as about 3 ft., and mounted longitudinally within the dryer drum in end abutting arrangement to extend for substantially the entire length of the dryer drum such as, for example, about 24 ft. Typically, spoiler bars are about 0.5 inch to about 1.5 inches high, and about 1.0 inch wide. This both facilitates the manufacture and installation of the spoiler bars as well as permitting the individual 3 ft. assembly sections to have a slight gap between them to allow for expansion of the backing plate and side rails as they become heated during operation. FIG. 4 illustrates another embodiment of a spoiler bar assembly wherein a horizontally arrayed (i.e. the magnetic flux field M is horizontal) magnet 128 is positioned within a box-like structural assembly comprising a top backing plate 120, a lower base plate 121 which is spaced above the inner surface of the dryer drum and extends parallel to the backing plate in the longitudinal direction of the spoiler bar, and a pair of vertical, parallel, longitudinally extending side rails 117, 119. As shown by arrow 134, the magnetic flux field M of the magnet is horizontal with the north and south poles abutting the left and right side rails 119, 117, respectively. The backing and base plates 120, 121 are non-magnetic stainless steel, and the side rails 117, 119 are mild steel. Since the stainless steel plates do not conduct the magnetic flux field, all of the flux is conducted through the side rails into the dryer drum so the lower edge surfaces 122, 124 of the side rails form the north and south poles, respectively. Since the cross sectional area of the side rails, taken in a horizontal plane extending longitudinally of the side rails, is preferably less than the cross sectional area of the rectangular prism shaped magnet taken through a vertical plane extending longitudinally of the magnet, the flux fields in the side rails are concentrated so the magnetic unit force by which the spoiler bar assembly adheres to the dryer drum is increased, or at least not decreased, thereby optimizing the strength of the magnet. In other words, within practical limits (i.e. not making the rail edge surfaces extremely narrow) if the cross sectional area of the side rails is less than, or equal to, the cross sectional area of the magnet, or magnetic segment, the unit magnetic force of attraction of the rail edge surfaces against the dryer drum is correspondingly greater than, or equal to, the unit strength of the magnet. FIG. 5 illustrates how the magnet 128 can comprise a plurality of similar magnetic segments 128, 128a, b, c, d, e, f, g, h aligned axially with their north and south pole faces aligned vertically on either side. The lower edge 126 is straight because the lower surface of the magnet(s) is flat against the stainless steel base plate 121 which is spaced above the dryer drum surface to retard fringing of the magnetic flux lines so they will be directed through the side rails into the dryer drum. In FIG. 6, a spoiler bar assembly similar to the spoiler bar in FIG. 4 is shgwn, but wherein a pair of horizontally arrayed magnets 228, 229 are mounted between a pair of side rails 217, 219 with an intermediate side rail 218 between the magnets. In this arrangement, the magnets are arrayed with their flux fields M horizontally disposed as shown by the arrows and the vertical south pole faces of each magnet are facing inwardly toward one another and abutting the intermediate rail 218. The vertically disposed north pole faces are facing outwardly away from one another with each pole face abutting a corresponding side rail 217, 219. The backing plate 220 and base plates 221, 221a are non-magnetic stainless steel and the side and intermediate rails 217, 218, 219 are mild steel, so the lower edge surfaces of the side rails 217, 219 form the north poles while the edge surface 223 of intermediate rail 218 forms the south pole. This arrangement both increases the area of the rail edge surfaces contacting the dryer drum as well as increasing the strength of the magnetic field securing the spoiler bar assembly to the dryer drum. FIG. 7 is similar to FIGS. 3 and 5 in that it illustrates how the magnets 228, 229 can comprise a plurality of longitudinally arrayed magnetic segments 228, 228a, b, c, d, e, f, g, h and 229, 229a, b, c, d, e, f, g, h. It also more clearly shows the north and south pole faces in their array as the magnets are positioned in the assembly shown in FIG. 6. FIG. 8 illustrates another embodiment of a spoiler bar assembly wherein a plurality of magnetic segments 328, 328a, 328b, 328c, 328d are positioned longitudinally along the length of the spoiler bar. Like the magnets in the spoiler bars shown in FIGS. 4, 6 and 10, the magnetic flux field M is parallel to the dryer drum surface. However, as shown by the two headed arrows 334, the magnetic flux fields of the individual segments are aligned, like the magnetic segments themselves, longitudinally along the length of the spoiler bar assembly. At the ends, and interposed between the magnet segments, are a plurality of side rails 340, 341, 342, 343, 344 and 345 which are all connected to the top backing plate 320, and each individual magnet segment has its corresponding base plate 321, 321a, 321b, 321c and 321d which are attached to the rails on either end of each plate. As in the embodiments as shown in FIGS. 4 and 6 (and FIGS. 10 and 12), backing plate 320 and base plates 321, 321a, 321b, 321c, 321d, are made of a non-magnetic field conducting material, such as stainless steel, while the rail members are made of a magnetic flux conducting material, such as mild steel. The stainless steel base plates are spaced above the dryer drum surface so that only the lower edge surfaces of the rails contact the dryer drum to prevent flux from short-circuiting through the base plates and not passing through the dryer drum. This maximizes the flux passing through the rails and dryer drum. If the magnetic segments are mounted within the spoiler bar assembly as shown in FIG. 9, with like magnetic poles abutting the rail between adjacent magnet segments, the magnetic poles alternate S, N, S, N, S, N along the longitudinal length of the spoiler bar assembly as shown in FIG. 8. The bottom edges of the rail members are rounded, such as shown at edge 346 on end rail 340 to enhance their area of contact against the dryer drum. The spoiler bar assembly shown in FIG. 10, and the magnetic segments shown in FIG. 11, are similar to the assembly shown in FIG. 6 and arrayed magnetic segments shown in FIG. 7 with one major difference. Specifically, as more clearly shown in FIG. 11, the pole faces of the magnetic segments are arrayed in the same direction so that the faces of the magnetic segments contiguous with intermediate rail 418 are of opposite poles. Thus, side rail 419 is contiguous with the north pole face of magnetic segment 428 and has a north pole at its lower edge surface 422, intermediate rail 418 is contiguous with the south pole face of magnetic segment 428 and with the north pole face of magnetic segment 429 and therefore has both a north and south pole at its edge surface 423 and the outer rail 417 is contiguous with the south pole face of magnetic segment 429 and therefore has a south pole at its lower edge surface 424. The edges 435, 435a-f of segments 429, 429a-f are aligned in a plane in the same manner as edges 433, 433a-f. In a manner analogous to the relationship between the assemblies in FIGS. 6 and 10, and FIGS. 7 and 11, the spoiler bar assembly in FIG. 12 is similar to that as shown in FIG. 8, and the magnetic segments shown in FIG. 13 are similar to those shown in FIG. 9 with the exception that the magnetic segments in the spoiler bar assembly in FIG. 12 are arrayed with the north and south magnetic poles in each magnetic segment pointing in the same direction. Thus for the two magnetic segments shown in FIG. 13, the faces 548, 548a of the south magnetic poles S of both segments are facing the viewer. This provides a spoiler bar assembly wherein the rail 340 on one end is magnetized with one pole, say south pole S, the intermediate rail members have both south and north poles, and the other end rail 345 has a north magnetic pole N. Backing plate 520 and base plates 521, 521a, 521b, 521c and 521d are made of some non-magnetic flux conducting material, such as stainless steel, while rail members 540, 541, 542, 543, 544, 545 are of a magnetic flux conducting material, such as mild steel. In all of the embodiments, the magnets, or magnetic segments, are secured in place by the backing plate, rails, base plate(s) and inside dryer drum surface, or a combination of these elements, depending on the embodiment, as previously described and shown in the figures. The backing plate, rails, and base plates are attached to one another, such as by welding, so the spoiler bar assemblies are quite rigid to maintain their shape during operation and to protect the magnets, which are preferably ceramic. The backing plate, rails and base plates also hold the magnets, or magnetic segments, securely in place with the faces containing the poles, such as faces 48 containing the south magnetic pole, in plane contact with the rail members, which are always of a magnetic flux conducting material, such as mild steel. The backing plate and base plates are always of a non-magnetic flux conducting material, such as stainless steel, except for the embodiment shown in FIG. 2 wherein backing plate 20 comprises a magnetic flux conducting material. In all arrangements, the pole faces of the magnets, or magnetic segments, are always in snug contact with a magnetic flux conducting component (i.e. backing plate, side rails or the dryer drum). This relationship between these components provides for an optimum amount of magnetic flux to be directed through rail members and through the iron dryer drum to maximize the force of attraction and adherence between the spoiler bar assembly and the dryer drum. Further, since the cross sectional area of the rail members is the same, or less than, the cross sectional area of the magnets, or magnetic segments, the unit force of attraction of the rail edge faces against the dryer drum is as great, or greater in the case of smaller rail cross sectional area, as it would be if the magnet itself were directly in contact with the dryer drum. Of course, if the rails were substantially larger in cross sectional area than the cross sectional area of the magnets, the magnetic face could be dissipated and the magnetic forces of adherence decreased, but obviously this would not be done by those skilled in the art.
An improved spoiler bar, for rotatable, steam heated cylindrical dryers, which comprises an assembly of magnets, non-magnetic flux conducting backing and base plates, and magnetic flux conducting rails constructed to position the magnets in spaced adjacency to the dryer drum whereby the installation of the assemblies is facilitated and their strength of adherence to the inner surface of the dryer drum is optimized.
3
FIELD OF THE INVENTION [0001] The present invention relates generally to the implementation of a memory. More specifically, the invention relates to the implementation of a queue, particularly a FIFO-type queue (First In First Out), in a memory. The solution in accordance with the invention is intended for use specifically in connection with functional memories. By a functional memory is understood a memory in which updates, such as additions, are carried out in such a way that first the path from the root of a tree-shaped structure to the point of updating is copied, and thereafter the update is made in the copied data (i.e., the update is not directly made to the existing data). Such an updating procedure is also termed “copy-on-write”. BACKGROUND OF THE INVENTION [0002] In overwrite memory environments, in which updates are not made in the copy but directly in the original data (overwrite), a FIFO queue is normally implemented by means of a double-ended list of the kind shown in FIG. 1. The list comprises nodes of three successive elements in a queue, three of such successive nodes being shown in the figure (references N(i−1), Ni and N(i+1)). The element on the first edge of each node has a pointer to the preceding node in the queue, the element on the opposite edge again has a pointer to the next node in the queue, and the middle element in the node has either the actual stored data record or a pointer to a record (the figure shows a pointer). [0003] However, such a typical way of implementing a FIFO queue is quite ineffective for example in connection with functional memories, since each update would result in copying of the entire queue. If, therefore, the queue has e.g. N nodes, all N nodes must be copied in connection with each update prior to performing the update. SUMMARY OF THE INVENTION [0004] It is an object of the present invention to accomplish an improvement to the above drawback by providing a novel way of establishing a queue, by means of which the memory can be implemented in such a way that the amount of required copying can be reduced in a functional structure as well. This objective is achieved with a method as defined in the independent claims. [0005] The idea of the invention is to implement and maintain a queue by means of a tree-shaped structure in which the nodes have a given maximum size and in which (1) additions of data units (to the queue) are directed in the tree-shaped data structure to the first non-full node, seen from below, on the first edge of the data structure and (2) deletions of data units (from the queue) are also directed to a leaf node on the edge of the tree, typically on the opposite edge. Furthermore, the idea is to implement the additions in such a way that the leaf nodes remain at the same hierarchy level of the tree-shaped data structure, which means that when such a non-full node is not present, new nodes are created to keep the leaf nodes at the same hierarchy level. The tree-shaped data structure will also be termed shortly a tree in the following. [0006] When the solution in accordance with the invention is used, each update to be made in the functional environment requires a time and space that are logarithmically dependent on the length of the queue, since only the path leading from the root to the point of updating must be copied from the structure. The length of this path increases logarithmically in relation to the length of the queue. (When a FIFO queue contains N nodes, log N nodes shall be copied, where the base number of the logarithm is dependent on the maximum size of the node.) [0007] Furthermore, in the solution in accordance with the invention the node to be updated is easy to access, since the search proceeds by following the edge of the tree until a leaf node is found. This leaf node provides the point of updating. [0008] In accordance with a preferred embodiment of the invention, the data structure also comprises a separate header node comprising three elements, each of which may be empty or contain a pointer, so that when one element contains a pointer it points to a separate node constituting the end of the queue, when a given second element contains a pointer it points to said tree-shaped structure that is maintained in the above-described manner, and when a given third element contains a pointer it points to a separate node constituting the beginning of the queue. In this structure, additions are made in such a way that the node constituting the end is always filled first, and only thereafter will an addition be made to the tree-shaped structure. Correspondingly, an entire leaf node at a time is always deleted from the tree-shaped structure, and said leaf node is made to be the node constituting the beginning of the queue, wherefrom deletions are made as long as said node has pointers or data units left. Thereafter, a deletion is again made from the tree. On account of such a solution, the tree need not be updated in connection with every addition or deletion. In this way, the updates are made faster than heretofore and require less memory space than previously. [0009] Since the queue in accordance with the invention is symmetrical, it can be inverted in constant time and constant space irrespective of the length of the queue. In accordance with another preferred additional embodiment of the invention, the header node makes use of an identifier indicating in each case which of said separate nodes constitutes the beginning and which constitutes the end of the queue. The identifier thus indicates which way the queue is interpreted in each case. The queue can be inverted by changing the value of the identifier, and the tree structure will be interpreted as a mirror image. BRIEF DESCRIPTION OF THE DRAWINGS [0010] In the following the invention and its preferred embodiments will be described in closer detail with reference to examples in accordance with the accompanying drawings, in which [0011] [0011]FIG. 1 illustrates a typical implementation of a FIFO queue, [0012] [0012]FIG. 2 a shows a tree-shaped data structure used in the implementation of a FIFO queue and the principle of updates made in a functional memory, [0013] [0013]FIG. 2 b illustrates the generic structure of a discrete node in the tree-shaped data structure used to implement the FIFO queue, [0014] [0014]FIGS. 3 a . . . 3 h illustrate making of additions to a FIFO queue when the memory is implemented in accordance with the basic embodiment of the invention, [0015] [0015]FIGS. 4 a . . . 4 g illustrate making of deletions from a FIFO queue when the memory is implemented in accordance with the basic embodiment of the invention, [0016] [0016]FIGS. 5 a . . . 5 h illustrate making of additions to a FIFO queue when the memory is implemented in accordance with a first preferred embodiment of the invention, [0017] [0017]FIGS. 6 a . . . 6 h illustrate making of deletions from a FIFO queue when the memory is implemented in accordance with the first preferred embodiment of the invention, [0018] [0018]FIG. 7 illustrates a preferred embodiment for a header node used in the structure, and [0019] [0019]FIG. 8 shows a block diagram of a memory arrangement in accordance with the invention. DETAILED DESCRIPTION OF THE INVENTION [0020] [0020]FIG. 2 a illustrates a tree-shaped data structure used to implement a FIFO queue in accordance with the invention and the principle of updating used in a functional memory environment. The figure illustrates a FIFO queue in an initial situation in which the queue comprises data records 1 . . . 5 and thereafter in a situation in which a further record 6 has been added to the queue. [0021] The data structure in accordance with the invention, by means of which the FIFO queue is established, comprises nodes and pointers contained therein. FIG. 2 b illustrates the generic structure of a node. The node comprises a field TF indicating the node type and an element table having one or more elements NE. Each element in the node has a pointer pointing downward in the structure. In accordance with the invention, a given upper limit has been set for the number of elements (i.e., the size of the node). Hence, the nodes are data structures comprising pointers whose number in the node is smaller than or equal to said upper limit. In addition to the pointers and the type field, also other information may be stored in the node, as will be set forth hereinafter. At this stage, however, the other information is not essential to the invention. [0022] The node at the highest level of the tree is called the root node, and all nodes at equal distance from the root node (measured by the number of pointers in between) are at the same (hierarchy) level. The nodes to which there are pointers from a given node are said to be child nodes of said node, and correspondingly said given node is said to be the parent node of these nodes. The tree-shaped data structure in accordance with the invention can have two kinds of nodes: internal nodes (N 1 , N 2 and N 3 ) and leaf nodes (N 4 , N 5 and N 6 ). Internal nodes are nodes wherefrom there are pointers either to another internal node or to a leaf node. Leaf nodes, on the other hand, are nodes at the lowest level of the tree, wherefrom only records are pointed to. Thus the leaf nodes do not contain pointers to other leaf nodes or internal nodes. Instead of pointers, the leaf nodes can also contain actual records, particularly when all records to be stored in the queue are of equal size. Whilst it was stated above that each element in a node has a pointer pointing downward in the structure, the leaf nodes make an exception to this if the records are stored in the leaf nodes. [0023] In FIG. 2 a, the rectangle denoted with broken line A illustrates a tree-shaped structure in an initial situation in which the structure comprises nodes N 1 . . . N 6 , in which case records 1 . . . 5 in the FIFO queue are either in leaf nodes N 4 . . . N 6 or leaf nodes N 4 . . . N 6 contain pointers to records 1 . . . 5 . When record 6 is added to this FIFO queue, an addition is made to node N 4 , wherein in the functional structure the path from the root node (N 1 ) to the point of updating (node N 4 ) is first copied. The copied path is denoted with reference P and the copied nodes with references N 1 ′, N 2 ′ and N 4 ′. Thereafter record 6 is added to the copy (node N 4 ′) and pointers are set to point to the previous data. In this case, the pointer (PO) of the second element of node N 1 ′ is set to point to node N 3 . After the updating, the memory thus stores a data structure represented by a polygon denoted by reference B. The nodes that are not pointed to are collected by known garbage collection methods. [0024] In the invention, a balanced tree structure is used to implement a queue. This tree meets the following two conditions: [0025] 1. all leaf nodes of the tree are at the same level. [0026] 2. All internal nodes of the tree are full, except for the nodes on the left or right edge of the tree, which are not necessarily full. [0027] The first condition is called the balance condition and the second condition the fill condition. In addition, a maximum size is set for the nodes of the tree, the nodes may e.g. be permitted only five child nodes. In the following, the maintenance of the FIFO queue in accordance with the invention will be described in detail. [0028] [0028]FIGS. 3 a . . . 3 h illustrate a procedure in which records 1 . . . 8 are added to an initially empty tree structure (i.e., a FIFO queue) one record at a time. In this example, as in all the following examples, the following presumptions and simplifications have been made (for straightforwardness and clarity): [0029] a node may have a maximum of two pointers only, [0030] the records (i.e., their numbers) are drawn within the leaf nodes, even though each leaf node typically has a pointer to said record. It is presumed in the explication of the example that the leaf nodes have pointers to records, even though the leaf nodes may also contain records. [0031] the copying to be carried out in the functional structure is not shown in order to more clearly highlight the principle of the invention. Thus, the same reference is used for the copy of a node and the corresponding original node. [0032] In the initial situation, the queue is empty, and when an addition is made to the queue, single-pointer internal node (N 1 ) pointing to the added record is formed (FIG. 3 a ). When another record is added to the queue, the node is made into a two-pointer node containing pointers to both the first and the second record (FIG. 3 b ). When a third record is added, a new two-pointer internal node (N 2 ) is created, the right-hand pointer of which points to the old internal node and the left-hand pointer of which points to a new leaf node (N 3 ) having as a single child the new added record (FIG. 3 c ). When a fourth record is added, the addition is made (FIG. 3 d ) to the single-child node (N 3 ) on the left-hand edge of the tree. In connection with the addition of a fifth record, a new two-pointer root node (N 4 ) is again created, the right-hand element of which is set to point to the old root node and the left-hand element of which is set to point through two new single-pointer nodes (N 5 and N 6 ) to the added record (FIG. 3 e ). These new nodes are needed in order for the balance condition of the tree to be in force, that is, in order that all leaves of the tree may be at the same level. [0033] The addition of the next record (record six) is again made to the single-child leaf node N 6 on the left-hand edge of the tree (FIG. 3 f ). Thereafter, in connection with the addition of the next record, the node (N 5 ) on the left-hand edge of the tree next to the leaf node is filled, and the new pointer of said node is set to point to the added record (seven) through a new (single-child) leaf node N 7 . The last record (eight) is added by adding another pointer to this leaf node, pointing to the added record. [0034] As stated previously, the copying carried out in the structure has not been illustrated at all for simplicity and clarity, but the figures only show the result of each adding step. In practice, however, copying is carried out in each adding step, and the update is made in the copy. Thus, for example record two is added in such a way that a copy is made of leaf node N 1 and the record pointer is added to this copy. Correspondingly, for example in connection with the addition of record five, the content of the two-pointer node (N 2 ) that is the root node is copied into the correct location before the addition and the update is made in the copy (nodes N 4 . . . N 6 with their pointers are added). FIG. 2 a shows what kind of copying takes place for example in connection with the addition of record 6 (cf. FIGS. 3 e and 3 f ). Since such a functional updating policy is known as such and does not relate to the actual inventive idea, it will not be described in detail in this context. [0035] Deletion from the tree takes place in reverse order, that is, the right-most record is always deleted from the tree. FIGS. 4 a . . . 4 g illustrate a procedure in which all the records referred to above are deleted one at a time from the FIFO queue constituted by the tree structure of FIG. 3 h which contains eight records. In the initial situation, the rightmost record (i.e., record one) of the tree is first searched therefrom, the relevant node is copied in such a way that only record two remains therein, and the path from the point of updating to the root is copied. The result is a tree as shown in FIG. 4 a. Similarly, record two is deleted, which gives the situation shown in FIG. 4 b, and record three, which gives the situation shown in FIG. 4 c. If during deletion an internal node becomes empty, the deletion also proceeds to the parent node of said node. If it is found in that connection that the root node contains only one pointer, the root node is deleted and the new root will become the node which this single pointer points to. When record four is deleted, it is found that internal node N 2 becomes empty, as a result of which the deletion proceeds to the root node (N 4 ). Since the root node contains only one pointer after this, the root node is deleted and node N 5 will be the new root. This gives the situation of FIG. 4 d. Thereafter the deletions shown in the figures proceed in the manner described above, i.e. the rightmost record is always deleted from the tree and the root node is deleted when it contains only one pointer. [0036] The copying to be carried out has not been described in connection with deletion either. The copying is carried out in the known manner in such a way that from the leaf node wherefrom the deletion is made, only the remaining part is copied, and in addition the path from the root to the point of updating. The pointers of the copied nodes are set to point to the nodes that were not copied. [0037] As will be seen from the above explication, in a FIFO queue in accordance with the invention [0038] all leaf nodes in the tree are always at the same level (the lowest level if the records are not taken into account), [0039] all nodes in the tree are full, except for the nodes on the edges of the tree, and [0040] nodes are filled upwards. This means that in the first place, a non-full leaf node on the edge of the tree is filled. If such a leaf node is not found, the next step is to attempt to fill a non-full internal node on the edge next to a leaf node. [0041] The additions and deletions can also be expressed in such a way that when an addition is made to the tree, the new record is made to be a leaf in the tree, which is obtained first in a preorder, and when a deletion is made from the tree the deletion is directed to the record that is obtained first in a postorder. [0042] The above-stated structure can also be implemented as a mirror image, in which case the node added last is obtained first in a postorder and the one to be deleted next is obtained first in a preorder. This means that the additions are made on the right-hand edge and deletions on the left-hand edge of the tree (i.e., contrary to the above). [0043] The above is an explanation of the basic embodiment of the invention, in which a FIFO queue is implemented merely by means of a tree-shaped data structure. In accordance with a first preferred embodiment of the invention, a three-element node, which in this context is called a header node, is added to the above-described data structure. One child of this header node forms the leaf node at the end (or pointing to the end) of the FIFO queue, the second child contains a tree of the kind described above, forming the middle part of the FIFO queue, and the third child forms the leaf node at the beginning (or pointing to the beginning) of the queue (provided that such a child exists). The separate nodes of the beginning and the end are called leaf nodes in this connection, since a filled node of the end is added as a leaf node to the tree and a leaf node that is deleted from the tree is made to be the node of the beginning. [0044] [0044]FIGS. 5 a . . . 5 h illustrate a procedure in which records 1 . . . 8 are added to an initially empty queue one record at a time. The header node is denoted with reference HN, the leftmost element in the header node, which in this case points to a (leaf node at the end of the queue, is denoted with the reference LE, and the rightmost element in the header node., which in this case points to a (leaf) node at the beginning of the queue, is denoted with reference RE. [0045] When a record is added to the end of the queue, a copy is made of the leaf node of the end and the record pointer is added to the copy (FIGS. 5 a and 5 b ). If, however, the leaf node of the end is already full (FIGS. 5 d and 5 f ), said leaf node is transferred to the tree in the header node (pointed to from the middlemost element in the header node). Thereafter a new leaf node for the end is created, in which said record is stored (FIGS. 5 e and 5 g ). The addition of the leaf node to the tree is made in the above-described manner. The addition thus otherwise follows the above principles, but an entire leaf node is added to the tree, not only one record at a time. Hence, all leaf nodes in the tree are at the same level. The node pointed to from the leftmost element of the header node is thus always filled, whereafter the entire leaf node is added to the tree. [0046] When a deletion is made from the beginning of the queue, it is first studied whether the beginning of the queue is empty (that is, whether the right-most element in the header node has a pointer). If the beginning is not empty, the rightmost record is deleted from the leaf node of the beginning. If, on the other hand, the beginning is empty, the rightmost leaf node is searched from the tree representing the middle part of the queue. This leaf node is deleted from the tree in the manner described above, except that an entire leaf node is deleted from the tree at a time, not only one record at a time as in the basic embodiment described above. This deleted leaf node is made to be the leaf node of the beginning of the queue, and thus the beginning is no longer empty. If also the tree is empty, the leaf node of the end is made to be the leaf node of the beginning. If also the end is empty, the entire queue is empty. Deletion from the beginning of the queue is made by copying the leaf node of the beginning in such a way that its last record is deleted in connection with the copying. [0047] [0047]FIGS. 6 a . . . 6 h illustrate a procedure in which the records 1 . . . 8 added above are deleted from the queue one record at a time. The initial situation is shown in FIG. 5 h. In the initial situation, the beginning of the queue is empty, and thus the rightmost leaf node is searched from the tree, said node being deleted from the tree and the deleted leaf node being made into the leaf node of the beginning of the queue. This gives the situation of FIG. 6 a. The next deletion is made from the leaf node of the beginning, as a result of which the beginning becomes empty. Thereafter the rightmost record in the tree (record three) is again deleted. Since in that case only a single pointer remains in the root node of the tree, said root node is deleted. Also the new root node has only one pointer, wherefore it is deleted too. This gives the situation of FIG. 6 c, in which the next record to be deleted is record four. When this record is deleted, the beginning of the queue is again empty (FIG. 6 d ), and thus in connection with the next deletion the leaf node pointing to record six is moved to the beginning of the queue, which makes the tree empty (FIG. 6 e ). When record six has been deleted, also the beginning is empty (FIG. 6 f ), and thus in connection with the next deletion the leaf node of the end is made to be the leaf node of the beginning (FIG. 6 g ). When also the end is empty (in addition to the fact that the beginning and the tree are empty), the entire queue is empty. [0048] For the header node, the updating policy of the functional structure means that in connection with each addition, the header node and the leaf node of the end of the queue are copied. From this copy, a new pointer is set to the tree and to the old beginning (which thus need not be copied). Correspondingly, in connection with deletions the header node and the remaining portion of the leaf node of the beginning of the queue are copied and a new pointer is set from the copy to the tree and the old end. [0049] By adding a header node to the memory structure, the updates will be made faster and less space-consuming than heretofore, since for the header node the additions require a (constant) time independent of the length of the queue. For example, if the maximum size of the node is five, only a fifth of the additions is made to the tree, and thus four fifths of the additions require a constant time and a fifth a time logarithmically dependent on the length of the queue. [0050] In accordance with another preferred embodiment of the invention, a bit is added to the header node, indicating which edge of the header node constitutes the end and which the beginning of the FIFO queue. In other words, the value of the bit indicates whether the queue is inverted or not. If the bit has for example the value one, the leaf node pointed to from the leftmost element LE of the header node is construed as the end of the queue and the leaf node pointed to from the rightmost element RE as the beginning of the queue, respectively. If the value of the bit changes to be reverse, the beginning and end are construed in the reverse order and, furthermore, the tree representing the middle part of the queue is construed as a mirror image in relation to the previous interpretation. FIG. 7 illustrates the generic (logical) structure of the header node. In addition to the inversion bit IB, the node comprises the above-stated type field TF, indicating that a header node is concerned. In addition, the node has the above-stated three elements, each of which may be empty or contain a pointer. The order of these elements can also vary in such a way that the beginning, middle, or end of the queue can be pointed to from any element. Thus, the middle part is not necessarily pointed to from the element in the middle and the beginning or end from an element on the edge. [0051] Since copying the header node and making an update in the copy and updating the above-stated bit to an inverse value of the original value is sufficient for inversion of the queue, the queue can be inverted in constant time and space. Since the structure is also fully symmetrical, the queue can be used as a double-ended queue, that is, additions can also be made to the beginning and deletions can be made from the end of the queue (FIFO or LIFO principle). For a double-ended queue, the shorter term deque is also used. [0052] The bit indicating the direction of the queue can also be used in the basic embodiment of the invention in which there is no header node. In such a case, the bit can be added to the individual nodes, and thus the bit indicates which edge of the tree is the beginning of the queue and which the end in that part of the tree which is beneath said node. [0053] [0053]FIG. 8 illustrates a block diagram of a memory arrangement in accordance with the invention, implementing a memory provided with a header node. The memory arrangement comprises an actual memory MEM, in which the above-described tree structure with its records is stored, a first intermediate register IR_A in which the leaf node of the end (or beginning) of the queue is stored, a second intermediate register IR_B in which the leaf node of the beginning (or end) of the queue is stored, and control logic CL maintaining the queue (making additions of records to the queue and deletions of records from the queue). [0054] For the control logic, the memory arrangement further comprises a flag register FR in which the value of the inversion bit is maintained. Furthermore, the memory arrangement comprises an input register IR through which the input of the record pointers takes place and an output register OR through which the record pointers are read out. [0055] As normally in systems of this kind, the records are stored in advance in the memory (MEM), and in this record set a queue is maintained by means of pointers pointing to the records. [0056] When a record pointer is supplied to the input register, the control logic adds it to the leaf node in the first intermediate register IR_A. If the first intermediate register is full, however, the control logic first stores the content of the register in the tree stored in the memory MEM. This takes place in such a way that the control logic follows the edge of the tree and copies the path from the root to the point of updating and makes the update in the copy. Thereafter the control logic adds a pointer to the intermediate register IR_A. [0057] When records are deleted from the queue, the control logic reads the content of the second intermediate register IR_B and deletes the record closest to the edge therefrom, if the intermediate register is not empty. If the intermediate register is empty, the control logic retrieves from memory, following the edge of the tree, a leaf node and transfers its remaining part to the second intermediate register. At the same time, the control logic updates the tree in the manner described above. [0058] Even though the invention has been explained in the above with reference to examples in accordance with the accompanying drawings, it is obvious that the invention is not to be so restricted, but it can be modified within the scope of the inventive idea disclosed in the appended claims. For example, the maximum size of the nodes is not necessarily fixed, but it can e.g. follow a pattern, for example so that at each level of the tree the nodes have their level-specific maximum size. Since the actual records can be stored separately and the tree only serves for forming a queue therefrom and maintaining the queue, the records can be located in a memory area or memory block separate from the tree.
The invention relates to a method for implementing a queue, particularly a FIFO queue, in a memory (MEM) and to a memory arrangement. In order to enable reducing the amount of copying particularly in a functional environment, at least part of the queue is formed with a tree-shaped data structure (A, B) known per se, having nodes at several different hierarchy levels, wherein an individual node can be (i) an internal node (N 1 -N 3 ) containing at least one pointer pointing to a node lower in the tree-shaped hierarchy or (ii) a leaf node (N 4 -N 6 ) containing at least one pointer to data unit ( 1 . . . 6 ) stored in the memory or at least one data unit. A given maximum number of pointers that an individual node can contain is defined for the nodes. The additions to be made to said part are directed in the tree-shaped data structure to the first non-full node (N 4 ), seen from below, on a predetermined first edge of the data structure and they are further implemented in such a way that the leaf nodes remain at the same hierarchy level of the tree-shaped data structure, wherein when a non-full node is not present, new nodes are created to maintain the leaf nodes at the same hierarchy level. The deletions to be made from said part are typically directed to the leaf node on the opposite edge of the tree.
6
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority from U.S. patent application No. 60/600,661 entitled “Method and System for Automatic Cue Sheet Generation” filed Aug. 11, 2004, now pending, which is incorporated herein by reference. BACKGROUND [0002] Companies that use music in productions that are broadcast in any public way, such as television stations, radio stations or advertisers are required to pay royalties for such use. Agreements with performing rights societies (“PRS”) which represent the music owners require these companies to create and file “cue sheets” in order to report the specific music they have used in each of their productions. Example PRS are ASCAP and BMI. [0003] A “cue sheet” usually lists the name of the track used, how and where the track was used, the writer(s) of the track, the publisher of the track, and the performing rights society to which the track is affiliated. A cue sheet lists, in sequence, all music used in a particular production, duration of use, and form of use (i.e., whether it use as background instrumental music, as a theme, or as a featured performance). This information affects the royalty rate paid by the PRS to the owners of the music. [0004] Ordinarily, an administrator at the broadcaster production facility complies the cue sheet data from information indicating the music content used in a particular broadcast program. The administrator employs the musical content identification to retrieve data required for the cue sheet. The data is generally retrieved by reference to published indicis available either in print or online. SUMMARY [0005] The present invention provides an automated method for generating cue sheets from Edit Decision Lists (EDL) which are generated by production facilities. The present invention recognizes the EDL are generated by production facilities as part of an editing process when employing digital editing tools. The data in the EDL can be used to arrive at information which is required for a cue sheet submission. Accordingly, the present invention parses the EDL data to retrieve information for a cue sheet. The cue sheet information is then entered into corresponding fields of a cue sheet to provide a ready-for-submission cue sheet. [0006] In one embodiment, the invention provides a method for generating a cue sheet for submission to a PRS. The method includes a computer receiving production piece information and an associated EDL file. The computer parses the EDL file to extract track file names, a duration of use, and a time code in the production piece for each file. The computer searches a database for the track file name to retrieve a composer, publisher, and PRS associated with the track file name. In a final step, the computer stores the extracted information and said retrieval information in a cue sheet template to provide a cue sheet for submission to a PRS. BRIEF DESCRIPTION OF THE DRAWINGS [0007] FIG. 1 illustrates a contact information screen of the web application of the invention; [0008] FIG. 2 illustrates a show details screen of the web application; [0009] FIG. 3 illustrates a web application screen for importing EDL data; and [0010] FIG. 4 illustrates the EDL presentation screen of the web application. DESCRIPTION [0011] An edit decision list (“EDL”) is a list of instructions for all the edit actions taken during the creation of a program. Some of the information provided by an EDL includes cuts, wipes, fades, dissolves, and black edits. The EDL organizes the instructions as a series of chronological edits called events. Each event specifies a timecode for the edit on the source and master. EDLs can display additional types of information such as comments and the different audio and video tracks in the sequence. [0012] EDLs are created automatically by all forms of digital editing software (Avid, Final Cut Pro, Pro Tools). EDLs can be exported from the editing software as an EDL file or as a text file in a variety of formats. Each provides for different format data and possibly different presentation arrangement. The present application is adapted to operate with any EDL format as long as minimal music identification data is included. [0013] The Cue Sheet Application automatically generates a cue sheet which contains all meta-data required by performing rights societies and is correctly formatted, by reference to the Edit Decision List created by any digital video/audio editing software. [0014] The structure and operation of a system in accordance with the invention will now be discussed by reference to screen diagrams for a web based application that receives an EDL file and provides a corresponding output cue sheet. FIG. 1 illustrates a contact information screen 19 of the web application of the invention. The user preferably logs in to the web-application by entering a username and password. In the screen of FIG. 1 , the user submits contact information by entering corresponding text in the name 20 and email 21 fields of the contact information screen 19 . [0015] The form data is transmitted to the web server by selecting a Submit Data button 23 . The form data is cleared by selecting a Reset Data button. FIG. 2 illustrates a show details screen 30 of the web application. The user enters data specific to the subject production in fields of the screen. These fields include: the network airing the show 31 , the production company 32 , the producer 33 , name of the show 34 (including episode number 35 ), the length of the show 36 , the airing date 37 , and any miscellaneous comments 38 . This information is generally required for a cue sheet since it identifies the manner and form of use. As discussed above, this information is critical to the PRS as it directly affects the royalty calculation. [0016] FIG. 3 illustrates a web application screen for importing EDL data. As discussed above, the user imports the EDL file corresponding to the production for which the cue sheet is required. The user is first prompted to select an EDL format for a file upload from a selection drop-down box 41 . In another embodiment, the user pastes the text of an EDL file directly into a special web application window (not shown). In the second step, the user either selects an EDL to upload 42 or pastes the EDL text as discussed above. [0017] FIG. 4 illustrates the EDL presentation screen of the web application. As discussed above, the EDL file is imported to the application web server via the internet by the upload procedure of FIG. 3 . The user selects from available formats 50 , 51 , 52 for the cue sheet information. In the illustrated embodiment, the formats include a Word file 50 , an Excel spreadsheet 51 , or an Email attachment 52 . The web application parses the imported EDL file and extracts the information needed to generate a cue sheet. The cue sheet information is displayed in a cue sheet display area 60 of the web application. The fist section of the cue sheet display provides the show details discussed with reference to FIG. 2 . Additionally, the section includes a field for a producer signature 53 . The second section of the cue sheet provides detail as to the works used in the show as extracted from the input EDL file. The detail information includes the track title 61 duration of use 62 , the timecode in the program during which the music track was used 63 , 64 and form of use 65 . A third section of the cue sheet displays information retrieved from databases which is required for the cue sheet submission. The information is retrieved by the application searching a database which contains additional key data for cue sheet purposes: writer name 66 , publisher 67 , and affiliated PRS 68 . In one embodiment, the database is an internal database maintained by the web application provider. In another embodiment, the database is an external public database. Preferably, the internal database is a database of works compiled from both local and external sources providing musical work information. The application dynamically formats the entire cue sheet, based on built-in templates that fulfill the required PRS formatting. As discussed above, the cue sheet data illustrated in FIG. 4 is preferably displayed to the user in HTML format. As discussed above, the user downloads a copy of the cue sheet from the web based application server to their local computer as either a Microsoft Word or Microsoft Excel document. This feature allows the user to subsequently alter the document to suit the individual user purposes. In some implementations, the user emails copies of the cue sheet in either format to other users directly through the web application without saving a local copy on the user computer by employing the e-mail option. [0018] Although the present invention was discussed in terms of certain preferred embodiments, the invention is not limited to such embodiments. A person of ordinary skill in the art will appreciate that numerous variations and combinations of the features set forth above can be utilized without departing from the present invention as set forth in the claims. Thus, the scope of the invention should not be limited by the preceding description but should be ascertained by reference to claims that follow.
A cue sheet generation system is used to compose a cue sheet for submission to PRS from an input EDL. The system parses the EDL to extract data relating to use of musical works associated with a PRS. The system employs both local and remote databases to retrieve information relating to the extracted musical work data. The information is then used to construct a cue sheet in a form appropriate for submission to a PRS.
6
BACKGROUND OF THE INVENTION This invention relates to industrial heat recuperators, and more particularly relates to a heat recuperative apparatus employing a composite ceramic cross-flow heat recuperator for use on furnaces, calciners, ovens and preheaters. Recent concern about energy conservation and rising fuel costs has caused renewed interest in industrial recuperators to recover waste heat losses and to preheat incoming combustion air to increase the efficiency of furnaces, calciners, ovens and preheaters. While such recuperators are usually constructed from metal parts, the ceramic recuperator has several advantages over conventional metallic recuperators. For example, ceramics in general have high corrosion resistance, high mechanical strength at elevated temperatures, low thermal expansion coefficients (TEC'S) and good thermal shock resistance, and thus exhibits excellent endurance under thermal cycling; are light in weight (about 1/3 the weight of stainless steel); and are cost competitive with high temperature alloys. Furthermore, ceramic recuperators are available in a variety of shapes, sizes, hydraulic diameters, (hydraulic diameter is a measure of cross-sectional area divided by wetted perimeters) and compositions. Because their TEC'S are typically lower than those of most metals and alloys, however, ceramic recuperators present a compatibility problem to the design engineer desiring to incorporate them into existing furnace, calciner, oven and preheater structures. In co-pending U.S. patent application Ser. No. 686,040, filed May 13, 1976, and assigned to the present assignee, there is described a cross-flow ceramic recuperator employing a single ceramic composition. The relatively high cell density of the disclosed structures (for example, 125 cells per square inch) enabled use of such recuperators in forced draft applications, permitting relatively small hydraulic diameters. Where larger hydraulic diameters and/or larger size recuperators are desired (for example, in natural draft applications where back pressures on the order of 0.1 inch of water are desired), fabrication problems are encountered. For example, consideration has been given to assembling large recuperator structures by building them up from blocks or sections of smaller size. However, an attendant problem has been leakage of the heat transfer fluids between subsections or component parts, resulting in the decreased overall efficiency of the recuperative apparatus. SUMMARY OF THE INVENTION In accordance with the invention, a composite ceramic cross-flow recuperator composed of a plurality of sectioned ribbed layers sealed together, is incorporated into a metallic housing adapted for coupling to the metallic fittings of existing furnaces, calciners, ovens and preheaters. Sealing means between the layer sections prevents leakage of heat transfer fluids such as exhaust flue gases and incoming combustion air, and thus minimizes heat loss, between core layers. In accordance with a preferred embodiment, the sealing means comprises an effectively fluid-impervious ceramic cement of a lower melting material than that of the layer material, which cement is plastic at the firing temperature used to sinter the ceramic recuperator structure. In accordance with another preferred embodiment, the seal is achieved by use of the ceramic cement between the layer sections and adjacent reinforcing members of a material similar to that of the layer material, the reinforcing members positioned adjacent the outer ribs of abutting layer sections. In accordance with yet another preferred embodiment, a coating of the ceramic cement is located on continuous bond lines of the external surfaces of the ceramic cellular structure assembly to seal alternate sectioned layers from one another. The recuperative apparatus is useful to preheat incoming heating or combustion air and/or fuel and thus increase the efficiency of existing furnaces, calciners, ovens and preheaters of varying types and sizes. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of one embodiment of a recuperative ceramic cellular structure of stacked ribbed bi-sectional layers; FIG. 2 is a front elevation view of a portion of one bi-sectioned ribbed layer showing abutting sections having the outer ribs between an inverted U-shaped channel as one embodiment of means for sealing the sections together; FIG. 3 is a front elevation view similar to that of FIG. 2, showing another embodiment of means for sealing the layer sections; FIG. 4 is a front elevation view, showing yet another embodiment of a means for sealing the layer sections; FIG. 5 is a perspective view, cut away, of a portion of the outer surface of the stacked structure of FIG. 1 showing a coating of cement on the continuous bond lines between alternate layers; FIG. 6 is a front elevation view, in section, of one embodiment of a heat recuperative apparatus of the invention, wherein the recuperator of a composite ceramic structure of stacked ribbed bi-sectioned layers is held within a metallic housing; FIG. 7 is a schematic diagram of a heat recuperative system employing two recuperative apparati of the invention on a two-burner horizontal radiant tube furnace. DETAILED DESCRIPTION OF THE INVENTION For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-identified drawings. Referring now to FIG. 1 of the drawings, there is shown one embodiment of the composite ceramic recuperator structure 10 of the invention. This ceramic structure is made up of a plurality of stacked ribbed bi-sectioned layers, 11 and 13, positioned so that the ribs of layers 11 and 13 are transverse to one another. The ribbed sections 11, 11a, 13 and 13a may be formed by casting, molding, extruding, tape casting and embossing, or other suitable ceramic forming technique. These ribbed sections, referred to as being in the unfired or "green" state, are then sealed together in the following manner. Channel-shaped members 12 and 12' of a material similar to that of the ribbed sections, which may have been formed by a similar or dissimilar ceramic forming technique, and of a length dimension substantially identical to the length dimension of the ribbed sections, are filled with a ceramic cement 15. The ceramic cement 15 is preferably of a material having a lower melting point than that of the section and channel materials so that at the firing temperatures encountered at a later stage in processing, the cement will assume a plastic state, flowing into irregularities in the bonding surfaces of the ribs and channel and thereby achieving an adequate seal between the sections. The channel is filled with the cement and fitted over the outer ribs of abutting sections. FIG. 2 shows the seal structure in more detail. It will be noted from FIG. 2 that the outer ribs 11' and 11a' are of a height lower than that of the remaining ribs in order that the top surface of the channel 12, when positioned in place will contact the lower surface of the base portion of the next sectioned layer. The process of assembling the bi-sectioned layers is repeated and the resulting layers are stacked so that the ribs of alternate layers are transverse to one another. In a preferred embodiment, the ribbed sections have length dimensions approximately twice that of their width dimensions so that the resulting stacked structure has a square cross-section and may be built up to an approximate cubic configuration. The stacked layers are then fired in the conventional manner (within the sintering range but below the melting temperature of the materials) to convert the green ceramic materials into a polycrystalline ceramic body. During firing, the stacked layers bond together by sintering at points or areas of contact, resulting in a unitary structure having mechnical strength. Nevertheless, deviations from planarity of the stacked green layers result in incomplete sintering together of these layers, leaving voids or cracks along the contact or bonding surfaces. Such voids or cracks may be evident at the visible edges or "bond lines" of the bonding surface between the outermost rib of one layer and the flat surface of the base portion of an adjacent layer. In accordance with a preferred embodiment, these bond lines are covered with layers or coatings 46 of the ceramic cement prior to firing, as shown in FIG. 5. Alternate stacked ribbed layers 41 and 43 form the cross-flow paths for the heat transfer fluids. In FIG. 3 is shown another embodiment of a sealing means for the layer sections, in which a I-beam shaped member 22 is located on shelf portions 21' and 21a' of the abutting layers 21 and 21a extending beyond the outermost ribs of the abutting layers. Cement 15 surrounds the I-beam shaped member and is also located in a space between the abutting shelf portions 21' and 21a'. It will be noted that the outermost ribs in this embodiment are of the same height as the other ribs of the sections. FIG. 4 shows yet another embodiment of a sealing arrangement in which a more massive beam member 32 is used. This member 32 has dimensions such that its top surface may contact the lower surface of the base portion of the next layer, which may be desired for added support, for example, where thin walled structures are employed. Other details of the cross-sectional configurations of the stacked recuperator structure will be dependent upon the particular application envisioned, including such considerations as furnace type and design, furnace operating conditions, recuperator size required, etc. In general, however, for natural draft conditions, the hydraulic diameter will fall within the range of approximately 0.5 to 1.50 inches, the cell wall thicknesses will range from about 0.025 inches to about 0.10 inches, and the aspect ratio (the ratio of the height to the width of the cells) will fall within the range of about 0.1 to 1. It will of course be appreciated by those skilled in the art that in order to maximize the efficiency of heat transfer, the heat transfer surface should be maximized. This may be achieved by both narrowing the width and reducing the number of the supporting ribs, both of which adjustments would result in a reduced aspect ratio, that is, increased width of the cells verses height of the cells. Attendant mechanical weakening of the structure could be at least partially overcome by reducing the height of the cells, further reducing the aspect ratio. However, the undesirable condition of excessive back pressure limits the ability to maximize the heat transfer surface in which manner. Accordingly, the aspect ratio should be maintained within the range of about 0.1 to 1, below which excessive back pressures would be encountered and above which the effective heat transfer surface would be undesirably reduced. Exemplary materials and conditions for forming a cellular recuperative structure suitable for use in a heat recuperative system will now be presented. Such materials and conditions are in no way limiting or necessary to the successful practice of the invention, but are merely presented to aid the practitioner in the production of a preferred embodiment of the invention. A ceramic composition having the raw materials in the proportions shown in Table I was formed and extruded through a die to form ribbed layers and channel members for later sealing and stacking into a recuperative structure. TABLE I______________________________________RAW MATERIAL WEIGHT PERCENT______________________________________Talc (S. #200) 38.40Talc (W. #6) 18.33Tenn. Ball Clay 14.23Alumina 23.53Extruding aids 5.51______________________________________ Typical approximate compositions of the raw materials in weight percent is shown in Table II. TABLE II__________________________________________________________________________TYPICAL APPROXIMATE COMPOSITION(IN WT. PERCENT) OF RAW MATERIALS TALC (S.#200) TALC (W. #6) TENN. BALL CLAY ALUMINA__________________________________________________________________________Si.sub.O 2 61.0 73.84 58.13 0.08MgO 32.0 0.02 0.30 --Al.sub.2 O.sub.3 0.5 20.15 27.16 99.7Fe.sub.2 O.sub.3 0.5 0.07 1.18 0.30TiO.sub.2 0.03 0.15 1.93 --CaO 0.2 0.06 0.05 --Na.sub.2 0 -- 0.20 0.18 0.06K.sub.2 O -- 1.54 0.57 --Ignition Loss 5.3 4.00 10.51 --H.sub.2 O 5.0 -- -- --__________________________________________________________________________ The combined weight percents on an oxide basis of the compositions is shown in Table III. TABLE III______________________________________OXIDE WEIGHT PERCENT______________________________________Si.sub.0 2 50.23MgO 13.69Al.sub.2 O.sub.3 34.64Fe.sub.2 O.sub.3 0.49TiO.sub.2 0.35CaO 0.11Na.sub.2 O 0.09K.sub.2 O 0.40______________________________________ The composition shown in Table III melts at approximately 1430° C. and fires at approximately 1400° C. The extruded porosity of the "green" ribbed layers and channel members was measured by a mercury porosimeter technique as approximately 20 percent. The interconnected porosity (that which forms a continuous channel or void from one surface to another of the extruded material) was found to be effectively undetectable to air using a conventional soap solution test. The channel members were then filled with a ceramic cement formed from raw materials in the amounts shown in Table IV. TABLE IV______________________________________RAW MATERIAL WEIGHT PERCENT______________________________________Talc (S. #200) 41.61Talc (W. #6) 27.87Alumina 29.04Plasticity vehicle 1.48______________________________________ The composition expressed as the component oxides in weight percent is shown in Table V. TABLE V______________________________________OXIDE WEIGHT PERCENT______________________________________SiO.sub.2 48.39MgO 14.02Al.sub.2 O.sub.3 36.59Fe.sub.2 O.sub.3 0.33TiO.sub.2 0.05CaO 0.11Na.sub.2 O 0.07K.sub.2 O 0.45______________________________________ This composition melts at 1410° C. and becomes plastic within the range of about 1370° C. to 1400° C. The ribbed layers were cut into sections having length dimensions (the dimension parallel to the ribs) approximately twice the width dimension. Approximately square layers were then formed by abutting two ribbed layers together along their length dimensions, and by placing the cement-filled channel member over the outermost ribs of the abutting layer sections. The square layers were then stacked so that the ribs of alternate layers were transverse to one another, and so that the overall height of the stacked structure was approximately equal to the length and width dimensions, forming an approximately cubic stacked structure. The structure was fired at approximately 1400° C., at which the cement took on a plastic state and wetted the surfaces of the contact layers. The fired assemblies were then tested for leakage by incorporating them into a metallic housing of the type shown in FIG. 6, attaching one outlet of the housing to a blower and sealing the opposite communicating outlet. Thus, air forced into the recuperative structure could exit through the remaining outlets of the housing only by leaking into alternate transverse layers whose cells communicated with these unrestricted outlets. Visual inspection indicated acceptable leakage. Referring now to FIG. 6, there is shown a recuperative apparatus 60 in which the completed ceramic structure 61 is incorporated into a metallic housing 62. The metallic housing 62 may be formed of a single casting, or of machined and welded parts, and is preferably of a corrosion resistant metal such as stainless steel in corrosive applications and above 600° F. housing outer skin temperatures. Tapered conduit portions 52 and 52' terminate in flanged portions 53 and 53' for connection into the incoming heating or combustion air or fuel line. Sidewall portions 54 and 54' define openings terminating in flanged portions 55 and 55' for connection into the exhaust heat or flue gas outlet. The ceramic recuperator is thus heated by the passage of hot exhaust gases through it, and incoming cold air or fuel is in turn preheated as it passes through in the transverse direction. Because of the large differences in thermal expansion coefficients between most ceramics and most metals, and the relatively high thermal conductivity of most metals relative to most ceramics, seal 57, having both resilient and insulating properties is used to maintain an effectively gas-impervious seal between the ceramic core 51 and the metallic housing 50. A detailed description of such a composite seal is not a necessary part of this invention. An example of a composite seal suitable for use in the apparatus of this invention is described in detail in Ser. No. 686,040, referred hereinabove. Sidewall portion 54 of the metallic housing defines an opening just large enough to admit the recuperator cellular structure 51 and seal 57 after expansion of the metallic housing by moderate heating. Thus, upon cooling, a force fit is achieved. After placement of the structure in the housing, a ceramic insert 56, preferably cast in situ, is positioned atop the structure to contact the mating surface of a ceramic lining of an exhaust or flu gas opening or conduit. Flange 55 connects to the flu gas conduit or furnace housing and maintains the ceramic members in intimate contact. Referring now to FIG. 7, there is shown in schematic form an arrangement whereby recuperator 61 is installed on the exhaust ports 62, 63 and 64 of a three zone natural draft tunnel furnace 60. Preheated combustion air is supplied through conduit 65 to burner inlets 66, 67, 68, 69, 70 and 71. This is of course but one example of numerous arrangements which may be used to realize the advantages of the invention. Furnaces, ovens, calciners and preheaters of any design may incorporate one or more of these recuperative apparati in order to improve efficiency of operation. While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. For example, the substantial rectangular cell cross-sections could be replaced by a sinusoidal configuration produced by contacting corrugated and flat layers.
Layered composite cross-flow ceramic recuperators having minimal leakage between layers and consequent high efficiencies are utilized for industrial waste heat recovery in an apparatus in which the ceramic recuperator is surrounded by a metallic housing adapted for coupling to the metallic fittings of existing furnaces, calciners, ovens and preheaters. The ceramic recuperators are formed from stacks of bi-sectioned ribbed layers, the sections of each layer being sealed together to minimize leakage of the heat transfer fluids between layers, and thus to increase the efficiency of the heat transfer.
5
BACKGROUND Field This technology as disclosed herein relates generally to two force members and, more particularly, to a link having an energy absorbing component. Background Current solutions for providing an energy absorbing link, are limited or not in practice at all. One possible example of a current practice is the use of metallic solutions such as corrugated and slotted tubes, however, these solutions are typically heavy and are not typically capable of absorbing a sufficient amount of energy. Energy-absorbing bearings are feasible but have a limited stroking distance to absorb an amount of energy that is adequate for what is needed. Fluid-filled struts are in practice for energy absorbing links. An energy-absorbing link structure that attenuates the energy produced by heavy mass items is needed that is lighter in weight than prior solutions and that has a longer stroke length during maximum load conditions. SUMMARY The technology as disclosed herein is a method and apparatus for a two force structural member that is utilized as a link between two heavy structures comprising an energy absorbing tab adjacent a mounting hole of a link member. One embodiment of the technology is a composite structural transmission support link which has a novel integral energy-absorbing feature. The link can be a two-force member that can carry structural loads up an ultimate load. When loaded beyond ultimate load, such as in a crash event, features in the design allow sections of the link to fail in a progressive manner to absorb energy over a defined stroking distance. The energy absorbing link technology as disclosed can be utilized to connect or link two heavy structures. A link can be designed to support a heavy mass during normal operations of the heavy mass components up to an ultimate load. When this load is exceeded, for example, during a crash event, the energy absorbing technology as disclosed is designed to attenuate energy of the heavy mass by means of controlled failure through a defined stroke distance—which acts to shed energy of the system, for example, an aircraft system. After completion of the stroke of the mass over a defined distance, the link remains intact and imparts a reduced force to the heavy structure, such as an airframe, during the stroke. In one implementation of the technology as disclosed, a slot can be machined or formed into a link to form a weak region under a bushing area. With one implementation, the weak region can be positioned between two thru-holes used to attach the link between two heavy structures, which can absorb compression loads. With another implementation, the weak region can be position on a far side of a thru-hole between the thru-hole and the end of the link, which can absorb tension loads (tensile loads). When the component is loaded in compression, the slot can absorb the energy via progressive failure. Ply drops serve as sacrificial components that will fail when stressed beyond maximum capacity, thereby reducing the initial load spike. Ply drops (ply drop-offs) are thickness variations in the laminate composite accomplished by dropping or eliminating plies along the length where, in this case, the ply drops are designed as fail points forming a weak region. This invention has significant weight advantages over a fluid filled strut, with similar energy absorbing capabilities. One implementation for the basic design of a link can include a composite tube with a rectangular shaped cross section. Cutouts can be formed on each end of the link to act to form a clevis joint. Metallic bushings can be installed through the thru-holes in each arm of the clevis. The technology as disclosed can be a two-force structural member that is loaded double-shear when subjected to a tensile or compressive load. A novel feature of this technology is a weak area designed into a section of the link on each clevis arm face, adjacent to the thru-hole, through which the clevis pin is inserted. The material in this area can form a slot with a width that roughly matches the outer diameter of the bushing installed through each clevis arm thru-hole. This feature is positioned so that, when the part is loaded in compression, the pin bushing fails and the composite material in the slot area and the ensuing crushing action absorbs energy. The combination of the length of the slot and depth of the clevis arms define the stroke distance for energy absorption. The layup of the composite material in the slot can be configured to fail through progressive crushing at a relatively constant load, while the link stays intact during the failure event. The slot feature can be formed by a variation in the composite ply layup compared to the link layup, which may include: composite ply drop-offs; composite ply breaks; or, a machined taper in the slot. Ply breaks are when the fibers in a single composite ply are intentionally cut or a gap is left between two different plies. An energy-absorbing (EA) slot can be integral to the link and can be designed to fail by crushing during a max-load event, thereby attenuating the energy of a heavy mass. One (1) EA slot at each end of link can effectively double the stroking distance and energy absorbed. A slot can be machined or formed into the EA link to form a ‘weak’ region adjacent a bushing bearing area when loaded in compression. If the bushing bearing is appropriately spaced from the end of the link, a slot can be formed in the EA link between the thru-hole and the end of the link to form a weak region adjacent a bushing area when loaded in tension. The slot can absorb energy by the crushing of the material of the slot. The slot can be formed of a composite material. In another implementation, a gradual variation in the number of plies (ply drops) can be utilized to act as sacrificial components that will fail when stressed beyond maximum capacity to initiate crushing and reduce an initial load spike. The thickness and layup orientation of composite material in the slot can be tuned for a required energy attenuation. One implementation of a two-force member energy-absorbing link structure can include an elongated structural member having first and second opposing ends and a lengthwise extending central axis where at least the first and second opposing ends of the elongated structural member is constructed of a primary material having a strength characteristic sufficient to link together two structures. A thru-hole can extend substantially orthogonally with respect to the central axis and through one or more of the first and second ends. A section of the elongated structural member constructed of a secondary material and having a lesser strength characteristic than the strength characteristic of the material sufficient to link the two structures can be adjacent the thru-hole. The section can extend a lengthwise distance substantially along a direction that the lengthwise extending central axis extends and the section can extend from a point of the material proximate and adjacent the thru-hole. In one implementation, the elongated structural member can be a tubular elongated member, and one or more of the first and second opposing distal ends can have a u-shaped clevis structure with opposing first and second prong members forming the u-shaped clevis structure. One implementation of the technology as disclosed herein can be a two-force member energy-absorbing link structure including an elongated structural member having first and second opposing distal ends and a lengthwise extending central axis where at least the first and second opposing distal ends of the elongated structural member are constructed with a primary material thickness having a strength characteristic sufficient to link together two structures. A thru-hole can extend substantially orthogonally with respect to the central axis and through one or more of the first and second distal ends. A recessed cutaway slot section of the elongated structural member, i.e. the link, can be constructed having a lesser thickness and lesser strength characteristic than the strength characteristic of the material sufficient to link the two structures, wherein the section extends a lengthwise distance substantially along a direction that the lengthwise extending central axis extends and wherein the section extends from a point of the material proximate and adjacent the thru-hole. The level of energy absorbed can be adjusted through a combination of the design of the layup and form features. Composite materials can be utilized to enhance the performance parameters of the design. The benefits of a design using high performance composite materials is that very high levels of specific-sustained crush stress (per unit energy-absorption, in Joules/gm) may be obtained throughout a relatively large stroke distance, compared to metallic designs. This is particularly useful approach where the structural members also have the ability to attenuate the energy of heavy mass items, such as a rotorcraft transmission during a crash, for virtually no weight penalty. The features, functions, and advantages that have been discussed can be achieved independently in various implementations or may be combined in yet other implementations, further details of which can be seen with reference to the following description and drawings. These and other advantageous features of the present technology as disclosed will be in part apparent and in part pointed out herein below. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present technology as disclosed, reference may be made to the accompanying drawings in which: FIG. 1A is an illustration of two heavy mass structures being connected by links; FIG. 1B is a magnified view of an encircled portion of FIG. 1A illustrating two links, which can be used to connect two heavy mass structures; FIG. 2A is a sectional view of a clevis of a link; FIG. 2B is another sectional view of a clevis and bushing bearing of a link; FIG. 3A is a front sectional view of a clevis of a link; FIG. 3B is a perspective view of a clevis of a link; FIG. 3C is a magnified view of a portion of FIG. 3B , providing a sectional perspective view of a slot area; FIG. 4A is a magnified view of one end of a link prior a controlled failure; and FIG. 4B is a magnified view of one end of a link after a controlled failure. While the technology as disclosed is susceptible to various modifications and alternative forms, specific implementations 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 presented herein are not intended to limit the disclosure to the particular implementations as disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present technology as disclosed and as defined by the appended claims. DESCRIPTION According to the implementation(s) of the present technology as disclosed, various views are illustrated in FIG. 1-4 and like reference numerals are being used consistently throughout to refer to like and corresponding parts of the technology for all of the various views and figures of the drawing. Also, please note that the first digit(s) of the reference number for a given item or part of the technology should correspond to the figure number in which the item or part is first identified. One implementation of the present technology as disclosed (comprising an energy-absorbing slot feature) teaches a novel apparatus and method for an energy-absorbing link. The details of the technology as disclosed and various implementations can be better understood by referring to the figures of the drawings. Referring to FIGS. 1A and 1B , an illustration of two heavy mass structures being connected by a link system 106 is shown, and an illustration of two links 108 and 110 , which can be used to link two heavy mass structures, is shown. A two-force member energy-absorbing link structure 110 (see FIG. 1B ) is shown, which can be connected between to two heavy structures, as illustrated in FIG. 1A , a first heavy structure 104 and a second heavy structure 102 , (see FIG. 1A ) of the two structure system 100 . As illustrated in FIG. 1A , for example, the first heavy structure can be an aircraft main structure 104 and the second heavy structure can be an aircraft drive system 102 . Encircled area 106 is further illustrated in FIG. 1B . Referring to FIG. 1B , an elongated structural member, which is a link 110 , is shown having first 112 and second 114 opposing ends. The portion of the link system 106 as illustrated shows a first link 108 and a second link 110 . First link 108 does not illustrate the present technology as disclosed herein while second link 110 does. Both the first link 108 and the second link 110 are connected by their respective second opposing ends 114 to a mounting structure 116 . The second link 110 has a lengthwise extending central axis (identified by reference numeral 214 in FIGS. 2B and 3A ) where at least the first and second opposing ends 112 , 114 of the link 110 are constructed of a primary material 134 having a strength characteristic sufficient to link together two structures (for example, structures 104 and 102 ). A first thru-hole 118 and a second thru-hole 120 can extend substantially orthogonally with respect to the central axis (see item 214 of FIGS. 2B and 3A ) and through one or more of the first 112 and second 114 opposing ends. A first section 126 and/or a second section 128 of the elongated structural member, which is the second link 110 , can be constructed of secondary material having a lesser strength characteristic than the strength characteristic of the material sufficient to link the first heavy structure and the second heavy structure. The first and second sections 126 and 128 can extend a lengthwise distance substantially along a direction that the lengthwise extending central axis 214 extends. The first and second sections can extend from a location 124 of the material proximate and adjacent the thru-hole. In one implementation of the technology, the two-force member energy-absorbing link 110 can be constructed such that the elongated structural member, link 110 , is a tubular elongated member. The two-force member energy-absorbing link 110 as illustrated where one or more of the first 112 and second 114 opposing distal ends have a u-shaped clevis structure with opposing first 132 and second 130 prong members (i.e. arms) forming the u-shaped 122 clevis structure. The first and second thru-holes, as illustrated at 118 and 120 , can extend through one or more of the first 130 and second 132 prong members. The section, illustrated by 126 or 128 , of the elongated structural member 110 can be constructed of a secondary material and can be an elongated slot 126 or 128 extending a lengthwise distance. The first and second sections of weakened material 126 and 128 of the elongated structural member, link 110 , can be formed in the primary material as a weakened region of the elongated structural member, i.e. the link 110 , to allow the weakened sections 126 and 128 to crush when sufficient compression loads are applied to the elongated structural member in the direction that the lengthwise extending central axis 214 extends. Referring to FIGS. 2A and 2B , a sectional view 200 of first and second arms 130 and 132 of a link is shown. Referring to FIG. 2B , another sectional view of the clevis arms 130 and 132 and bushing bearing 210 of a link is shown. The section (i.e. slot) 126 can be formed with ply-drops 206 and 208 proximate the thru-hole 118 to act as a weakened area to induce a controlled failure and to initiate crushing of the slot 126 constructed of a secondary material to reduce an initial load spike. The slot 126 comprising the secondary material can also be a recess 202 . With one implementation of the technology as disclosed, the section of secondary material 126 , which can be a recessed slot 202 , can be formed having lengthwise slits 216 (See FIG. 2B ) extending at least partially from one end of the slot to the opposing end of the slot in the direction that the lengthwise extending central axis extends. With one implementation of the technology as disclosed a two-force member energy-absorbing link structure can include an elongated tubular member—i.e. a link 110 . The tubular member can have a rectangular cross section. The link can have first and second opposing distal ends and a lengthwise extending central axis where the elongated structural member is constructed of a primary material having a strength characteristic sufficient to link together two structures. With this implementation a thru-hole can extend substantially orthogonally with respect to the central axis and through one or more of the first and second distal ends. A section 126 of the elongated structural member can be constructed of secondary material 134 having a lesser strength characteristic than the strength characteristic of the material sufficient to link two structures and said section can extend a lengthwise distance 212 substantially along a direction that the lengthwise extending central axis 214 extends and said section extends from a location 124 of the material proximate and adjacent the through hole. The first and second opposing ends can have a u-shaped clevis structure 204 with opposing first 130 and second 132 prong members forming the u-shaped clevis structure 204 . The thru-hole 118 extends through one or more of the first and second prong members 130 , 132 . The section of the elongated structural member constructed of a secondary material is an elongated slot 126 extending a lengthwise distance 212 (see FIG. 2B ). In one implementation of the technology, the section of the elongated tubular member can be formed in the primary material as a weakened region of the elongated tubular member to allow the section to crush when sufficient compression loads are applied to the elongated tubular member in the direction that the lengthwise extending central axis 214 extends. The section can be formed with ply-drops 206 proximate the thru-hole 118 to act to initiate crushing of the secondary material to reduce an initial load spike. The section can be formed having lengthwise slits 216 extending at least partially in the direction that the lengthwise extending central axis extends. Referring to FIGS. 3A, 3B and 3C , a front sectional view of a clevis of a link is shown, a perspective view of a clevis of a link is shown and a sectional perspective view a slot area is shown. An elongated structural member, i.e. the link 110 , can have first and second opposing ends. The first end 112 is shown in FIG. 3A . A lengthwise extending central axis 214 can extend in the direction illustrated where at least the first and second opposing ends of the link 110 is constructed having a primary material thickness having a strength characteristic sufficient to link together two structures. As can be seen, a thru-hole 118 extends substantially orthogonally with respect to the central axis 214 . A recessed cutaway slot 202 section in the link 110 is shown and can be constructed of a material having a lesser thickness and lesser strength characteristic than the strength characteristic of the material sufficient to link the two structures. The recessed cutaway slot 202 can extend a lengthwise distance substantially along a direction that the lengthwise extending central axis extends and said section can extend from a location proximate and adjacent the thru-hole. The first and second opposing ends can have a u-shaped 204 clevis structure with opposing first and second arm members forming the u-shaped clevis structure. The section can be formed with ply-drops 206 proximate the thru-hole 118 to allow for the initiation of the crushing of the secondary material to reduce an initial load spike. The section can be formed having lengthwise slits 216 extending at least partially in the direction that the lengthwise extending central axis extends. Referring to FIGS. 4A and 4B , an illustration is provided for one end of a link before ( FIG. 4A ) and after ( FIG. 4B ) a controlled failure. A view of one end 114 of a link 110 is shown. The link 110 is shown mounted to a structure 116 using the clevis 122 and a mounting bolt 402 and washer 403 . The bolt 402 is shown extending through a thru-hole 120 of the clevis 122 and attaching the link 110 to the structure 116 . The link 110 is constructed of a primary material 134 . The link 110 can have a section of weakened material 128 . The section of weakened material 128 can be an elongated slot 404 that extends lengthwise in the same direction as the central axis 214 . The elongated slot 404 can also have a recess 406 as illustrated where material can be removed further weakening the area. FIG. 4B illustrates one end 114 of the link 110 after a controlled failure where the bolt 402 has traversed along the stroke distance 408 and proximately along the same direction as the axis 214 , thereby crushing the section of weakened material 128 , while bolt 402 remains sufficiently intact such that the link 110 is still mounted to the structure 116 . The various energy-absorbing link examples shown above illustrate a link between two heavy structures. A user of the present technology as disclosed may choose any of the above implementations, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject energy-absorbing link could be utilized without departing from the scope of the present invention. As is evident from the foregoing description, certain aspects of the present technology as disclosed are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the scope of the present technology as disclosed and claimed. Other aspects, objects and advantages of the present technology as disclosed can be obtained from a study of the drawings, the disclosure and the appended claims.
An apparatus and method for a composite structural aircraft transmission support link having an integral energy-absorbing feature is disclosed. The link is a two-force member that can carry structural loads up an ultimate load. When loaded beyond ultimate load the design allows sections of the link to fail in a controlled and progressive manner, so that energy is absorbed over a defined stroking distance.
5
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority from, and incorporates by reference the entire disclosure of, Japanese Patent Application No. 2012-169585, filed on Jul. 31, 2012. FIELD [0002] The present application relates to a hinge device which is used for opening and closing a housing of a display part with respect a housing of a keyboard part and to an electronic apparatus which uses the hinge device. BACKGROUND [0003] In a notebook PC or other such electronic apparatus which is provided with a keyboard part and a display part, the housing of the display part is connected to the housing of the keyboard part to be able to open and close by a hinge device. The hinge device is provided at a part forming the axis of opening/closing of the two housings (see Japanese Laid-Open Patent Publication No. 2011-58607 and Japanese Laid-Open Patent Publication No. 2008-250635). Further, when the electronic apparatus is not being used, the hinge device is used to close the display part and lay it flat over the keyboard part thereby enabling the electronic apparatus to be made more compact. [0004] A hinge device in general is provided with a bracket which is attached to one housing and a pivot which is attached to the other housing and is designed so that the bracket holds the pivot in a rotatable manner. In an electronic apparatus which is provided with a keyboard part and a display part, the pivot can be made to turn with respect to the bracket so as to open or close the display part with respect to the keyboard part. This hinge device is a part which stands out in the appearance of an electronic apparatus, so a hinge cover is used to cover the hinge device and maintain a beautiful design and to prevent injury due to mistaken insertion of a finger into the hinge device. Various ideas are used to improve the method of installation of the cover for covering the hinge device. [0005] Among these, there is the technique of arranging the pivot itself of the hinge device at the outside of a side surface of the far side of the housing of the keyboard part of the electronic apparatus to conceal the hinge device from the side which opens and closes the display part and thereby make the hinge device invisible to the user. In this regard, even if employing this technique, the hinge device is exposed at the outside of the side surface at the far side of the housing of the keyboard part of the electronic apparatus. For this reason, when the user puts his hand at the back side of the keyboard part of the electronic apparatus, he might mistakenly insert a finger in the hinge device. To prevent this, a hinge cover which covers the hinge device is necessary. On the other hand, in a structure which conceals the hinge device at the far side of the housing of the keyboard part of the electronic apparatus, the structure for connecting the display part to the hinge device becomes complicated and the hinge cover member also becomes complex. [0006] In an electronic apparatus which employs a structure which conceals the hinge device from the side which opens and closes the display part, the hinge cover which conceals the pivot of the hinge device is provided at the far side of the housing of the keyboard part. Further, if adopting a structure in which the hinge cover is screwed to the housing of the keyboard part, the hinge cover will come off if the screws are removed. In such a structure, when performing maintenance on the display part, the screws are removed in the state with the display part closed, the display part is opened as it is, and the front cover of the display part is removed. When the display part finishes being maintained, the display part is attached to the keyboard part by assembly by the reverse procedure. [0007] In this regard, when fastening a hinge cover by screws to the housing of the keyboard part of an electronic apparatus, the hinge cover is liable to fall off when opening and closing the apparatus. For this reason, even if possible to remove the hinge cover to detach the front cover of the display part, attaching the front cover to the display part and connecting the display part to the keyboard part become extremely difficult in terms of assembly process. [0008] Therefore, it may be considered to fasten the hinge cover to the housing of the keyboard part of the electronic apparatus by a tab member which is provided at the hinge cover. However, when fastening a hinge cover by a tab member to a housing of a keyboard part of an electronic apparatus, there is the issue that the hinge cover will easily detach from the keyboard part when disassembling the front cover of the display part. Further, if fabricating the hinge cover so that the hinge cover does not mistakenly detach from the keyboard part during use of the electronic apparatus by the user, the structure of the hinge cover will end up becoming complicated. SUMMARY [0009] In one aspect, the present application has as its object to provide a hinge device which connects a keyboard part and a display part of an electronic apparatus, wherein a hinge cover will not be mistakenly detached at the time of use by a user and the hinge cover can be simply detached when detaching the front cover of the display part at the time of maintenance of the display part, and to provide an electronic apparatus which uses the hinge device. [0010] According to one aspect, the present application provides a hinge device which is provided between a first housing and a second housing which is provided with a front cover of a display and which connects the second housing to the first housing to be able to open and close, wherein the hinge device is provided with a bracket which is provided with a first mounting part and a rotatable holding part of a pivot, the first mounting part being fastened to an end part of one of the housings, a hinge pivot member which is provided with a second mounting part and a pivot, the second mounting part being fastened to an end part of the other of the housings, the pivot being held by the rotatable holding part, and a hinge cover which is attached to the pivot of the hinge pivot member to be able to slide in its axial direction and which covers the pivot and the rotatable holding part of the bracket in a state where the pivot is held at the rotatable holding part, the hinge cover has an engagement tab which engages with the second housing to prevent the hinge cover from detaching from the pivot by the cover being slid after being attached to the pivot and a space part which opens in the direction of the second housing in the engaged state of the engagement tab, the front cover is provided with a projecting piece which is inserted into the space part if attached to the second housing when the engagement tab of the hinge cover is engaged, and the hinge cover is blocked from movement in the axial direction by the projecting piece in the state where the front cover is attached. [0011] According to another aspect, the present application provides an electronic apparatus which uses a hinge device which is provided between a first housing and a second housing provided with a front cover of a display and which connects the second housing to the first housing to be able to be opened and closed. BRIEF DESCRIPTION OF DRAWINGS [0012] FIG. 1A is a perspective view which illustrates the appearance of an electronic apparatus which is provided with a keyboard part and a display part which are connected by a hinge device of the present application. [0013] FIG. 1B is a perspective view which illustrates the appearance of an electronic apparatus which is provided with a conventional hinge device of the present application. [0014] FIG. 2A is a perspective view which illustrates one example of a hinge unit which forms a hinge device of the present application. [0015] FIG. 2B is a disassembled perspective view which illustrates an embodiment where the hinge unit which is illustrated in FIG. 2A is used to connect the display part and the keyboard part. [0016] FIG. 3A is a perspective view of the electronic apparatus of FIG. 1A which is provided with the hinge device which is illustrated in FIG. 2A as seen from the bottom surface side. [0017] FIG. 3B is an assembled perspective view of the partially enlarged view of part A of FIG. 3A plus a hinge cover which is used for the hinge device of the present application. [0018] FIG. 4A is a partially enlarged perspective view which illustrates the same portion as FIG. 3B which illustrates the state of attachment of the hinge cover which is illustrated in FIG. 3B attached to the hinge device of the electronic apparatus. [0019] FIG. 4B is a bottom surface view of an electronic apparatus in a state where hinge covers are attached to hinge devices as seen from the bottom surface. [0020] FIG. 5A is a perspective view of a hinge cover which is used at the left side of the back surface of the electronic apparatus which is illustrated in FIG. 4B as seen from the front surface. [0021] FIG. 5B is a perspective view of the hinge cover which is illustrated in FIG. 5A as seen from the back surface. [0022] FIG. 5C is a perspective view of a hinge cover which is used at the right side of the back surface of the electronic apparatus which is illustrated in FIG. 4B as seen from the front surface. [0023] FIG. 5D is a perspective view of the hinge cover which is illustrated in FIG. 5C as seen from the back surface. [0024] FIG. 6 is a perspective view which illustrates the structure of one embodiment of a front cover which is used for the hinge device of the present application of the electronic apparatus which is illustrated in FIG. 1A . [0025] FIG. 7A is a partially enlarged perspective view which illustrates a state of a stage before a hinge cover is attached to a hinge device which is attached to a display part of the electronic apparatus which is illustrated in FIG. 1A . [0026] FIG. 7B is a partially enlarged perspective view which illustrates a state where the hinge cover which is illustrated in FIG. 7A is attached to the hinge device. [0027] FIG. 7C is a schematic cross-sectional view which illustrates the connected state of the hinge cover and the housing of the display part along the line B-B of FIG. 7B . [0028] FIG. 8A is a partially enlarged perspective view which illustrates the state where the hinge cover is made to slide along the pivot of the hinge device from the state of FIG. 7B so as to engage with the housing of the display part. [0029] FIG. 8B is a schematic cross-sectional view which illustrates the connected state of the hinge cover and the housing of the display part along the line C-C of FIG. 8A . [0030] FIG. 8C is a partially enlarged assembled perspective view which illustrates the process of attaching the front cover to the display part which is illustrated in FIG. 8B . [0031] FIG. 9A is a partially enlarged perspective view which illustrates the state of attaching the front cover which is illustrated in FIG. 8C to the display part. [0032] FIG. 9B is a schematic cross-sectional view which illustrates the connected state of the hinge cover and the housing of the display part along the line D-D of FIG. 9A . [0033] FIG. 9C is a partially enlarged perspective view which illustrates the state of fastening a screw in a through hole of a projecting piece which projects from the front cover which is illustrated in FIG. 9A and FIG. 9B . [0034] FIG. 9D is a schematic cross-sectional view which illustrates the connected state of the hinge cover and the housing of the display part along the line E-E of FIG. 9C . [0035] FIG. 10A is a perspective view which illustrates the appearance of the display part alone of the present application to which hinge devices and the front cover are attached. [0036] FIG. 10B is a partial cross-sectional view which illustrates the position of a hinge cover in an electronic apparatus which is provided with the hinge devices of the present application which are illustrated in FIGS. 4A and 4B . DESCRIPTION OF EMBODIMENTS [0037] Below, using the attached drawings, embodiments of the present application will be explained in detail based on specific examples. [0038] FIG. 1A is a perspective view which illustrates the appearance of an electronic apparatus 10 which is provided with a hinge device 4 of the present application. The electronic apparatus 10 has a keyboard part 1 which is provided with input keys 5 and a display part 2 which is provided with a display. The display part 2 has a front cover 3 which protects the display attached to it. The display part 2 can be folded over the keyboard part 1 by the hinge device 4 . The hinge device 4 which is provided in the electronic apparatus 10 which is covered by the present application is at a position which is hidden from the user of the electronic apparatus 10 when opening and closing the display part 2 with respect to the keyboard part 1 . [0039] As opposed to this, FIG. 1B is a perspective view which illustrates the appearance of an electronic apparatus 50 which is provided with a conventional hinge device 54 . The electronic apparatus 50 has a keyboard part 51 which is provided with input keys 55 and a display part 52 which is provided with a display. The display part 52 has a front cover 53 which protects the display attached to it. The display part 52 can be folded over the keyboard part 51 by the hinge device 54 . In the hinge device 54 which is provided at the electronic apparatus 50 , the pivot of the hinge device 54 is at the upper side of the keyboard part 51 , so the hinge device 54 is provided to be visible to the user of the electronic apparatus 50 . [0040] FIG. 2A is a perspective view which illustrates one example of a hinge unit 4 U which is used as the hinge device 4 which is used in the electronic apparatus 10 . The hinge unit 4 U of this embodiment is provided with a bracket 20 which rotatably holds a pivot 33 and with a hinge pivot member 30 to which the pivot 33 is fastened. The bracket 20 is attached to the display part 2 , while the hinge pivot member 30 is attached to the keyboard part 1 . For this reason, the bracket 20 has two mounting parts 21 and 22 which are provided with mounting surfaces parallel to the pivot 33 and has rotatable holding parts 23 and 24 which are provided projecting from the mounting parts 21 and 22 and rotatably hold the pivot 33 . [0041] Further, the hinge pivot member 30 has a pivot mounting part 36 which fastens the pivot 33 . This pivot mounting part 36 is provided at a front end part of an arm part 31 in a direction perpendicular to the arm part 31 . A base part of the arm part 31 is bent at right angles to the arm part 31 to form the mounting part 32 to the display part 2 . The mounting part 32 is provided with three through holes 34 for passing screws in this embodiment. The hinge unit 4 U which is illustrated in FIG. 2A , as illustrated in FIG. 2B , is attached to the display part 2 by the two mounting parts 21 and 22 . [0042] On the other hand, the bottom surface 11 B of the housing 11 of the keyboard part 1 of the electronic apparatus 10 is provided with a boss part 13 for attachment of the hinge pivot member 30 . The top surface of the boss part 13 is provided with screw holes 14 to which screws may be fastened. The number of screw holes 14 is matched with the number of through holes 24 at the mounting part 32 of the bracket 20 . The arm part 31 of the bracket 20 is attached to the boss part 13 along the side surface of the boss part 13 . The mounting part 32 of the hinge pivot member 30 can be fastened to the boss part 13 by screwing a screw 6 which is passed through a through hole 34 to a screw hole 14 of the boss part 13 . [0043] FIG. 3A is a perspective view of the electronic apparatus 10 which is illustrated in FIG. 1A which is provided with the hinge device 4 which was explained in FIGS. 2A and 2B as seen from the bottom surface, while FIG. 3B is an assembled perspective view including the partially enlarged view of part A of FIG. 3A plus a hinge cover 40 which is used for the hinge device 4 of the present application. As illustrated in FIG. 3A , the single electronic apparatus 10 is provided with hinge devices 4 at two locations. In the electronic apparatus 10 to which the present application is applied, as illustrated in this figure, the hinge devices 4 are provided at the back side of the keyboard part 1 at a lower side position of the display part 2 . Therefore, as illustrated in FIG. 1A , in the electronic apparatus 10 to which the present application is applied, the hinge devices 4 are not visible to the party operating the electronic apparatus 10 . [0044] On the other hand, the hinge devices 4 which are provided with the brackets 20 and hinge pivot members 30 which are explained in FIGS. 2A and 2B are at positions which are not visible to the operator of the electronic apparatus 10 . However, the rotatable holding parts 22 of the brackets 20 and the pivots 33 of the hinge pivot members 30 of the hinge devices 4 are exposed at slots 15 of the housing 11 . Therefore, in the hinge devices 4 of the present application, as illustrated in FIG. 3B , hinge covers 40 are attached to the slots 15 to cover the rotatable holding parts 22 of the brackets 20 and the pivots 33 of the hinge pivot members 30 and prevent the user from mistakenly touching the rotatable holding parts 22 and pivots 33 . The configuration of the hinge covers 40 will be explained in detail later, but each hinge cover 40 has a blind plate 41 , a circular hole 42 , a pivot mounting plate 43 , an engagement tab 44 , a space 45 , and mounting plates 46 . [0045] FIG. 4A is a partially enlarged perspective view which illustrates the state of attachment of a hinge cover 40 which is illustrated in FIG. 3B attached to a slot 15 of the housing 11 of the keyboard part 1 to conceal the hinge device 4 . In the state with the hinge cover 40 attached to the slot 15 , the hinge cover 40 does not slide inside the slot 15 . Further, as illustrated in FIG. 3A , the electronic apparatus 10 is provided with hinge devices 4 at two locations, so two hinge covers 40 which cover the hinge devices 4 are required. [0046] FIG. 4B is a bottom surface view of an electronic apparatus 10 which illustrates a state where hinge covers 40 are attached to the hinge devices 4 at two locations of the back surface of the electronic apparatus 10 . The hinge covers 40 which are attached to two locations of the back surface of the electronic apparatus 10 are not the same but are symmetrical in shape to the left and right at the back surface of the electronic apparatus 10 . Here, the hinge cover 40 at the left side of the back surface of the electronic apparatus 10 is referred to as the “hinge cover 40 L”, while the hinge cover 40 at the right side is referred to as the “hinge cover 40 R”. The hinge covers 40 L and 40 R are attached by screws 6 to the back surface of the electronic apparatus 10 . [0047] FIG. 5A is a perspective view of the hinge cover 40 L which is used at the left side of the back surface of the electronic apparatus 10 which is illustrated in FIG. 4B as seen from the front surface, while FIG. 5B is a perspective view of the hinge cover 40 L which is illustrated in FIG. 5A as seen from the back surface. Further, FIG. 5C is a perspective view of the hinge cover 40 R which is used at the right side of the back surface of the electronic apparatus 10 which is illustrated in FIG. 4B as seen from the front surface, while FIG. 5D is a perspective view of the hinge cover 40 R which is illustrated in FIG. 5C as seen from the back surface. The hinge covers 40 L and 40 R are just symmetric in shape to the left and right. They are configured exactly the same. Here, the hinge covers will be assigned the representative numbers “ 40 ” to explain their structures. [0048] Each hinge cover 40 is provided with the blind plate 41 , the circular hole 42 which is provided at the blind plate 41 , the pivot mounting plate 43 , and the plurality of mounting plates 46 . The blind plate 41 is curved and covers the rotatable holding part 22 , pivot 33 , and slot 15 which are illustrated in FIG. 3B . Further, the pivot mounting plate 43 is attached to the pivot 33 , while the plurality of mounting plates 46 are inserted into the slot 15 . The pivot mounting plate 43 has a recessed part 43 a into which the pivot 33 is inserted, while the mounting plates 46 are shaped similar to the cross-sectional shape of the slot 15 in the direction vertical to the longitudinal direction. [0049] Further, at the end part of the mounting plate 46 the furthest from the pivot mounting plate 43 , an engagement tab 44 is provided for engaging the hinge cover 40 with part of the housing 12 of the display part 2 to prevent it from detaching from the housing 12 of the display part 2 . Furthermore, the two mounting plates 46 at the center part of the hinge cover 40 are arranged at the two sides of the circular hole 42 at the blind plate 41 . Between these two mounting plates 46 , a space 45 of a predetermined distance is provided. Each hinge cover 40 is made of plastic and has a total length shorter than the length of the slot 15 in the longitudinal direction by exactly a length of at least the height of the engagement tab 44 from the mounting plates 46 . [0050] FIG. 6 is a perspective view of the electronic apparatus 10 which is illustrated in FIG. 1A which illustrates extracted just the front cover 3 which protects the display at the display part 2 . The front cover 3 is provided with a transparent acrylic sheet or glass sheet at the inside of a frame 3 f. At the bottom end part of the frame 3 f, projecting pieces 7 are provided at two locations. The projecting pieces 7 are provided with through holes 8 which pass screws for attaching the front cover 3 to the display part 2 . Furthermore, the widths of the projecting pieces 7 are widths which enable insertion with substantially no clearance into the space 45 at the hinge covers 40 explained in FIG. 5A to 5D . [0051] Above, FIGS. 1A and 1B to FIG. 6 were used to explain the configuration of the hinge device 4 of the electronic apparatus 10 and configuration of the hinge cover 40 which covers the hinge device 4 and, furthermore, the configuration of the front cover 3 which is attached to the display part 2 of the electronic apparatus 10 . Next, FIGS. 7A to 7C to FIGS. 10A and 10B will be used to explain the process of attaching the hinge cover 40 to a hinge device 4 which is already attached to the display part 2 and attaching the front cover 3 to the display part 2 so as to prevent the hinge cover 40 from detaching from the display part 2 . [0052] FIG. 7A is a partially enlarged perspective view which illustrates the state of the stage before attaching a hinge cover 40 to a hinge device 4 which is attached to the display part 2 of the electronic apparatus 10 which is illustrated in FIG. 1A . In this state, the bracket 20 is already attached to the display part 2 . The pivot 33 of the hinge pivot member 30 is rotatably held by the rotatable holding parts 23 and 24 of the bracket 20 . Further, this state is the state where the hinge pivot member 30 is detached from the keyboard part of the electronic apparatus. The configuration of the hinge pivot member 30 has already been explained, so here only reference numerals will be attached to the members forming the hinge pivot member 30 and explanations will be omitted. Furthermore, reference numeral 9 which is illustrated in FIG. 7A is a screw hole which is provided at the housing 12 of the display part. [0053] FIG. 7B is a partially enlarged perspective view which illustrates the state where the hinge cover 40 which is illustrated in FIG. 7A is attached to the hinge device 4 , while FIG. 7C is a schematic cross-sectional view which illustrates the connected state of the hinge cover 40 and the housing 12 of the display part along the line B-B of FIG. 7B . Note that, FIG. 7C illustrates only the positional relationship of the hinge cover 40 and the housing 12 of the display part. Illustration of the pivot 33 of the hinge device 4 is omitted. The hinge cover 40 is attached to the pivot 33 by the pivot mounting plate 43 which was explained in FIG. 5A to FIG. 5D . In this state, the screw hole 9 and the circular hole 32 of the hinge cover 40 are not centered with each other and the engagement tab 44 of the hinge cover 40 is not inserted in the engagement hole 12 H at the housing 12 of the display part. [0054] FIG. 8A is a partially enlarged perspective view which illustrates the state of sliding the hinge cover 40 from the state of FIG. 7B along the pivot 33 of the hinge device 4 in the direction illustrated by the white arrow L to engage with the housing 12 of the display part. Further, FIG. 8B is a schematic cross-sectional view which illustrates the connected state of the hinge cover 40 and the housing 12 of the display part along the line C-C of FIG. 8A . FIG. 8B also illustrates only the positional relationship between the hinge cover 40 and the housing 12 of the display part. Illustration of the pivot 33 of the hinge device 4 is omitted. In this state, the screw hole 9 and the circular hole 32 of the hinge cover 40 are centered with each other and the engagement tab 44 of the hinge cover 40 is inserted in the engagement hole 12 H at the housing 12 of the display part. Therefore, in this state, the hinge cover 40 is engaged with the engagement hole 12 H at the housing 12 of the display part by the engagement tab 44 , so will not detach. [0055] FIG. 8C is a partially enlarged assembled perspective view which illustrates the process of attachment of the front cover 3 to the display part 2 which is illustrated in FIG. 8B . The position of a projecting piece 7 which is provided at the frame of the front cover 3 matches the position of the space 45 at the hinge cover 40 after sliding which is illustrated in FIG. 8A . Therefore, if attaching the front cover 3 to the display part 2 , the projecting piece 7 is inserted into the space 45 of the hinge cover 40 . [0056] FIG. 9A is a partially enlarged perspective view which illustrates the state where the front cover 3 which is illustrated in FIG. 8C is attached to the display part 2 , while FIG. 9B is a schematic cross-sectional view which illustrates the connected state of the hinge cover 40 and the housing 12 of the display part along the line D-D of FIG. 9A . As explained in FIG. 6 , the width of a projecting piece 7 is a width enabling insertion with substantially no clearance into the space 45 at the hinge cover 40 . Further, if the projecting piece 7 is inserted into the space 45 , as illustrated in FIG. 9B , the projecting piece 7 enters the space 45 with no clearance and the through hole 8 which is provided at the projecting piece 7 is aligned with the screw hole 9 which is provided at the housing 12 of the display part. [0057] FIG. 9C is a partially enlarged perspective view which illustrates the state where a screw 6 is passed through the through hole 8 of a projecting piece 7 which is provided at the front cover 3 which is illustrated in FIGS. 9A and 9B and screwed to a screw hole 9 which is provided at the housing 12 of the display part. Further, FIG. 9D is a schematic cross-sectional view which illustrates the connected state of a hinge cover 40 and the housing 12 of the display part along the line E-E of FIG. 9C . The screw 6 may be engaged with the through hole 8 of the projecting piece 7 through the circular hole 42 of the hinge cover 40 and screwed with the screw hole 9 through the circular hole 42 by a screwdriver. In this state, the screw 6 is used to prevent the front cover 3 from detaching from the housing 12 of the display part. The hinge cover 40 does not move since the projecting piece 7 enters the space 45 with no clearance. Accordingly, the hinge cover 40 is held in a state connected to the housing 12 of the display part and will not detach from the housing 12 of the display part. [0058] FIG. 10A is a perspective view which illustrates the appearance of the display part 2 , standing alone, which illustrates the state of the display part 2 to which the hinge devices 4 have been attached through the process of FIGS. 7A to 7C to FIGS. 9A to 9C to which, further, the hinge covers 40 and front cover 3 are attached. Further, FIG. 10B is a partial cross-sectional view which illustrates the position of a hinge cover 40 in the electronic apparatus 10 which is provided with the hinge devices 4 which are illustrated in FIGS. 4A and 4B . In this way, the display part 2 in the state with the hinge covers 40 being used to cover the hinge devices 4 can be detached from the keyboard part of the electronic apparatus. If attaching the display part 2 to the keyboard part, the hinge covers 40 are fit in the slots 15 which were explained in FIGS. 3A and 3B . Further, at the time of inspection of the display part 2 , if detaching the display part 2 from the keyboard part and inserting a screwdriver into the circular holes 42 to remove the screws, the front cover 3 can be detached. [0059] With the structure of the hinge device explained above, it is possible to remove the keyboard cover by just detaching the screws in the hinge covers. When desiring to detach a hinge cover, it is possible to detach the hinge cover by just removing the screw and sliding off the hinge cover. As a result, it is possible to maintain the disassembly ability of the electronic apparatus while realizing prevention of detachment of the hinge covers etc. The reliability of the electronic apparatus also rises. Further, the hinge covers are easy to attach to and detach from the hinge devices and will not detach at the time of use by the user. Further, using such hinge devices, it is possible to realize an electronic apparatus which is provided with pivot structures which are easy to disassemble and assemble at minimal cost. [0060] Note that, in the embodiments which are explained above, the projecting pieces 7 which are formed at the frame 3 f of the front cover 3 are provided with through holes 8 , and the front cover 3 is screwed to the screw holes 9 which are provided at the housing 12 of the display part by screws 6 which are inserted into the through holes. However, the front cover 3 can be attached to the housing 12 of the display part at other locations and the projecting pieces 7 which are formed at the frame 3 f of the front cover 3 can be given only the function of restricting movement of the hinge covers and the through holes 8 omitted. In this case, the front cover 3 may be provided with mounting pieces which are provided with mounting holes in addition to the projecting pieces 7 and screws which are passed through the mounting pieces may be used to screw them to the screw holes which are provided in the housing 12 of the display part 2 . [0061] Furthermore, if changing the shapes of the mounting parts of the brackets of the hinge units and the mounting parts of the hinge pivot members, the brackets can be attached to the keyboard part side and the hinge pivot members can be attached to the display part side. [0062] Although only some exemplary 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 embodiments 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.
A hinge device which rotatably connects a display to a keyboard part comprised of a hinge pivot member which attaches the keyboard part and a bracket which is attached to the display and holds the hinge pivot member and of a hinge cover, wherein if making the bracket hold the hinge pivot member, then attaching the hinge cover to the pivot of the hinge pivot member and making it slide in the axial direction to engage it with the housing of the display part and attaching the front cover to the display part in this state, a projecting part which is provided at the front end part of the front cover is inserted in the hinge cover and return of the hinge cover in the axial direction is prevented, so the front cover and hinge cover can be simply removed at the time of maintenance of the display part.
8
[0001] This application claims the benefit of U.S. Provisional Application No. 61/564,702, filed Nov. 29, 2011. TECHNICAL FIELD OF THE INVENTION [0002] The present invention relates to food patty-molding machines. The invention particularly relates to food patty-molding machines which incorporate a moving old plate having one or more patty-forming cavities which are filled to form patties, and then emptied by action of one or more knockout plungers, the patties being discharged to a patty-receiving area. BACKGROUND OF THE INVENTION [0003] Food patty-forming or molding machines are described, for example, in U.S. Pat. Nos. 7,255,554; 8,011,914; 6,454,559; 6,368,092; 3,887,964; 4,372,008 and 4,821,376. A known food patty-forming machine or apparatus 20 is illustrated in FIG. 1 . This machine is described in detail in U.S. Pat. No. 3,887,964 and has been marketed as the FORMAX F-26 machine by Formax, Inc., of Mokena, Ill. Molding machine 20 includes a machine base 21 which supports the operating mechanisms of the machine and contains hydraulic actuating systems, electrical actuating systems, and most of the machine controls. [0004] The food patty-molding machine 20 includes a supply mechanism 24 for storing and supplying a moldable food product ; such as ground beef, fish, pork ; chicken, potatoes, or the like, to the processing mechanisms of the machine. Supply mechanism 24 includes a large food product storage hopper 25 that supplies a food pump system 26 . System 26 includes two alternately operating food pumps (one shown); other machines typically include only a single food pump. The two food pumps continuously pump food, under pressure, into a valve manifold connected to a cyclically operable molding station 28 . Molding station 28 includes a multi-cavity mold plate 32 that moves cyclically between a fill position, as shown in FIG. 1 , and a discharge position ire which its mold cavities are outside of station 28 , aligned with a set of plungers having patty-displacing end portions in the form of knockout cups 33 . The cups are sized and shaped to be slightly smaller than, but to closely conform to, the cavities in the mold plate. [0005] Food supply mechanism 24 includes a conveyor belt 31 that extends completely is across the bottom of hopper 25 . In FIG. 1 , a limited supply of food product 38 is shown in hopper 25 ; a much greater supply could be stored in the hopper without exceeding its capacity. The forward end of hopper 25 communicates with a vertical hopper outlet 39 that leads downwardly into two pump chambers; only one pump chamber 69 is shown. Three motors drive three vertical feed screws. Only one motor 47 and one feed screw 3 are shown in FIG. 1 . [0006] The upper part of a pump housing 71 comprises a plate 81 that supports the mold plate 32 . The mold plate 32 includes a plurality of individual mold cavities 86 distributed in a single row or multiple rows across the width of the mold plate; mold cavities 86 are alignable with the manifold outlet fill passage 79 . A mold cover 82 is disposed immediately above mold plate 32 , closing off the top of each of the mold cavities 86 . The mold cover 82 may include a conventional breather plate. Suitable spacers (not shown) are provided to maintain the spacing between the cover 82 and the support plate 81 , essentially equal to the thickness of the mold plate 32 . A housing 88 is positioned over the cover plate 82 . The housing 88 encloses the operating mechanism (not shown) for reciprocating the knockout cups 33 . [0007] In the operation of the patty-molding machine 20 , a supply of ground meat or other moldable food product 38 is placed into the hopper 25 , and is advanced toward the hopper outlet 39 by the conveyor 31 . Whenever one of the food pump plungers, such as the plunger 68 , is retracted to expose a pump cavity (e.g., the cavity 69 ), the vertical feed screws 53 aligned with that pump cavity are actuated to feed the food product into the pump cavity. [0008] In FIG. 1 , pumping system 26 is illustrated with the mold plate 32 in its fill position, and with the pump 61 pumping the moldable food product through the manifold 27 . The pump 61 , as shown, has just begun its pumping stroke, and has compressed the food product in pump cavity 69 , forcing it under pressure into the manifold 27 . As operation of the machine 20 continues, the plunger 68 advances and food product flows into the mold cavities 126 , there is a relatively constant pressure on the food product and chamber 69 , manifold 27 , fill passage 79 , and cavities 86 . [0009] In each molding cycle, mold plate 32 remains in this fill position for a limited dwell interval. As the mold cavities 86 move into the fill position, one of the two food pumps of machine 20 pumps food product through manifold 27 and fill passage 79 , filling the mold cavities. To assure complete filling of the mold cavities, the food pump must apply a substantial pressure to the food product. [0010] Following the fill dwell interval, mold plate 32 is moved outwardly, to the right from its fill position, as shown in FIG. 1 , until it reaches a discharge position with its mold cavities 86 aligned with knockout cups 33 . As mold plate 32 moves toward its discharge position, mold cavities 86 all move dear of fill passage 79 before any part of those cavities projects out of mold station 28 , beyond support plate 81 and cover 82 . Thus, the food pump in machine 20 , as shown in FIG. 1 , remains sealed off at all times. A second dwell interval occurs at the discharge position of mold plate 32 , during which knockout cups 33 move downwardly through the mold cavities, discharging the molded food patties onto a patty-receiving area, e.g. a take-off conveyor (not shown). [0011] The knock out cups are typically concave cups each having a surrounding edge, typically 3/32 inch thick, which presses on an outside circular perimeter of the patty to dislodge the patty from the mold plate. [0012] Following discharge of the molded food patties, mold plate 32 is moved back toward its fill position so that mold cavities 86 can again be filled with food product. Again, mold cavities 86 are completely inside molding mechanism 28 , sealed off, before they come into alignment with the fill passage 79 . [0013] For some food products a radiant heating element (not shown in FIG. 1 ) is used to heat the knockout cups 33 to an elevated temperature of between 180-210° F. in order to liquefy the fat in the food product, thereby facilitating release of patties from the cups at the bottom of knockout cup travel. [0014] The present inventors have recognized that on occasion, depending on the product, the perimeter of the heretofore known knockout cup can cause an indentation on the perimeter of the patty which is visible after cooking. The present inventors have recognized that it would be desirable to provide a knockout plunger for a patty-forming apparatus that did not cause a visible irregularity in cooked patties. The present inventors have recognized that it would be desirable to provide a knockout cup for a patty-forming apparatus that was cost effectively produced and that would be durable in operation. SUMMARY OF THE INVENTION [0015] The present invention provides an improved plunger for a food patty-forming apparatus having a mold plate with mold cavities adapted to be filled with food product to form patties, wherein the patties are removed from the cavities by action of the plunger. Preferably, the patty-displacing end portion has a perimeter that closely matches an inside perimeter of the cavity. The improved plunger includes plural, spaced-apart raised portions or standoffs on a bottom surface thereof that press on a top surface of the patty to dislodge the patty from a mold plate. [0016] The standoffs have sufficient surface area to minimize surface pressure on the patty to avoid indentations or alternately, leave spaced-apart isolated indentations that visually blend into the typical irregular texture of the patty product. [0017] Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0018] FIG. 1 is a diagrammatic sectional view of a prior art food patty-molding machine; [0019] FIG. 2 is a diagrammatic fragmentary perspective view of a portion of a food patty forming machine incorporating the improvement of the present invention; [0020] FIG. 3 is a diagrammatic sectional view of a food patty-forming apparatus according to the present invention, with the apparatus mold plate in a knockout position; and [0021] FIG. 4 is a bottom perspective view of a plunger taken from FIG. 3 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0022] While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated. [0023] FIG. 2 illustrates a modified food patty-forming apparatus 120 of the present invention. Except as otherwise described herein, the apparatus 120 can be of a reciprocating type such as described in U.S. Pat. Nos. 7,255,554; 8,011,914; 6,454,559; 6,368,092; 3,887,964; 4,372,008 and 4,821,376, herein incorporated by reference, or a rotary type as described in U.S. Ser. No. 13/187,426, filed Jul. 20, 2011. Like components compared to the components of the prior art apparatus of FIG. 1 carry like reference numerals. [0024] The apparatus 120 includes a mold plate 32 that moves cyclically between a fill position as shown in FIG. 1 and a discharge or knockout position as shown in FIG. 3 . In the discharge position, a row of food patties 130 which occupy mold cavities 86 within the mold plate 32 , are discharged by downward movement of a row of knockout plungers 133 . The food patties 130 can be delivered to a take-off conveyor 135 such as shown in FIG. 3 . [0025] FIG. 2 illustrates a knockout mechanism 140 that includes two knockout drive units 142 , 144 . The drive units 142 , 144 can be configured in various known fashions such as those described in U.S. Pat. Nos. 7,255,554; 8,011,914; 6,368,092; 4,768,260; or 3,887,964, or U.S. Ser. No. 13/187,426, filed Jul. 20, 2011, all herein incorporated by reference. Each drive unit 142 , 144 can include a rod housing 145 within which a reciprocating knockout rod 147 is at least partially enclosed. Each knockout rod 147 can be fastened to a knockout bar assembly 148 . [0026] A plurality of knockout support blocks 150 are mounted to a bottom side of the bar assembly 148 spaced apart along a length of the bar assembly. Each block 150 mounts one of the plurality of the knockout plungers 133 . The number and spacing of knockout plungers 133 corresponds to the number and location of the plurality of the cavities 86 , that are arranged in rows across a width of the mold plate 32 . [0027] A radiant electric heater 160 circumscribes the two knockout rods 147 and is located at an elevation approximately equal to the bar assembly 148 when fully elevated at the top of its reciprocating stroke. A heat deflector shield or hood 162 (shown in fragmentary fashion in FIG. 3 ) directs heat from the heater 160 to the plungers 133 . The heater 160 is configured to heat the knockout plungers to an operating temperature of 180-210° F. depending on the food material being formed in order to assist in dislodging of the patties from the mold plate and to prevent sticking to the plungers. A rheostat (not shown) is wired to the heater element 160 to manually set the temperature of the plungers 133 . A more sophisticated control system using a temperature sensor and an automatic adjustment can also be used. [0028] FIG. 3 illustrates the apparatus 120 with the mold plate 32 in the discharge or knockout stage or position. The knockout plungers 133 are shown in a downward position, having just discharged patties 130 from cavities 86 respectively. The patties 130 can be deposited on the product conveyor 135 to move to a collection area for packaging. [0029] FIGS. 3 and 4 illustrate the configuration of the plungers 133 . According to one embodiment of the invention, the plunger 133 can be composed of aluminum with a USDA compliant coating, or acetyl copolymer or stainless steel. The acetyl does not need a coating. The stainless steel version could be used with or without a coating. The plunger 133 includes a plunger body 220 . Each plunger 133 can be fastened to the respective support block 150 using a pair of fasteners 166 that are inserted through holes 222 , 224 through the body 220 . [0030] The size and shape of the plunger body 220 is in direct relation to the patty size. Depending on the size of the product to be knocked out, the plunger body 220 could be as small as 2 inches in diameter or as large as 4 inches by 6 inches. A circular disc shaped plunger body 220 is shown in the figures. [0031] A plurality of raised formations, such as pins or standoffs 230 extend downwardly from a bottom surface 234 of the body 220 . Each raised formations or standoff 230 has a flat distal surface 230 a. According to the illustrated embodiment, each raised formation 230 is in the form of a tapered post or pin that is tapered from a base end 230 b on the body 220 to the distal end 230 a. The base end 230 b can be mounted on, formed with, or connected to ; a reinforcing pad 230 c on the bottom surface 234 of the body. During knockout of a product from the mold plate, the body is moved downward to the mold cavity and the flat distal surfaces 230 a of the plural standoffs 230 push the patty from the mold plate. The raised formations or standoffs 230 are numbered such that the aggregate surface area of the distal surfaces 230 a decreases the contact pressure by any one of the standoffs 230 during pressing of a patty to dislodge the patty from the mold plate. Additionally, the number and spacing of the standoffs 230 over the surface of the body 220 are such that any surface mark caused by the standoffs on the patty being dislodged will be hardly noticeable given the typical irregular texture of the patty material. [0032] Traditional cups impact the product just inside of the mold cavity edges around the entire perimeter of the cavity. Since products are typically softer around the edges, the knockout cups can leave an impression in the product due to the force of the impact. The impact impression can be unattractive to some customers. By using spaced-apart standoffs 230 the knockout force is dispersed throughout more of the product top surface. In some applications, the standoffs can be spaced inward from the perimeter of the product to be knocked out by 1/16 inch or greater to prevent damage to the softer surrounding edge of the product to be knocked out. Also, traditional cup-shaped knockout cups, with contact only around the perimeter of the portion to be knocked out, allow the center of the portion being knocked out to bulge up into the empty center space of the knockout cup, causing negative effects such as stretching and/or cracking, especially on thin portions. The standoff locations inward of the perimeter of the knockout cup could prevent this bulging effect, allowing the patty to remain flatter throughout the knockout process. Although a flat disc shaped body 220 is shown, the standoffs 230 may also be used together with the existing ::perimeter“” or cup design to provide effective knockout with minimal portion marking and/or distortion. According to this design, multiple standoffs within the traditional knockout cup, and the perimeter of the knockout cup both knock out the product. [0033] The number of standoffs 230 would be determined by multiple variables such as portion weight, portion thickness, product density and product texture. A minimum number of standoffs would be desired in order to minimize the contact area with the product yet provide effective knockout. [0034] When the area of the bottom surface 234 is substantially equivalent to the top surface of the patty to be knocked out, an exemplary range of aggregate surface area of the distal surfaces 230 a to the gross area of the bottom surface 234 , which includes the area occupied by the pins 230 and pads 230 c, can be between 1% and 10%. Stated another way, an exemplary range of aggregate surface area of the distal surfaces 230 a to the area of a top surface of the patty to be knocked out, can be between 1% and 10%. The standoffs 230 can be spaced apart evenly on the bottom surface 234 or can be spaced apart unevenly depending on the product properties and test results. Advantageously, the height of the standoffs 230 on a given plunger are such that the distal surfaces 230 a reside in a single plane, although the invention encompasses standoffs of varying heights and residing in multiple planes in a single plunger. Where the standoffs extend from a single planar bottom surface 234 , an equal standoff height “h” defines a single plane for the distal surfaces 230 a. According to exemplary embodiments, a height “h” of the single plane of the aggregate distal surfaces 230 a of the standoffs 230 could vary between about 1/16 inch for some knockout applications to about 2 inches for other knockout applications. The reason for the height range is that the plunger body can act as a deflector, shielding the product to be knocked out from heat and moisture. In cases where this deflecting action is desired, very short standoffs would be used in order to get the plunger disc very dose to the product to be knocked out. In other cases where the deflecting action is not desired, longer standoffs can be used to move the plunger disc away from the surface of the product to be knocked out. According to exemplary embodiments, the number of standoffs can vary with an anticipated density of 1 to 10 standoffs per square inch of the top surface of the product to be knocked out. [0035] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred.
A patty-displacing end portion is provided for a plunger for a food patty-molding apparatus, the apparatus comprising an apparatus frame, a mold plate, the plunger and a heating element. The mold plate has at least one cavity and is mounted to move with respect to the frame in a direction to position the cavity between a fill position wherein the cavity is filled with food product material to form a molded patty, and a molded patty knockout position. The plunger is arranged to move vertically into the cavity to dislodge or knock the olded patty out of the cavity. The plunger has a body and raised formations or standoffs extending down from the body, the raised formations being numbered and positioned to be spread out over the body. The number and position of the raised formations provides a decreased contact pressure on the patty being dislodged.
0
FIELD OF THE INVENTION The present invention relates to a device for balancing a rotating body during rotation. BACKGROUND As an example of such a body there may be mentioned, above all, the rotors of large machines, for example turbo-machines or electric machines. Such rotors are usually balanced first of all in the manufacture and thereafter in connection with the erection at the place where the machine is to be used, and then in both cases normally by means of weight balancing, correction balances being placed at appropriate places. This procedure is time-consuming and expensive and does not always lead to a satisfactory result in the case of machines with great susceptibility to unbalance. This is true in particular if the unbalance is due in a minor degree on a real mass unbalance, but more to a deformation of the rotor, in which case weight balancing often does not give good results. In addition, the rotor may change with time, and also the pressure on the rotor may cause a change in balance. The art also evidences devices to selectively cut away small portions of the rotating body so as to counteract unbalance. See U.S. Pat. No. 3,499,136 and corresponding thereto U.K. Pat. No. 1,178,337. To be able to satisfy high demands on the balance of a rotary machine it would therefore be desirable to be able to perform an after-balancing of the rotor during operation, and according to the invention a device for this purpose is proposed according to the appending claims. SUMMARY OF THE INVENTION The invention is based on an unsymmetrical, local heating of the rotor, which is to be bent as a result of the heating so that the unbalance is counteracted. More particularly, the phase and magnitude of any unbalance is detected and an energy source supplies energy pulses to the rotating body for local asymmetric heating to cause thermal deformation of the axis of the body without removing or adding material from or to the body. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in more detail with reference to the accompanying drawings, in which FIG. 1 shows a machine with a device according to the invention, FIG. 2 showing a detail of FIG. 1, FIG. 3 shows a diagram of the vibration of the rotor and the energy pulses fed to the rotor, and FIG. 4 shows the device according to the invention applied to a more complicated machine plant. DETAILED DESCRIPTION FIG. 1 shows a rotary machine with rotor 1, a shaft 2 and bearings 3, the stator of the machine being omitted for the sake of simplicity. For indication of a possible unbalance in the rotor in operation there are arranged sensing members 4 which, as shown, may be inductive or electro-magnetic transducers sensing the variation in the distance between the shaft 2 and the members 4, as indicated in FIG. 3. Instead of electro-magnetic transducers it is possible to use capacitive transducers or optical transducers which may operate, for example, according to the echo method by means of light pulses reflected from the surface of the shaft. Instead of sensing the deflection of the shaft it would be possible to build in pressure-sensitive transducers in the bearings 3 or in connection with the oil film of the bearings. There are different types of such transducers to choose from depending on what signal processing is preferred. The essential point is that transducers are used which are able to emit distinct signals in clear synchronism with the rotor and with a magnitude which reflects the degree of the unbalance. In order to compensate for the unbalance, according to the invention, the rotor is asymmetrically heated at appropriate places while in operation, which thus means that the rotor is to be supplied with energy pulses synchronously with the rotation so that the asymmetric heating causes a deformation which counteracts the unbalance. To achieve such an asymmetric heating it is necessary to have an energy source capable of conveying distinct pulses with a sufficiently high energy and with a short duration synchronously with the rotation of the rotor. As such an energy source there may be used a high-frequency generator 5 which is controlled by a control device 7 and feeds energy pulses through a coil 6 to pre-selected places on the shaft 2. The location and construction of the high-frequency coils 6 depend partly on how the shaft and the rotor may be expected to become deformed at the operating speed, partly on where it will be possible to place the coils, and also on how the rotor or the shaft can be affected by the heat influence. This, in turn, may depend on whether the rotor or the shaft is ferromagnetic, electrically conducting or electrically insulating. The drawings, which show the coils 6 adjacent shaft 2 are intended to generally depict heating of the rotating body. Thus the invention contemplates heating either the rotor 1, shaft 2, or both. FIG. 2 shows in axial section how the member 4 and the coil 6 can be located in relation to the shaft 2. FIGS. 1 and 2 further indicate an angle reference system 9, 10, comprising a marking point 9, for example a boss on, or a hole in, the shaft 2 and a sensing member 10 which may be of the same type as the member 4. The signals from the members 4 and 10 are supplied to a signal transducer 8 for the control device 7, the energy pulses thus being supplied to the coil 6 with a correct phase position in relation to rotation of the rotor. Thus the transducer 8 may well include a transducer per se to convert the output of members 4 and 10 to suitable electrical signals, a pulse shaper and a delay circuit as shown, for example in U.K. Pat. No. 1,178,337. The delay may be manually adjustable, as shown in the referenced patent. In addition, a divider may optionally be included, as mentioned below. The control device 7 can be implemented in the form of a switch to start or stop the generator 5 at appropriate times, or to control the phase and amplitude of the output of generator 5 both as shown in FIG. 3. To attain the asymmetric heating, the energy pulses are controlled in time with the rotation of the rotor. This can be done either by amplitude modulation or by pulse modulation, which are both shown in FIG. 3. The first line in FIG. 3 indicates the signal p4 from the member 4, i.e., the variation of the unbalance. The second line indicates the pulses p10 from the member 10, the phase position θ of the amplitude of the unbalance thus being defined. Through the angle θ and the angle between the member 4 and the coil 6, the desired phase position φ of the energy pulses can be determined. Often it may be desirable to make a manual adjustment of φ within a precalculated range in order to achieve an exact balance. The degree of asymmetrical supply of heat is then determined by the amplitude A of the modulation or the duration α of the pulse, respectively, as indicated in lines 3 and 4 of FIG. 3. The values of A and α as well as φ are controlled by means of the control device 7. A, α, and φ are selected based on the amplitude δ and phase angle θ of the vibrations. How the relations between A, α and δ and φ and θ are to be chosen may in exceptional cases be determined by a theoretical analysis, but must in general be determined by tests. Generally the heating should be applied to an area centered 180° out of phase with the unbalance. However, to determine φ it is also necessary to take into account the time constants of the circuits and the thermal transmission characteristics of the heating system. If, during heating, θ changes, the phase angle φ should be altered in the opposite sense, by an equal amount. If, on the other hand, θ does not change, then φ should also remain constant, if δ is reduced by the application of heat. If δ grows then φ must be changed 180°. In either event α or A should be maintained or increased until δ is reduced to zero. Where the control pulses take the form shown in the fourth line of FIG. 3, the frequency of the pulses may be the same as that of the signal pulses, i.e., p4 or a sub-multiple thereof. In the latter instance, heat would only be applied 1 out of n revolutions where the frequency of the control pulses was 1/n the frequency of the signal pulses. This can be implemented by using a 1/n divider in the control device 7. Instead of a high-frequency generator as the energy source, it would be possible to have any energy source which is able to supply controlled, energy-rich pulses with the desired frequency and phase position. As a very simple energy source, particularly at lower speeds of rotation, it would be possible to use a welding torch controlled by a rotating or oscillating diaphragm. As one further extremity a laser beam might be used, which is able to fulfill the highest demands both with regard to energy and controllability. In principle, the phase position of the energy pulses over the coils 6 could be determined directly in relation to the signals from the members 4, in which case the reference system 9, 10 could be omitted. However, the purpose of the arrangement according to the invention is to balance out the vibrations completely so that the signals from members 4 fall away. Then in order to maintain the balance, the phase position and magnitude of the energy pulses must be secured by providing the transducer 8 with some kind of memory device which records the original phase position θ of the signals from member 4 in relation to the reference system 9, 10. For this reason, and possibly also to be able to point out the phase position of the unbalance after stopping, the reference system 9, 10 is desirable. In FIGS. 1 and 2 there are indicated connections for transmitting signals from transducer 8 to control device 7. It is within the scope of the invention to employ manually made connections between transducer 8 and control device 7 so that, for example, balancing in the proper sense is assured when a newly installed plant is started up for the first time. FIG. 4 shows as an example a more complicated machine plant comprising the connected rotors for a high-pressure turbine HT, a number of low-pressure turbines LT and a generator G. In such a case there are a great number of bearings 3, and therefore the unbalance must be measured by members 4 in so many places as are required to have a desirable survey of any unbalance. Furthermore, heating coils 6 or similar energy pulse devices must be located at such places where a local heating may provide a desired compensation for the unbalance. To achieve a correct signal processing, the signal transducer 8' in such a case should be constructed as a programmed arithmetic unit of a minicomputer type or the like, so that the control device 7' is able to achieve proper distribution of the energy pulses from the high-frequency generator 5'.
A balancing device and method for balancing a rotating body during operation. The device and method detects the phase and amount of unbalance and provides signals in synchronism with the unbalance. Local heating of the rotating body is provided to counteract the unbalance by thermal deformation of the axis of the body without removing material. The phase and amount of the local heating are controlled in relation to unbalance detected.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a cap for a beverage container and more particularly, to a drink mix dispensing apparatus adapted to store and controllably release selected drink mix ingredients from a plurality of compartments in order to combine with the out flow of the beverage as it is poured out. 2. Description of Related Art Pre-mixed flavored or fortified drink beverages are commonly available and sold in grocery and convenience stores. Drink beverages are composed primarily of water. Beverage container caps are well known to prevent the contents of a beverage container from escaping. In addition to pre-mixed flavored or fortified beverages, concentrated mixes are available for preparing flavored or fortified beverages. These mixes are commonly in the form of powder or concentrated syrup. To prepare a flavored or fortified beverage from concentrated syrup or powder, a large container such as a pitcher is commonly filled with water and the powder or syrup is mixed with the water in the container. A large container is commonly used to prepare multiple servings of the beverage so that the effort required to prepare the beverage is conserved. The prepared beverage is then poured into a glass or other drinking container and consumed. To prepare a flavored drink, a flavored liquid syrup or powder must first be mixed with water in a container. The contents of the container are poured out and the flavored drink is consumed. To create a different-flavored drink, the same steps must be repeated with a different-flavored mix. A different flavored drink can be mixed in a separate container or can be mixed in the same container after the previously mixed drink has been consumed. The above method of preparing one flavored beverage after another is time consuming and requires the user to use a container, then re-use the container only after its contents have been emptied. When a consumer wishes to purchase different flavored drinks, whether it is different flavored sodas, i.e. cherry soda or orange soda, or different flavored non-carbonated drinks, he or she must purchase each desired flavor. This proves to be quite costly. In families where there is a diversity of drink favorites, it becomes extremely costly to purchase drinks or sodas to please every family member. In today's health conscious world, herbal and vitamin supplements are in vogue. Many of these supplements are water-soluble and dissolve easily in water, juice or tea. However, it would be cumbersome to add a supplement to a container of water, juice or tea, empty the bottle of its contents, consume the mixture and then re-fill the container again with water, juice or tea so a different supplement can be added. What is needed is a drink mix bottle cap dispenser that can be easily attached to a liquid-holding container, and which contains compartments, each housing a different flavored syrup, liquid and/or powder, or a different vitamin and/or herbal supplement, where the user can simply select a flavor or supplement and tip the bottle over so the flavored mix or supplement from the selected container mixes with the liquid to instantly form a flavored drink or soda, or a vitamin-fortified drink. If any contents are remaining in the container, the process can be repeated for a different selection, or the cap can be easily and quickly removed, the beverage replenished, the compartments refilled with drink mixes, or a new cap reattached and the process repeated. A virtually unlimited number of flavored drinks or herbal-fortified beverages can be produced thereby eliminating the need to purchase different flavored beverages. BRIEF SUMMARY OF THE INVENTION The present invention provides a beverage cap adapted to be removeably secured to the open end of a liquid-holding container that stores a plurality of concentrated mixes in separate compartments within the cap, which are selectively dispensed and combined with the outflow of the liquid stored in the container thereby producing a variety of liquid-concentrated mix combinations. In the preferred embodiment, the liquid within the container is a drinkable beverage, such as water or carbonated water, and the concentrated mixes are different flavored liquid or powdered mixes, or different herbal or vitamin supplements. In an alternate embodiment, the mixes could each be a different type of oil. A cap dispenser for use with a beverage container, which separately stores concentrated beverage mixes that are selectively released and combined with the outflow of the drinkable liquid contained in the beverage container. The resealable cap stores concentrated beverage mixes which are selectively dispensed within the outflow of the beverage container when the liquid is being poured out so that different flavored or vitamin fortified drinks are produced. The resealable cap includes a base, a selector disc and a head assembly. The base is substantially cylindrical in shape with a top end, a bottom end, an inside surface and an outside surface. The bottom end is open and the inside surface is tapered in diameter from the bottom end to the top end so that at the bottom end the inside surface is substantially the diameter of the base and towards the top end the diameter is reduced so that a bottle aperture is formed. The inside surface of the bottle aperture is sized to accommodate the mouth of a conventional beverage container and is adapted with bottle threads to engage the mouth of a conventional beverage container. The threaded mouth of a conventional bottle is inserted into the bottom end of the base and is rotated upon engaging the bottle threads of the flow aperture until fully engaged and sealed. Within the base are a plurality separate compartments which hold concentrated mixes. Each compartment is tapered in shape to conform to the tapered shape of the inside surface of the base. A circular selector platform is disposed upon the base. The selector platform is adapted with six pairs of radially disposed alignment dimples and inner and outer circular ring channels. The inner circular ring channel surrounds the bottle aperture. The outer ring channel is positioned so that it separates pairs of alignment dimples. Compartment apertures are positioned within three pairs of alignment dimples so that compartment apertures alternate in occurrence within alignment dimple pairs. Each pair of compartment apertures open into a corresponding compartment. A selector disk rotatably engages the selector platform. The selector disk is adapted with six pairs of radially disposed raised alignment flanges which are equally spaced apart along the bottom surface of the disk so that they may properly engage corresponding dimples located on the selector platform. Each pair of alignment flanges corresponds with a pair of alignment dimples so that when the selector disk engages the selector platform the corresponding alignment flanges engage the corresponding alignment dimples. The bottom surface of the selector disk is also adapted with a pair of raised circular ring tracks. The ring tracks are positioned so that when the selector disk engages the selector platform the corresponding tracks of the selector disk engage the corresponding channels of the selector platform. The selector disc includes apertures, which allow access to the drink fluid of the attached bottle and the concentrated drink mixes contained within the compartments. A hollow flow spout extends from the top of the selector disc towards the outside perimeter of the selector disc. A mix spout extends from the top of the selector disc and is connected to the lower portion of the flow spout thereby allowing the selected drink mix to combine with the drink beverage. A vacuum spout extends from the top of the selector disc in the opposite direction of the flow spout to allow for unimpeded flow of the combined liquid and concentrated mix. A head assembly holds the selector disk in engagement with the selector platform of the base. The head assembly is formed by a substantially cylindrical body and a top. The top of the head assembly is adapted in shape to receive the selector disc so that the flow spout is exposed through a pour aperture. When the head assembly fully engages the base, the raised ring tracks of the selector disc engage the cooperating ring channels of the selector platform and corresponding alignment flanges engage of the selector disc engage alignment dimples of the selector platform. In use, the head assembly and selector disc enclosed therein are rotated in relation to the base. While rotating, the head assembly snaps into six unique positions that are created when the alignment dimples of the selector platform and the raised flanges of the selector disc engage. Each position is unique and is identified by indicator markings on the outside of the base and which are revealed through one or more windows in the head assembly as the head assembly is rotated into different positions. Each position causes the alignment of apertures within the selector disc with respect to the selector platform to change. A closed position causes all apertures to be closed and sealed so that neither the bottle's liquid contents or the concentrated mixes can escape. To pour out the contents of the attached container, the head assembly is rotated to one of the five positions that do not completely seal the container. The container is then simply tipped over so that gravity causes the bottle contents to flow out through the bottle aperture of the base through the flow spout. When a drink blended with a concentrated mix is desired the head assembly is rotated so that the aperture within the selector disc opens into the compartment containing the desired drink mix and as the container is tipped over the desired drink mix contained in the corresponding compartment are allowed to combine with and flow out along with the bottle contents. The concentrated mix is blended with the bottle contents within the outflow so that a flavored or fortified drink is formed as the container's contents are being poured out. To prepare a different-flavored drink, the head assembly is simply rotated so that the compartment containing the desired concentrated mix is selected and the contents of the container is blended with the concentrated mix as it is being poured out. Another position can be selected to release the bottle's liquid contents, i.e. plain water or carbonated water, tea or juice, without releasing any of the drink mixes, thereby releasing only the bottle's contents, i.e. water, tea or juice. In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS FIG. 1 is a top exploded perspective view of the drink mix dispensing apparatus of the present invention. FIG. 2 is a bottom exploded perspective view of the drink mix dispensing apparatus of the present invention. FIG. 3 is a side view showing the drink mix dispensing apparatus in use. FIG. 4 is a front view showing the drink mix dispensing apparatus of the present invention affixed to a conventional beverage container. DETAILED DESCRIPTION OF THE INVENTION Referring now to FIG. 1, an exploded view of the drink mix dispensing apparatus of the present invention is illustrated. The invention includes a base assembly 100 , a selector disc 200 and a head assembly 300 which together form a dispensing cap 10 used to seal a conventional beverage container 20 which contains a liquid drink as seen in FIGS. 3 and 4. Container 20 can be off-the-shelf two-liter bottles, 500 ml bottles and other bottles or cans offered for sale containing soda, juice, water, carbonated water and other beverages. In the preferred embodiment, container 20 is a conventional water or soda bottle with a threaded spout. Base 100 is substantially cylindrical in shape with a closed top end 102 , an open bottom end 104 , a tapered inside surface 106 and an outside surface 108 as shown in FIGS. 1 and 2. Bottom end 104 is open and inside surface 106 is tapered in diameter from bottom end 104 to top end 102 so that at bottom end 104 , inside surface 106 is substantially the diameter of base 100 and towards top end 102 the diameter of inside surface 106 is reduced so that a bottle receiving aperture 110 is formed. Bottle receiving aperture 110 is sized to accommodate the mouth of a conventional beverage container 20 . Inside surface 106 is adapted in size to accommodate the top portion of container 20 . Inside surface 106 at bottle aperture 110 includes bottle threads 112 to engage corresponding threads on the mouth of conventional beverage container 20 . In use, the threaded mouth of container 20 is inserted into bottom end 104 of base 100 and is rotated upon bottle threads 112 until fully engaged and sealed within bottle aperture 110 as seen in FIGS. 3 and 4. Top end 102 is substantially flat forming a circular selector platform 120 . In FIG. 2, embedded within base 100 are three compartments 130 , 132 and 134 , which hold concentrated mixes (preferably liquid). Each compartment 130 , 132 and 134 is tapered in shape to conform to the tapered shape of inside surface 106 . In the preferred embodiment, three mix-holding compartments 130 , 132 and 134 , each containing a different flavored liquid drink mix or a different vitamin or herbal supplement, are embedded within base 100 . The concentrated drink mix combines with a liquid flowing out of the container to form a mixed liquid, preferably a drinkable mixed beverage. It is, however, within the scope of the invention to include either a greater or a fewer number of compartments, and for each compartment to house powdered or granular drink mixes, herbal or vitamin supplements, or various types of oils, each of which, when dispensed, combines with the liquid contents of the container as it exits the container. Circular selector platform 120 is disposed upon and is an integral part of base 100 . In the preferred embodiment, platform 120 is adapted with three pairs of spaced apart radially disposed alignment dimples 122 . Each pair of alignment dimples is comprised of a mix dimple 122 a and a vacuum dimple 122 b . Each mix dimple 122 a is positioned radially around bottle aperture 110 creating an interior circle. Each vacuum dimple 122 b is positioned adjacent and just outside a corresponding mix dimple 122 a . Each vacuum dimple 122 b is positioned radially along an outer circle, said outer circle encircling the inner circle formed by mix dimples 122 a . Both inner circle of mix dimples 122 a and the concentric outer circle of vacuum dimples 122 b , encircle bottle aperture 110 . Circular selector platform 120 is also adapted with inner and outer circular ring channels 124 a and 124 b . Inner ring channel 124 a surrounds bottle aperture 110 . Outer ring channel 124 b is positioned so that it separates each mix dimple 122 a from its corresponding vacuum dimple 122 b. Along with the alignment dimples 122 , and also disposed on the upper face of base 100 , are three pairs of compartment apertures 126 . Each pair of compartment apertures 126 is comprised of a mix compartment aperture 126 a and a vacuum compartment aperture 126 b . Compartment apertures 126 alternate in occurrence within pairs of alignment dimples 122 . Each pair of compartment apertures 126 open into a corresponding compartment 130 , 132 or 134 . Six alignment divots 123 are positioned radially between mix dimples 122 a and mix compartment apertures 126 a. Although both mix compartment apertures and vacuum compartment apertures open into a corresponding compartment, drink mix only flows out of mix compartment aperture, as can be seen more clearly in FIG. 3 . Due to gravity, the drink mix contents (indicated by the arrows) flow out of compartment 132 through mix compartment aperture 126 a as seen in FIG. 3 . Vacuum compartment aperture 126 b allows air to flow freely, facilitating the dispensing and flow of drink mix through mix compartment aperture 126 a into mix spout 246 . Selector disc 200 is a substantially flat, circular disk having a top surface 200 a and a bottom surface 200 b . Selector disc 200 and selector platform 120 are substantially the same diameter. Selector disc 200 rotatably engages selector platform 120 . Selector disc 200 is adapted with six pairs of radially disposed circular raised alignment flanges 210 which are equally spaced apart along bottom surface 200 b . Each pair of raised alignment flanges 210 is comprised of a mix flange 210 a and a vacuum flange 210 b which are sized to properly engage mix dimples 122 a and vacuum dimples 122 b respectively. Each pair of alignment flanges 210 corresponds with a pair of alignment dimples 122 so that when selector disk 200 engages selector platform 120 , corresponding alignment flanges 210 engage corresponding alignment dimples 122 . Additionally, selector disc 200 is adapted with a biased alignment finger 125 which projects from the bottom surface 200 b of disk 200 . Alignment finger 125 engages an alignment divot 123 located on base 100 , when corresponding alignment flanges 210 properly engage corresponding alignment dimples 122 . Bottom surface 200 b is adapted with raised inner and outer ring tracks 220 a and 220 b which correspond in position with the inner and outer ring channels 124 a and 124 b so that when selector disk 200 engages selector platform 120 , corresponding inner ring track 220 a engages inner ring channel 124 a and corresponding outer ring track 220 b engages ring channel 124 b thereby providing an additional sealing mechanism of disc 200 upon base 100 . Selector disc 200 provides apertures which allow access to the drink fluid contained in the attached bottle 20 and the concentrated mixes contained within compartments 130 , 132 and 134 . Referring to FIG. 2, a mix selector aperture 236 and a vacuum selector aperture 238 are positioned between a pair of alignment flanges 210 . One mix selector aperture 236 is positioned between one mix flange 210 a and one vacuum selector aperture 238 is positioned between a corresponding vacuum flange 210 b . Mix selector aperture 236 allows the out flow of the selected mix from its compartment via mix spout 246 when a selector aperture 236 is aligned directly over a compartment aperture 126 . This is accomplished by simply rotating the head assembly 300 , which in turn, rotates disk 200 upon base 100 . Vacuum selector aperture 238 allows for the transfer of air and the unimpeded flow of liquid mix through mix spout 246 . A bottle flow aperture 232 is disposed within inner ring track 220 a . A bottle vacuum aperture 234 is located inside inner ring track 220 a substantially adjacent to inner ring track 220 a and substantially opposite bottle flow aperture 232 . Three vacuum stopper dimples 235 are disposed inside inner ring track 220 a so that bottle vacuum aperture 234 and vacuum stopper dimples 235 form a circle around the center of selector disc 200 . A hollow flow spout 242 is disposed upon the top surface 200 a of selector disc 200 covering bottle flow aperture 232 . Flow spout 242 extends from the top of selector disc 200 towards the outer perimeter of selector disc 200 opposite mix and vacuum selector apertures 236 and 238 . Mix spout 246 is connected to the top surface 200 a of selector disc 200 covering mix selector aperture 236 . Mix spout 246 is connected at one end to top surface 200 a of selector disc 200 and at the opposite end to flow spout 242 . A vacuum spout 244 is connected to the top 200 a of selector disc 200 covering bottle vacuum aperture 234 and extends towards the outer perimeter of selector disc 200 in substantially the opposite direction of flow spout 242 . Vacuum spout 244 does not reach the outer edge of selector disc 200 . Vacuum spout 244 allows for the flow of liquids through and out of flow spout 242 . Vacuum spout 244 is bent towards the back of disk 200 away from and in the opposite direction of flow spout 242 so that when bottle 20 is tipped in pouring position, liquid does not flow inadvertently out of vacuum spout 244 instead of flow spout 242 . A head assembly 300 holds selector disk 200 in engagement with the selector platform portion 120 of base 100 . Head assembly 300 is formed by a hollow substantially cylindrical body 310 , top end 312 and is open at its opposite end. The interior of head assembly 300 is adapted in shape to receive selector disc 200 so that flow spout 242 extends through a pour aperture 314 . The diameter of body 310 is substantially equivalent to the diameter of base 100 at bottom end 104 . The upper portion of outside surface 108 of base 100 is reduced in diameter forming collar 150 . Body 310 is adapted with periodically occurring raised rotator flanges 316 located along the inside surface of body 310 substantially adjacent to the open end of body 310 as seen in FIG. 2 . Alternatively, rotator flanges 316 can be a continuous raised ring along the inner circumference of the open lower end of body 310 . The outer circumference of collar 150 is adapted with a rotator channel 152 which is adapted to receive rotator flanges 316 . Head assembly 300 engages collar 150 so that body 310 overlaps collar 150 and rotator flanges 316 engage rotator channel 152 . The engagement of rotator flanges 316 and rotator channels 152 lock head assembly 300 onto base 100 while allowing it to rotate in either direction in relation to base 100 . When head assembly 300 engages base 100 , selector disc 200 fully engages selector platform 120 so that inner and outer raised ring tracks 220 a and 220 b engage cooperating inner and outer ring channels 124 a and 125 b. Head assembly 300 is rotatable in relation to base 100 so that one of a plurality of positions may be selected. In the preferred embodiment, six selections are available: three drink mix selections; two selections to allow only the contents of the beverage container 20 and not any drink mixes to flow, and one selection to prevent any liquid or drink mix from exiting. Selector disk 200 rotates along with head assembly 300 . Selector disk 200 is held in alignment with head assembly 300 by four protrusions 320 which extend from top 312 and are received by grooves 250 in selector disc 200 . While rotating, head assembly 300 snaps into six unique positions which are created when alignment dimples 122 engage raised alignment flanges 210 and alignment finger 125 engages alignment divot 123 . Each unique position may be identified by indicator markings 154 located along collar 150 which are revealed by an indicator window 322 within body 310 as shown in FIG. 4 . Each discrete position causes mix selector aperture 236 and vacuum selector aperture 238 to be positioned over either a pair of (closed) alignment dimples 122 or (open) compartment apertures 126 . Alignment over the dimples 122 causes all apertures to be closed and sealed so that the concentrated mixes cannot escape from the compartments 130 , 132 , and 134 . In one or more of the alignment positions, not only do mix selector aperture 236 and vacuum selector aperture 238 cover closed dimples 122 preventing egress of the drink mix from the compartment, but flow stopper 127 also covers bottle flow aperture 232 thereby preventing liquid from exiting container 20 . Therefore, in the closed position, bottle flow aperture 232 and bottle vacuum aperture 234 are closed by a biased flow stopper 127 and vacuum stopper 128 , respectively, which extend from selector platform 120 within bottle aperture 110 . In the closed position, compartment apertures 126 are sealed by engagement with alignment flanges 210 , which do not contain apertures. In the closed position, mix and vacuum selector apertures 236 and 238 are sealed by engagement with dimples 122 , which do not contain apertures. When not in a closed position, vacuum stopper 128 may engage vacuum stopper dimples 235 . To pour out only the contents of the attached bottle, without any drink mixes, head assembly 300 is rotated to one of the positions where bottle flow aperture 232 and vacuum aperture 234 are not blocked by flow stopper 127 and vacuum stopper 128 . Bottle 20 is simply tipped over horizontally so that gravity causes the bottle contents to flow out the bottle mouth through bottle aperture 110 , bottle flow aperture 232 and out flow spout 242 as seen in FIG. 3 . When a drink blended with a drink mix is desired, mix selector aperture 236 and vacuum selector aperture 238 are aligned over one of the three pairs of compartment apertures 126 which open into compartments 130 , 132 or 134 . As bottle 20 is tipped over, the concentrated drink mix contained in the corresponding compartment 130 , 132 or 134 is allowed to flow out into the mix spout 246 and combine with the out-flowing liquid from the bottle in flow spout 242 , as seen in FIG. 3 . The concentrated mix is blended with the bottle contents within flow spout 242 so that a flavored or fortified drink is produced as the bottle contents are poured out. Each of the six functional positions including the closed position may be marked so that the desired position is easily located by placing indicator markings 154 along collar 150 which are correspondingly revealed through window 322 as head assembly 300 is rotated so that the function of each position is easily identified. For example, indicator markings 154 could be “1”, “2”, and “3”, each representing a different compartment containing a different drink mix; “w”, representing water only (or whatever the liquid is within container 20 ), without the release of a drink mix; and “x” representing no exit of either the liquid within the container or a drink mix, i.e. a “sealed” selection. Head assembly 300 , selector disc 200 and base 100 may be constructed of any resilient waterproof material such as plastic or resin. In an alternate embodiment, head assembly 300 and selector disk 200 are one integral component. The instant invention has been shown and described in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to persons skilled in the art.
A cap dispenser for use with a liquid-holding container that separately stores concentrated mixes within one or more compartments. The mixes are selectively released within the outflow of the liquid contained by the liquid-holding container. By rotating the head assembly of the dispenser, the user can select which concentrated mix, if any, is to be released. The head assembly also offers a sealed position that seals the liquid within the container and the concentrated mixes within their respective storage compartments. The concentrated mixes are selectively dispensed into the outflow of the liquid from the container when the liquid is being poured out so that a mixed liquid, or flavored or fortified a drink is produced.
1
CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. Ser. No. 10/202,374, filed 2002 Jul. 24 now abandoned, which claims the benefit of U.S. Provisional Application No. 60/329,964, filed 2001 Oct. 18, both of which are hereby incorporated herein by reference. BACKGROUND OF INVENTION The invention relates to a communication device and more particularly to the communication device which is capabile to communicate with another communication device in a wireless fashion. U.S. Pat. No. 6,532,374 is introduced as a prior art of the present invention of which the summary is the following: ‘A radiotelephone includes a base unit mounted within the vehicle having a wide area transceiver for communicating with a station outside the vehicle, a control unit disposed in the vehicle remotely from the base unit, and a local area network for establishing a communication link between the base unit and the control unit. The local area network is adapted to transmit control and data signals between the base unit and the control unit. The control unit includes a keypad for entering commands and data that are transmitted to the base unit via the local area network, and a display for displaying information to the user. The control unit may also include a speaker and microphone. Alternatively, the speaker and microphone may be contained in a remote audio unit that is linked to the base unit via the local area network. The control unit may, for example, be incorporated into the steering wheel of a vehicle while the base unit is concealed in the trunk or under the seat of the vehicle.’ U.S. Pat. No. 6,525,768 is introduced as a prior art of the present invention of which the summary is the following: ‘A location tagged data provision and display system. A personal communication device (PCD) with electromagnetic communication capability has a GPS receiver and a display. The PCD requests maps and location tagged data from data providers and other for display on the PCD. The data providers respond to requests by using searching and sorting schemes to interrogate data bases and then automatically transmitting data responsive to the requests to the requesting PCD.’ U.S. Pat. No. 6,515,595 is introduced as a prior art of the present invention of which the summary is the following: ‘A location tagged data provision and display system. A personal communication device (PCD) with electromagnetic communication capability has a GPS receiver and a display. The PCD requests maps and location tagged data from data providers and other for display on the PCD. The data providers respond to requests by using searching and sorting schemes to interrogate data bases and then automatically transmitting data responsive to the requests to the requesting PCD.’ U.S. Pat. No. 6,456,854 is introduced as a prior art of the present invention of which the summary is the following: ‘A system and method for locating mobile telephone devices via the Web. The mobile telephone device obtains and provides its location to a Web server in GPS latitude and longitude format. The communication between the Web server and the mobile telephone device may be through a browser or through mobile originated short message service. The Web server records the location information along with the time of receipt. Over time, the Web server may record several locations for a single mobile telephone device so that the progress of the mobile unit may be mapped. The information contained in the Web server is accessible to devices with Web browsing capabilities. A Web browsing device queries the Web server for location information pertaining to a particular mobile telephone device. The Web server may require authorization for such information before sending the location to the requesting device. The location information may be sent in a text only format or as text with graphics, depending on the display capabilities of the requesting Web browsing device.’ U.S. Pat. No. 6,415,222 is introduced as a prior art of the present invention of which the summary is the following: ‘A navigation system includes an information storage unit that stores map data including fork pattern data. A retrieval device obtains fork information from the map data and retrieves the connection between an entrance lane and an exit lane and the number of lanes at an approaching fork. A fork schematic drawing generation device generates a schematic drawing of a approaching fork by a selecting a fork pattern based on the connection between the entrance and exit lanes and the number of lanes that have been retrieved.’ U.S. Pat. No. 6,401,035 is introduced as a prior art of the present invention of which the summary is the following: ‘An Interactive Real-Time Distributed Navigation system is disclosed. In the present invention a user's location is determined by generating a position signal at the user's location. Through wireless communication between the user and distributed navigation servers, the user is presented with a list of candidate locations. The user's choice from the candidate list are then used by the navigation servers to obtain an accurate measurement of the user's location. Having established a user's location, the system proceeds to provide navigational prompts to the user to reach a final destination.’ U.S. Pat. No. 6,362,778 is introduced as a prior art of the present invention of which the summary is the following: ‘A personal locator system for determining the location of a locator unit. The system includes a locator device in communication with both a central station and a GPS satellite. The locator unit includes a portable housing able to be worn about the wrist of a user. A communication system is positioned within the housing for contacting the central station and includes a transmitter and receiver. A GPS unit is also positioned within the housing for contacting the GPS system for determining a location of said locator device. Upon receipt of a location request signal by the receiver from the central station, the locator unit activates the GPS unit to contact the GPS system and receive location data therefrom. Upon receipt of the location data, the transmitter transmits the location data to the central station for analysis. A panic button is provided for transmitting an emergency signal to the central station and initiating detecting the location of the locator unit. A non-emergency call button is provided for transmitting a location request signal to the central station and in response thereto, informing a person on the contact list as to the location of the locator device. The communication system utilizes one of a POTS, cellular, PCS or internet communications network. A tamper detection sensor detects when said device is tampered with. A beacon generator generates an ultrasonic or radio frequency beacon signal for aiding a person in pinpointing a location of the device.’ U.S. Pat. No. 6,327,534 is introduced as a prior art of the present invention of which the summary is the following: ‘A system and method for unambiguously determining the position of a user terminal (for example, a mobile wireless telephone) in a low-Earth orbit satellite communications system. The system includes a user terminal, at least two satellites with known positions and known velocities, and a gateway (that is, a terrestrial base station) for communicating with the user terminal through the satellites. The method includes the steps of determining a range parameter, a range difference parameter, and either or both of a range-rate parameter and a range-rate difference parameter. A range parameter represents a distance between one of the satellites and the user terminal. A range difference parameter represents the difference between (1) the distance between a first one of the satellites and the user terminal and (2) the distance between a second one of the satellites and the user terminal. A range-rate parameter represents a relative radial velocity between one of the satellites and the user terminal. A range-rate difference parameter represents the difference between (a) a relative radial velocity between a first one of the satellites and the user terminal and (b) a relative radial velocity between a second one of the satellites and the user terminal. The position of the user terminal on the Earth's surface is then determined based on the known positions and known velocities of the satellites, the range parameter, the range difference parameter, and either or both of the range-rate parameter and the range-rate difference parameter.’ U.S. Pat. No. 6,327,471 is introduced as a prior art of the present invention of which the summary is the following: ‘A method and an apparatus is provided for acquiring satellite signals to establish the exact spatial position of a cellular radiotelephone, in order to perform a timely dropoff or smooth handoff to another base station or frequency. The cellular radiotelephone is equipped with its own positioning system which uses satellite data to determine its spatial position. The communication system is preferably a Code Division Multiple Access (CDMA) system, and the positioning system is preferably a Global Positioning System (GPS). The method of the present invention may be used to determine the base station closest to the cellular radiotelephone. In the alternative, it may be used to compute a distance between the cellular radiotelephone and a location where the quality level of the cellular radiotelephone communication signal is predicted to be less than the predetermined value, and to determine from the computed distance whether the cellular radiotelephone should be handed off.’ U.S. Pat. No. 6,323,803 is introduced as a prior art of the present invention of which the summary is the following: ‘A system for broadcasting GPS assistance data in a wireless communication network to mobile stations is disclosed herein. Each mobile station includes a transceiver operating in the wireless communication network and an integrated GPS receiver to make GPS positioning measurements. The system includes a GPS receiver for obtaining orbital modeling information for visible GPS satellites and DGPS correction data. A transceiver communicates with mobile stations in the wireless communication network. A broadcast controller is operatively associated with the GPS receiver and the transceiver for selectively establishing a direct point-to-point channel with select mobile stations for transferring the orbital modeling information and for periodically broadcasting the DGPS correction data on the wireless communication network to all mobile stations communicating in the wireless communication network.’ U.S. Pat. No. 6,321,161 is introduced as a prior art of the present invention of which the summary is the following: ‘A feature for a navigation system provides an evaluation of alternative routes. According to this feature, the navigation system provides information to the vehicle driver about departing from a route being followed. This allows the driver to make an assessment whether to depart from the route being followed or stay on the route. This feature enables driver-observable traffic conditions to be taken into account by the vehicle driver.’ U.S. Pat. No. 6,320,535 is introduced as a prior art of the present invention of which the summary is the following: ‘A system that tracks and monitors a vehicle by utilizing cellular communication componentry and global positioning system componentry is disclosed. The system provides for simultaneous and continuous transmission of a voice signal and location data to a monitoring center. The monitoring center comprises componentry to communicate with the vehicle and determine the vehicle's location on a digitized map using a computer. In one embodiment, the location data is modulated onto a carrier and the modulated carrier is inserted into a relatively narrow band of frequencies that have been removed from an audio data channel such as, for example, a cellular telephone voice channel.’ U.S. Pat. No. 6,317,684 is introduced as a prior art of the present invention of which the summary is the following: ‘The invention provides an apparatus and method for route planning and navigation using a portable communication device. A route planning and navigation unit receives a route request from a caller. The route planning and navigation unit checks the latest traffic/road condition data, long term map database, knowledge database, Internet resources, if necessary, and then determines the best route for the driver to reach the destination. The caller may also enter general destination information and be prompted to may a selection from the possible choices. The route planning and navigation unit may also provide exact location information to police officers and emergency personnel, if necessary. During the navigation phase, the caller may receive turn-by-turn navigation and reminders to change lanes in preparation for turns, etc. The route planning and navigation unit may monitor the caller's location, speed, and direction, and provide the caller with updates based on new traffic or road condition changes affecting the caller's route.’ U.S. Pat. No. 6,317,049 is introduced as a prior art of the present invention of which the summary is the following: ‘A micropower transponder operates in conjunction with a constellation of low-to-medium Earth-orbiting communication satellites. The transponder is attached to a person, animal, or object. The location of a missing person, animal, or lost object is ascertained by locating the transponder associated with that person, animal, or object. The transponder may be hidden in the individual's hair, timepiece, jewelry, or article of clothing; may be swallowed by the individual; may be implanted under the individual's skin; or incorporated into an inconspicuous hand-held device such as a cellular telephone, pager, or calculator. The transponder includes a receiver for receiving an interrogation radio signal and a transmitter for transmitting a response radio signal. The transponder transmits the response radio signal in response to the interrogation radio signal if the interrogation radio signal includes a code matching the access code stored in the transponder. The Doppler shift in frequency of the response radio signal is measured and the Doppler shift is used to determine the location of the transponder.’ U.S. Pat. No. 6,304,218 is introduced as a prior art of the present invention of which the summary is the following: ‘A method of detecting a position of a radio mobile station in radiocommunications, which is capable of accurately and simply finding the position of the mobile station. At a measuring point the mobile station measures the reception radio strength levels from a plurality of base stations and conveys the measurement results through the base station to a control station. The control station learns, through a neural network, the correlation between the reception radio strength levels and the position of the mobile station on the basis of the measurement results at a plurality of measuring points and the positions of the measuring points. Subsequently, when the mobile station communicates to the control station the reception radio strength levels measured at an arbitrary point, the control station estimates the position of the mobile station, causing those measurement results, on the basis of the correlation obtained through the learning.’ U.S. Pat. No. 6,285,317 is introduced as a prior art of the present invention of which the summary is the following: ‘A navigation system for a mobile vehicle includes a vehicle position data generator for generating signals indicating location of the mobile vehicle, and scene information provider which generates information representative of the layouts of local environs at various locations and a display. A real environment scene generator, using position data acquired from the vehicle position data generator, acquires information from the local scene information provider representative of the local scene at the vehicle position indicated by the position data. The real environment scene generator generates location pertinent information which is used by the display to display a scene depicting the locality setting in a three dimensional format. The real environment scene generator also generates direction information which is used to display directions overlaid on the displayed local scene. The displayed scene and overlaid directions are constantly updated to reflect the changing locality as the position of the vehicle changes.’ U.S. Pat. No. 6,278,383 is introduced as a prior art of the present invention of which the summary is the following: ‘A navigation apparatus for displaying most appropriately information such as character strings, routes, etc., when a map is displayed by bird's-eye view display. The navigation apparatus includes a portion for calculating the present position on the basis of information from sensors, a portion for executing perspective conversion operation for displaying a map by bird's-eye view display, a portion for disposing the present position or the present position and a position representing a destination at the most suitable positions, a portion for controlling so that overlap of character strings can be eliminated, a portion for controlling the same character strings, a portion for displaying most appropriately a background such as lines and planes, a portion for controlling marks to be displayed, and a portion for executing graphic plotting by using the resulting map data.’ U.S. Pat. No. 6,275,190 is introduced as a prior art of the present invention of which the summary is the following: ‘A method of detecting a position of a radio mobile station in radiocommunications, which is capable of accurately and simply finding the position of the mobile station. At a measuring point the mobile station measures the reception radio strength levels from a plurality of base stations and conveys the measurement results through the base station to a control station. The control station learns, through a neural network, the correlation between the reception radio strength levels and the position of the mobile station on the basis of the measurement results at a plurality of measuring points and the positions of the measuring points. Subsequently, when the mobile station communicates to the control station the reception radio strength levels measured at an arbitrary point, the control station estimates the position of the mobile station, causing those measurement results, on the basis of the correlation obtained through the learning.’ U.S. Pat. No. 6,261,247 is introduced as a prior art of the present invention of which the summary is the following: ‘An anatomical position sensing system (100) using one or more substantially spherical transponders for measuring relative positions and distances. Transponders (P) and (S) are capable of receiving and transmitting RF signals, and communicating between themselves and with a separate CPU (112). The CPU (112) is controlled by an operator at an operator control panel (114), interacts with an alarm (120) for providing audible alerts to the operator, and a display for displaying information to the operator. The CPU (112) controls a broadband antenna (118) to transmit, at a frequency f.sub.1, a low-frequency RF power signal (122) across a wide field to energize the transponders (P) and (S). Directional components (122a) and (122b) intercept and energize the transponders (P) and (S). Once energized, transponder (P) transmits a range signal in all directions including component (124) at a very high RF frequency f.sub.2, extending from transponder (P) to transponder (S). Upon receipt of the range signal (124), transponder (S) emits a data signal at a very high RF frequency f.sub.3 in all directions, including component (126), which is directed at the antenna (118). The distance (D) is determined by measuring the attenuation of the range signal (124) as it is received by transponder (S). Transponder (S) then modulates the value of the strength of the incoming range signal (124) onto the data signal. The CPU (112) computes the distance (D) from the incoming data signal (126) from a lookup table derived from a sequence of calibration steps prior to beginning normal operation.’ U.S. Pat. No. 6,259,405 is introduced as a prior art of the present invention of which the summary is the following: ‘A geographic based communications service system that includes a network and a plurality of access points connected to the network and arranged at known locations in a geographic region. One or more service providers or information providers may be connected to the network to provide services or information on the network. A mobile user (MU) may use a portable computing device (PCD) to connect to the network and access information or services from the network. The PCD may be configured to transmit a signal indicating a presence of the PCD as well as identification information indicating the mobile user. Upon detection of the wireless signal by a first access point in proximity to the PCD, and upon receipt of the identification information indicating the user of the PCD, the first access point may transmit the identification information, as well as the known geographic location of the first access point, to one or more providers on the network. The known geographic location of the first access point indicates the approximate location of the PCD of the mobile user. A first information provider may receive this information and provide content information or services to the mobile user. For example, the first information provider may select content information dependent upon the known geographic location of the first access point and demographic information or past activities of the mobile user of the PCD. The first information provider may then provide the selected content information through the network and through the first access point to the PCD of the mobile user.’ U.S. Pat. No. 6,246,960 is introduced as a prior art of the present invention of which the summary is the following: ‘An enhanced positioning method and system with altitude measurement includes the steps of receiving the inertial measurements from an inertial sensor, the global positioning system raw measurements from a global positioning system processor, and the altitude measurement from an altitude measurement device and performing integrated filtering, feeding the velocity and acceleration back to the global positioning system satellite signal tracking loops, and using integration solution to aid the global positioning system satellite signal carrier phase ambiguity resolution. The present invention provides a positioning method and system with high accuracy and robustness. The global positioning system measurements assure the long term positioning accuracy and the inertial measurements assure the short term positioning accuracy. The altitude measurement improves the vertical positioning accuracy. The velocity and acceleration from the inertial device aid the global positioning system signal tracking. The integrated positioning solution is employed to derive the global positioning system carrier phase ambiguity number. The present patent supports high precision navigation in general aviation and space applications. It also supports high precision approach and landing for aircraft, reusable launch vehicles, and other air transportation vehicles.’ U.S. Pat. No. 6,243,030 is introduced as a prior art of the present invention of which the summary is the following: ‘An electronic navigation system using wirelessly transmitted video map images from one or more ground based transmitters together with wireless receivers having visual display available to travelers, for receiving and displaying the video map images. In one embodiment a cellular system is provided using video map images covering different zones or cells of a city or other community. GPS reception is combined to additionally provide location, direction, and speed parameters on the received video maps. Transmitted video image information may also include names of streets, roads, as well as places of interest and to obtain service and assistance in emergencies. Interactive controls are provided as supplements to assist travelers in obtaining specific information as well as additional information.’ U.S. Pat. No. 6,222,482 is introduced as a prior art of the present invention of which the summary is the following: ‘A hand-held device has access to a three-dimensional geometry database and a GPS receiver, and provides information on the one or more closest features to the device location in the three-dimensional geometry database. The system has data input devices, optionally digital cameras, and a data processor executing a location process. A multiresolution process creates one or more models of the three-dimensional geometry database. The models have a hierarchy of resolutions. The models have vertices, edges and polygons. The multiresolution process preferably associates data to the vertices, edges and polygons. A data processor executes a location process that determines a distance between the position of the hand-held device and corresponding one or more closest features on the hierarchy of resolutions of the database. The data processor produces display commands for displaying data and geometry relative to the one or more closest features. Data input devices are used to collect data that is appended to or replaces data pertaining to the one or more closest features.’ U.S. Pat. No. 6,148,261 is introduced as a prior art of the present invention of which the summary is the following: ‘A location tagged data provision and display system. A personal communication device (PCD) with electromagnetic communication capability has a GPS receiver and a display. The PCD requests maps and location tagged data from data providers and other for display on the PCD. The data providers respond to requests by using searching and sorting schemes to interrogate data bases and then automatically transmitting data responsive to the requests to the requesting PCD.’ U.S. Pat. No. 6,133,853 is introduced as a prior art of the present invention of which the summary is the following: ‘A location tagged data provision and display system. A personal communication device (PCD) with electromagnetic communication capability has a GPS receiver and a display. The PCD requests maps and location tagged data from data providers and other for display on the PCD. The data providers respond to requests by using searching and sorting schemes to interrogate data bases and then automatically transmitting data responsive to the requests to the requesting PCD.’ U.S. Pat. No. 6,023,278 is introduced as a prior art of the present invention of which the summary is the following: ‘A digital map system for displaying three dimensional terrain data uses terrain data in the form of polygons. The polygon database is produced from a database of elevation points which are divided into, for example, n.times.n (where n is a positive integer) squares which have an elevation point in the center of the square. The center point forms four polygons with the corners of the square. The elevation of the center point may be chosen to be the highest elevation point in the n.times.n square, the average elevation of the elevation points in the n.times.n square, the elevation of the actual center point, or other methods. The method chosen depends on how the data base is to be used. The size of the n.times.n square chosen also depends on how the data base is to be used since there is a tradeoff between the resolution of the displayed scene and the amount of data reduction from the original database of elevation points. The polygon database may be used in a pilot aid using a synthetic environment, a flight simulator, as part of the control system for a remotely piloted vehicle, or in a video game.’ U.S. Pat. No. 5,918,183 is introduced as a prior art of the present invention of which the summary is the following: ‘A mobile communications system for transmitting or receiving a broadcast signal and designed for mounting on in a vehicle has a transmitter or receiver and one or more antennas electrically connected to the transmitter/receiver. The system is mounted on or in a vehicle so that the transmitter/receiver and the antenna(s) are concealed. The system includes a GPS unit for receiving and processing a GPS and signal a cellular telephone unit for transmitting a fix of the vehicle location (to the police, for example). The system is particularly useful in recovering stolen vehicles and deterring theft.’ U.S. Pat. No. 6,611,753 is introduced as a prior art of the present invention of which the summary is the following: ‘A navigation system includes a display which provides a 3-D perspective view. The angle of viewing in the perspective view is increased based upon the complexity of the intersection being displayed. Intersections of increased complexity are displayed at an increased viewing angle to facilitate understanding. A sky above a horizon on the display changes color based upon the time of day.’ U.S. Pat. No. 6,477,387 is introduced as a prior art of the present invention of which the summary is the following: ‘A display-based terminal (101) employs a method and apparatus for dynamically grouping (719, 723, 819, 823) communication units in a communication system. The terminal displays a map (703, 803) to the terminal user that indicates locations of communication units in at least a portion of the communication system. The terminal receives (705, 805) an indication of a geographic area on the map. After the area has been indicated and the talkgroup identified, the terminal automatically groups (719, 723, 819, 823) communication units that are in or have entered the selected area into the identified talkgroup. If a regrouped unit exits the selected area, the terminal automatically removes the exiting unit from the talkgroup. The terminal user may further input criteria to limit which units entering and leaving the indicated area are actually grouped or ungrouped.’ U.S. Pat. No. 6,366,782 is introduced as a prior art of the present invention of which the summary is the following: ‘A display-based terminal (101) employs a method and apparatus for allowing a user of the terminal to communicate with communication units (105-113) in a communication system (100). The terminal displays a map (300, 400) to the user indicating locations of communication units in at least a portion of the communication system. The terminal then receives a selection from the map of at least one communication unit (105, 108, 109, 113) and an indication (309, 311) of the user's desire to communicate with the selected communication unit. The indication of the user's desire to communicate may be contemporaneous with the user's selection of the communication unit, for example, when the user has, prior to such selection, indicated a desired type (302-305, 401-404) of communication and/or a desired transmission mode (406) for subsequent communications with the communication units. Responsive to receipt of the user's selection of the communication unit and indication of a desire to communicate, the terminal automatically initiates a communication with the selected communication unit.’ U.S. Pat. No. 6,292,747 is introduced as a prior art of the present invention of which the summary is the following: ‘A wireless network and an associated communication device are disclosed. The communication device is typically mounted in a first vehicle and includes a location device, such as a global positioning system receiver, suitable for determining the first vehicle's geographic position, a wireless transceiver enabled to communicate with a wireless transceiver of a second vehicle within a wireless range of the first vehicle, and a processor connected to the wireless transceiver and the location device. The processor is able to use the wireless transceiver and the location device to broadcast travel information of the first vehicle and to identify the presence of the second vehicle. The processor may also be enabled to display the position of the second vehicle on a display screen of the communication device or to enable the first vehicle to communicate with the second vehicle. The communication device may be configure to permit a user of the first vehicle, by clicking on an image of the second vehicle on the display screen, to obtain identification information of the second vehicle or to initiate a communication with the second vehicle. The communication with the traveler in the second vehicle may comprise a voice communication or an electronic message such as an email message. The first vehicle may include one or more environmental sensors connected to the processor that permit the communication device to broadcast weather information to other vehicle in the vicinity. The travel information exchanged among the vehicle may be organized into categories enabling the traveler to restrict information exchange based on one or more of the categories. The restriction criteria may include route criteria, transportation class criteria, and identity criteria.’ U.S. Pat. No. 5,732,383 is introduced as a prior art of the present invention of which the summary is the following: ‘An estimation of traffic conditions on roads located in the radio coverage areas of a wireless communications network is provided based on an analysis of real-time and past wireless traffic data carried on the wireless communications network. Data analyzed may include, for example, actual (current) and expected (past average) number of a) active-busy wireless end-user devices in one or more cells at a particular period of time, b) active-idle wireless end-user devices registered in a location area of the wireless communications network, c) amount of time spent by mobile end-user devices in one or more cells at a particular period of time.’ U.S. Pat. No. 4,937,570 is introduced as a prior art of the present invention of which the summary is the following: ‘A route guidance display device for an automotive vehicle capable of displaying route patterns with a three-dimensional effect to enhance the viewer's comprehension of the road route situation being encountered. The display device includes a plurality of intersecting display segments indicative of corresponding possible route configurations. A depth-enhancing segment is included in a portion indicating the straight-ahead route. An intersection name display section may be separately included to display the name and related information regarding an intersection laying ahead.’ U.S. Patent Publication No. 20030117316 is introduced as a prior art of the present invention of which the summary is the following: ‘Systems and methods for locating and tracking a wireless device including a database remotely located from the wireless device, the database operable for receiving and storing position information from the wireless device at a predetermined interval. The systems and methods also including a wireless network operable for communicating the position information from the wireless device to the database and a first algorithm operable for providing the position information upon request. The systems and methods further including a second algorithm allowing modification of the predetermined interval, a third algorithm operable for associating a landmark with the position information, a fourth algorithm operable for causing the position of the wireless device to be determined locally at the predetermined interval, a fifth algorithm operable for causing the position information to be stored locally within the wireless device, and a sixth algorithm operable for causing the position information to be communicated to the database via the wireless network when the battery power of the wireless device reaches a predetermined level. The position information is provided to a user via a land-line phone and a public switched telephone network (PSTN), a finding wireless device and the wireless network, or a personal computer (PC) and a globally-distributed computer network. The position information is provided to the user in the form of a voice synthetic message, a text message, or a graphical display.’ U.S. Patent Publication No. 20030100326 is introduced as a prior art of the present invention of which the summary is the following: ‘Methods are disclosed for sharing location and route information between communication units (e.g., talkgroup members) that are subscribed to a group location sharing service. The group location sharing service is event-based, such that the communication units may form a subset of a talkgroup desiring to actively participate or monitor an event. Communication units de-subscribe from the group location sharing service or talkgroup when they no longer desire to participate or monitor the event. Service levels may be determined for various subscribers to the group location sharing service. The service levels may include, for example, an information transmission service level and information reception service level that determine an amount, type, and/or timing of information to be sent or received by particular subscribers.’ U.S. Patent Publication No. 20030045301 is introduced as a prior art of the present invention of which the summary is the following: ‘The present invention is directed to an electronic system and method for managing location, calendar, and event information. The system comprises at least two hand portable electronic devices, each having a display device to display personal profile, location, and event information, and means for processing, storing, and wirelessly communicating data. A software program running in the electronic device can receive local and remote input data; store, process, and update personal profile, event, time, and location information; and convert location information into coordinates of a graphic map display. The system additionally includes at least one earth orbiting satellite device using remote sensing technology to determine the location coordinates of the electronic device. The electronic devices receive synchronization messages broadcast by the satellite device, causing the software program to update the personal profile, event, time, and location information stored in each hand portable electronic device.’ U.S. Patent Publication No. 20020111139 is introduced as a prior art of the present invention of which the summary is the following: ‘The object of the present invention is to provide a data distribution system that is capable of distributing to a mobile communication terminal at a specific location information suited for the location, e.g., guide information, and that is capable of allowing anyone to easily and freely access information. In order to achieve this object, the present invention provides a data distribution system communicating with a mobile data communication device capable of obtaining current position information indicating a current position. The present invention is equipped with data communication means sending and receiving data to and from the mobile data communication device and means for storing information storing area position information indicating a position of a specific area and information associated with the specific area. Control is provided so that, if the mobile data communication device is located in the specific area, information associated with the specific area is sent to the mobile data communication device via data communication means.’ U.S. Pat. No. 6,452,626 is introduced as a prior art of the present invention of which the summary is the following: ‘A reduced area imaging device is provided for use with a communication device, such as a wireless/cellular phone. In one configuration of the imaging device, the image sensor is placed remote from the remaining image processing circuitry. In a second configuration, all of the image processing circuitry to include the image sensor is placed in a stacked fashion near the same location. In the first configuration, the entire imaging device can be placed at the distal end of a camera module. In a second configuration, the image sensor is remote from the remaining image processing circuitry wherein available space within the phone is used to house the remaining circuitry. In any of the embodiments, the image sensor may be placed alone on a first circuit board, or timing and control circuits may be included on the first circuit board containing the image sensor. One or more video processing boards can be stacked in a longitudinal fashion with respect to the first board, or the video processing boards may be placed within the housing of the communication device. The communication device includes a miniature LCD-type monitor which is capable of viewing not only the images taken by the camera module, but also can show incoming video images. The camera module is of such small size that it can be easily stored within the housing of the communication device, and may be attached thereto as by a small retractable cable. Having a tethered camera module allows it to be pointed at any desired object within sight of the user, and without having to actually point or move the phone housing in order to take an image.’ U.S. Pat. No. 6,424,843 is introduced as a prior art of the present invention of which the summary is the following: ‘The telecommunication device comprises a speaker (32) and a microphone (33) in order to use the telecommunication device as a telephone. Further it comprises a camera (91, 1101) having a certain photographing direction, and a display (38, 1102) having a certain displaying direction, in order to use the telecommunication device as an image generating means. The photographing direction is substantially different from the displaying direction.’ U.S. Pat. No. 6,424,369 is introduced as a prior art of the present invention of which the summary is the following: ‘A reduced area imaging device is provided for use with a miniature hand-held computer referred to in the industry as a PDA. In one configuration of the imaging device, the image sensor is placed remote from the remaining image processing circuitry. In a second configuration, all of the image processing circuitry to include the image sensor is placed in a stacked fashion near the same location. In the first configuration, the entire imaging device can be placed at the distal end of a camera module. In a second configuration, the image sensor is remote from the remaining image processing circuitry wherein available space within the PDA is used to house the remaining circuitry. In any of the embodiments, the image sensor may be placed alone on a first circuit board, or timing and control circuits may be included on the first circuit board containing the image sensor. One or more video processing boards can be stacked in a longitudinal fashion with respect to the first board, or the video processing boards may be placed within the housing of the communication device. The PDA includes a miniature LCD-type video view screen which is capable of viewing not only the images taken by the camera module, but also can show incoming video images received from a personal computer connected to a global communications network. The camera module is of such small size that it can be easily stored within the housing of the PDA, and may be attached thereto as by a small retractable cable.’ U.S. Pat. No. 6,342,915 is introduced as a prior art of the present invention of which the summary is the following: ‘An image telecommunication system comprises a worker's device and a manager's device. The worker's device collects an image of an object and transmits it to the manager's device placed in a remote place, so that the image is displayed on a display screen of the manager's device. The manager's device transmits a designated position of the image, designated in a state where the image is displayed, to the worker's device. The worker's device indicates a position of the object corresponding to the designated position received from the manager's device. The worker's device detects a point of view of the worker. The manager's device suppresses fluctuation of the image displayed on the display screen, when it is determined that the worker looks at the object substantially continuously.’ U.S. Pat. No. 6,323,893 is introduced as a prior art of the present invention of which the summary is the following: ‘A portable video conference module supporting a network-based video conference comprising a processor, a video camera, and audio input device and several interfaces coupled to the processor. The processor includes a local instruction processor accessing a local non-volatile memory. The interfaces include a wireless data capture interface, a video display interface, an audio output interface and a network interface.’ U.S. Pat. No. 6,323,892 is introduced as a prior art of the present invention of which the summary is the following: ‘A display and camera device for a videophone comprises a liquid crystal display for displaying a picture, a camera such as a CCD sensor or a CMOS sensor, a free-form surface prism, and a prism for guiding light to the camera. The free-form surface prism has a concave reflector for optically enlarging a picture displayed on the display. A beam splitter is provided on a bonded surface between the free-form surface prism and the prism. The beam splitter is designed to reflect some of light beams from the display toward the reflector and transmit some of light beams from the reflector. A camera-system optical path extending from the camera is aligned with a display-system optical path extending from the display within the free-form surface prism and the outside space.’ U.S. Pat. No. 6,317,039 is introduced as a prior art of the present invention of which the summary is the following: ‘A method and system for remote assistance and review of a technician or multiple technicians, in real time, working with equipment of various complexity. A technician or multiple technicians at a remote location are coupled by a wireless means to an advisor at a local station, so that the advisor may view and hear the same stimuli as the technician, that the advisor and technician may communicate. The technician has limited training or otherwise in need of support, and may be a field engineer, technician or maintenance personnel. The advisor has extensive training and able to provide technical support, and generally has extended and specialized knowledge with regard to the remote apparatus, and may be a technical expert on the remote apparatus. The technician may comprise an individual or group with technical training and knowledge, but lacking managerial or other authority, while the advisor comprises an individual or group with such authority. The technician communicates with the advisor by visual cues or ordinary speech, while the advisor views and listens to the remote apparatus. The advisor gives advise to the technician for manipulating or repairing the remote apparatus. Alternatively, an intermediate advisor may advise the technician and be advised by a higher-level advisor.’ U.S. Pat. No. 6,304,729 is introduced as a prior art of the present invention of which the summary is the following: ‘A camera is provided with a radio receiver for receiving electromagnetic waves transmitted from a given radio base station, a GPS receiver for receiving electromagnetic waves transmitted from each of a plurality of artificial satellites, a place information generator for generating place information based on one of electromagnetic waves received by the radio receiver and electromagnetic waves received by the GPS receiver, and a selector for selecting activation of one of the radio receiver and the GPS receiver, the selector judging whether the receptive state of the radio receiver is satisfactory, and selecting activation of the GPS receiver if the receptive state of the radio receiver is judged to be unsatisfactory.’ U.S. Pat. No. 6,300,976 is introduced as a prior art of the present invention of which the summary is the following: ‘A digital image capturing device which communicates through an input/output interface with an external processing device which monitors and/or controls the camera. The image capturing device communicates with the external device in order to output status information to the external device, receive commands from the external device and to transfer images and sound between the image capturing device and the external device. Various parameters describing the state of the image capturing device are transmitted to the external device including characteristics of the captured images, whether the flash is ready, the state of the device battery, whether the memory is full, or the parameters used when capturing images. The commands which can be sent from the external device to the image capturing device include commands to change any of the parameters of the image capturing device and a command to capture an image or a series of images, and whether or not sound is recorded.’ U.S. Pat. No. 6,278,884 is introduced as a prior art of the present invention of which the summary is the following: ‘A conventional portable cellular phone modified such that the phone housing incorporates a digital cameras security alarm system and other functions. In another embodiment, the portable cellular phone is modified such that the phone housing incorporates a security alarm system, radio receiver and other functions.’ U.S. Pat. No. 6,192,257 is introduced as a prior art of the present invention of which the summary is the following: ‘A wireless communication terminal is configured for enabling a user to receive and transmit video images as well as receive and transmit audio or speech signals associated with the user of the terminal and another user at, for example, a remote location. The received video image is obtained from a video image signal received over a radio frequency communications link established between the wireless communication terminal and a cellular base station. This received video image is displayed in a video image display conveniently associated with the wireless communication terminal. The transmitted video image signal may be that of the user of the terminal, of a scene within the field of view of the video camera or of text either coupled to the terminal through one of many well known data interfaces, or an image of text as captured by the camera. This transmitted video image signal is obtained from a video camera associated with the wireless communication terminal and then transmitted over the radio frequency communications link established between the wireless communication terminal and the cellular base station for displaying in a remotely located video image display.’ U.S. Pat. No. 6,177,950 is introduced as a prior art of the present invention of which the summary is the following: ‘A personal communication device includes a display for displaying data and video signals; a loudspeaker for generating an audible signal; a microphone for receiving an audio signal; a keypad for entering data; a telecommunications interface for receiving and transmitting information; and an internal multi-position and multi-function reading head for producing an image signal when in a first position using a first lensing and for reading for image conversion using a second lensing when in a second position.’ U.S. Pat. No. 6,175,717 is introduced as a prior art of the present invention of which the summary is the following: ‘A mobile can transmit and receive broadcast quality video signals while in motion. The system includes a power generator and a microwave subsystem coupled to said power generator. The microwave subsystem transmits first local microwave signals modulated with first local digital data while in motion with respect to earth and also receives first remote microwave signals modulated with first remote digital data while in motion with respect to earth. A high speed digital station receives a video signal and transforms and compresses the video signal into the first local digital data and transforms and decompresses the first remote digital data into a first decompressed remote digital data. The mobile microwave system is housed in a vehicle which has a lower portion and an upper portion, wherein the first local microwave signals can pass through the upper portion.’ U.S. Pat. No. 6,073,034 is introduced as a prior art of the present invention of which the summary is the following: ‘The invention relates to a microdisplay system that utilizes a small high resolution active matrix liquid crystal display with an illumination system and a magnifying optical system to provide a hand held communication display device. The system can employ an LED illumination system and cellular communication or processor circuits within a compact housing to provide communication devices such as pagers, telephones, televisions, and hand held computer or card reader devices with a compact high resolution data and/or video display.’ U.S. Pat. No. 6,055,513 is introduced as a prior art of the present invention of which the summary is the following: ‘Apparatus and methods are provided for effecting remote commerce, such as in telemarketing (either inbound or outbound) and in electronic commerce, which are particularly adapted for the intelligent selection and proffer of products, services or information to a user or customer. In one aspect of the invention, goods, service or information are provided to the user via electronic communication, such as through a telephone, videophone or other computer link, as determined by the steps of first, establishing communication via the electronic communications device between the user and the system to effect a primary transaction or primary interaction, second, obtaining data with respect to the primary transaction or primary interaction, including at least in part a determination of the identity of the user or prospective customer, third, obtaining at least a second data element relating to the user, fourth, utilizing the primary transaction or primary interaction data along with the at least second data element as factors in determining at least one good, service or item of information for prospective upsell to the user or prospective customer, and offering the item to the prospective customer. In the preferred embodiment, the selection of the proffer of goods, services or information comprises an upsell with respect to the primary transaction or primary interaction data. The offer of the upsell is preferably generated and offered in real time, that is, during the course of the communication initiated with the primary transaction or primary interaction.’ U.S. Pat. No. 6,038,295 is introduced as a prior art of the present invention of which the summary is the following: ‘A communication system includes at least one telephone unit, a transmission system for communicating from the telephone unit, and a server for receiving information via the transmission system. The telephone unit includes a digital image pick up by which images are recorded, transmitted to the server, and stored in the server depending upon classification information which characterizes the digital images and which is associated with the digital image data. The classification information is determined by an analysis unit in the server.’ U.S. Pat. No. 5,966,643 is introduced as a prior art of the present invention of which the summary is the following: ‘Known hand-held mobile radiotelephones and cordless telephones have the dimensions of a handset, and their antennas radiate near the user's head; such may be improved by providing a hand-held radiotelephone which is of a compact design and fully user-controllable and exposes the user to only little RF radiation. A hand-held radiotelephone (HH1) is provided whose earpiece (R) and/or microphone (M) are spatially separated from the other components of the radiotelephone. It is also possible to provide an infrared link between the earpiece and/or microphone and the housing of the radiotelephone in order to further increase the user's freedom of movement. During operation of the hand-held radiotelephone, the keyboard and display are fully accessible.’ U.S. Pat. No. 5,959,661 is introduced as a prior art of the present invention of which the summary is the following: ‘A telephone terminal capable of sending and receiving images and sounds, having a movable camera for obtaining images of the surrounding area and a sound-collection microphone for collecting surround sounds, automatic answering circuitry which automatically responds to a call received from a calling terminal and which starts the transmission of surrounding area images and sounds, and a transmission switching circuit which, upon response by the automatic answering circuitry, switches connection from the fixed microphone and handset for TV telephone use to the movable camera and sound-collection microphone.’ U.S. Pat. No. 5,917,542 is introduced as a prior art of the present invention of which the summary is the following: ‘A system method for digital image capture and transmission includes an image fulfillment server, having a transceiver for sending and receiving channel assessment signals and receiving a digital image file and a memory for storing the received digital image file. The system also includes a digital camera having an electronic image sensor for sensing an image and producing a digital image; a short term memory for storing digital images produced by the image sensor in digital image files; a transceiver for communicating with and transmitting the digital image files to the image fulfillment server; a signal strength detector for monitoring the registration signal from the fulfillment server and producing a transmit enable signal; a long term memory for storing the digital image files; the transmit enable signal for disabling transmission of the digital image data when the channel assessment signal indicates that successful transmission of the digital image data is not possible; and a timer for transferring the digital image file from the short term memory to the long term memory after a predetermined period of time.’ U.S. Pat. No. 5,915,020 is introduced as a prior art of the present invention of which the summary is the following: ‘A portable device for receiving satellite signals and displaying the signals as video. Preferably, the device includes a portable supporting member such as a hinged enclosure case, a satellite antenna, and a display monitor. The satellite antenna is preferably of a flat configuration and is mounted to the support, and the display monitor is preferably a flat video screen mounted to the same support. The required satellite receiver electronics and video decoder may be mounted to the portable support and powered by one or more batteries to provide an integrated and easily transported system to receive and view video relayed by satellite. A PCMCIA card slot and a microcontroller can be provided with the device to provide additional features such as cellular modem use, PCS wireless access, RS-232 port emulation, or GPS position location.’ U.S. Pat. No. 5,879,289 is introduced as a prior art of the present invention of which the summary is the following: ‘A portable, hand-held endoscopic camera having all of the necessary components for performing endoscopic procedures comprises power source means, lens means, light source means, and video camera means. The portable endoscopic camera is adaptable to a wide variety of systems and includes a highly efficient means for focusing the illumination of the light source. The lens means includes a fiber bundle and the light source means includes a bulb. The bulb is positioned in an abutting relationship with the fiber bundle, thereby focusing light into the fiber bundle. The camera is selectively operable in a cordless and cord-operated mode.’ U.S. Pat. No. 5,550,754 is introduced as a prior art of the present invention of which the summary is the following: ‘A combination portable recording video camera and video-conferencing terminal is described, wherein a video camera and lens is adjustable so that it can either produce images of an operator's surroundings for recording on a medium such as video tape, as in normal recording video cameras, or of the operator as in video conferencing terminals. The device is preferably provided with a video display screen that functions as a viewfinder in video-graphing the surroundings. The device is equipped with communication electronics that establish a connection over a network, and then transmits video and audio signals from the device while displaying video signals and reproducing audio signals that arrive over the network. Attempts by the network to establish a connection with the device result in the device automatically establishing the connection. Then the device activates its internal recording systems to play the prerecorded video message and transmit it over the network. The operator is later able to play the recorded signals and view them on the device's built-in display.’ U.S. Pat. No. 5,491,507 is introduced as a prior art of the present invention of which the summary is the following: ‘A handy type video telephone equipment which permits a user to transmit and receive pictures and speech with a casing held in one hand. A speaker is arranged at the upper end part of the front of the casing which is thin and vertically long, while a microphone is arranged at the lower end part thereof. A display panel and a control panel are interposed between the speaker and the microphone. A camera is mounted on the casing so as to be capable of altering its angle. The speaker is detachably mounted, and it is usable as an earphone when detached. The user's movements are not hampered during the transmission and reception, and the equipment can assume various communication or service attitudes conforming to the contents of information for the communications.’ U.S. Pat. No. 5,414,444 is introduced as a prior art of the present invention of which the summary is the following: ‘A personal communicator for use in a wireless communication network includes a wireless communications LCD and a multimedia LCD with the communications, mounded on a hinged member, and superimposed on top of the multimedia LCD. The communications LCD is sufficiently transparent to permit viewing of the under multimedia LCD. Each provides visual information to the user relative to the present use of the communicator. The selected use of the communicator is primarily responsive to the open or closed position of the hinged keyboard supporting cover. When the hinged member is closed the communicator operates in a communication mode. When it is open the communicator operates primarily in a multimedia mode. The personal communicator includes a steerable video imager for controllably optimizing image field coverage and adjusting to the orientation of the user relative to the personal communicator. The video imager includes an optical lens set and the imager is mounted on a mounting shaft so as to allow controlled rotation about its axis. The video imager includes mechanical apparatus interactive with the hinged keyboard supporting cover to reset its orientation to a standard position when the cover is closed and allow differing orientations when the cover is open.’ U.S. Patent Publication No. 20010045978 is introduced as a prior art of the present invention of which the summary is the following: ‘A portable personal wireless interactive video device including a miniature camera, a portable wireless transmitter connected to the camera, a portable wireless receiver for receiving video signals from the transmitter, and a portable video display device connected to the receiver for presenting an image to a viewer corresponding to a view from the perspective of the camera. The viewer may select an image for display on the video display device corresponding to a view from his/her own camera, from a camera worn by another person, or from one of several cameras positioned in selected locations. In one embodiment, the camera may be located within a remotely controlled model vehicle, thereby providing the viewer with a view from the perspective of inside the vehicle for viewing while remotely controlling the vehicle. Enhanced realism may be achieved by providing a true depth perception “stereo-optic” display by using two spaced apart cameras viewing the same scene and by presenting two corresponding independent channels of video information to the two eyes of the viewer. A “videotronics” capability allows the angle of view of the camera to be responsive to head movements of the viewer to further enhance the remote viewing experience.’ However, the foregoing prior arts do not disclose the communication device which implements the current location identifying mode and the camera mode. For the avoidance of doubt, the number of the prior arts introduced herein (and/or in IDS) may be of a large one, however, the applicant has no intent to hide the more relevant prior art(s) in the less relevant ones. SUMMARY OF INVENTION It is an object of the present invention to provide a single device capable to implement a plurality of functions where each function had to be implemented by an individual device in the prior art. It is another object of the present invention to provide merchandise to merchants attractive to the consumers in the U.S. It is another object of the present invention to provide mobility to the users of communication devices. It is another object of the present invention to overcome the shortcomings associated with the foregoing prior arts. The present invention introduces the communication device which implements the current location identifying mode and the camera mode. BRIEF DESCRIPTION OF DRAWINGS The above and other aspects, features, and advantages of the invention will be better understood by reading the following more particular description of the invention, presented in conjunction with the following drawings, wherein: FIG. 1 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 2 a is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 2 b is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 2 c is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 3 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 4 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 5 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 6 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 6 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 7 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 8 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 9 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 10 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 11 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 12 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 13 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 14 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 14 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 15 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 16 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 17 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 17 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 18 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 19 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 20 a is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 20 b is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 21 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 22 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 23 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 24 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 25 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 26 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 27 a is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 27 b is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 28 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 29 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 30 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 31 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 32 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 32 a is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 32 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 32 c is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 32 d is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 32 e is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 32 f is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 32 g is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 33 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 34 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 35 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 35 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 36 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 37 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 38 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 39 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 40 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 41 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 42 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 43 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 44 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 44 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 44 c is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 44 d is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 44 e is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 45 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 46 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 47 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 48 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 49 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 50 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 51 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 52 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 53 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 53 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 54 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 55 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 56 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 57 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 58 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 59 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 60 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 61 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 61 b is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 62 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 63 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 64 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 65 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 66 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 67 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 68 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 69 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 70 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 71 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 72 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 73 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 74 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 74 a is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 75 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 76 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 77 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 78 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 79 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 80 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 81 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 82 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 83 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 84 is a flowchart illustrating an exemplary embodiment of the present invention. FIG. 85 is a block diagram illustrating an exemplary embodiment of the present invention. FIG. 86 is a simplified illustration illustrating an exemplary embodiment of the present invention. FIG. 87 is a flowchart illustrating an exemplary embodiment of the present invention. DETAILED DESCRIPTION The following description is of the best presently contemplated mode of carrying out the present invention. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of the invention. For example, each description of random access memory in this specification illustrates only one function or mode in order to avoid complexity in its explanation, however, such description does not mean that only one function or mode can be implemented at a time. In other words, more than one function or mode can be implemented simultaneously by way of utilizing the same random access memory. In addition, the figure numbers are cited after the elements in parenthesis in a manner for example ‘RAM 206 (FIG. 1 )’. It is done so merely to assist the readers to have a better understanding of this specification, and must not be used to limit the scope of the claims in any manner since the figure numbers cited are not exclusive. There are only few data stored in each storage area described in this specification. This is done so merely to simplify the explanation and, thereby, to enable the reader of this specification to understand the content of each function with less confusion. Therefore, more than few data (hundreds and thousands of data, if necessary) of the same kind, not to mention, are preferred to be stored in each storage area to fully implement each function described herein. The scope of the invention should be determined by referencing the appended claims. FIG. 1 is a simplified block diagram of the Communication Device 200 utilized in the present invention. Referring to FIG. 1 , Communication Device 200 includes CPU 211 which controls and administers the overall function and operation of Communication Device 200 . CPU 211 uses RAM 206 to temporarily store data and/or to perform calculation to perform its function, and to implement the present invention, modes, functions, and systems explained hereinafter. Video Processor 202 generates analog and/or digital video signals which are displayed on LCD 201 . ROM 207 stores the data and programs which are essential to operate Communication Device 200 . Wireless signals are received by Antenna 218 and processed by Signal Processor 208 . Input signals are input by Input Device 210 , such as a dial pad, a joystick, and/or a keypad, and the signals are transferred via Input Interface 209 and Data Bus 203 to CPU 211 . Indicator 212 is an LED lamp which is designed to output different colors (e.g., red, blue, green, etc). Analog audio data is input to Microphone 215 . A/D 213 converts the analog audio data into a digital format. Speaker 216 outputs analog audio data which is converted into an analog format from digital format by D/A 204 . Sound Processor 205 produces digital audio signals that are transferred to D/A 204 and also processes the digital audio signals transferred from A/D 213 . CCD Unit 214 captures video image which is stored in RAM 206 in a digital format. Vibrator 217 vibrates the entire device by the command from CPU 211 . As another embodiment, LCD 201 or LCD 201 /Video Processor 202 may be separated from the other elements described in FIG. 1 , and be connected in a wireless fashion to be wearable and/or head-mountable as described in the following patents: U.S. Pat. No. 6,496,161; U.S. Pat. No. 6,487,021; U.S. Pat. No. 6,462,882; U.S. Pat. No. 6,452,572; U.S. Pat. No. 6,448,944; U.S. Pat. No. 6,445,364; U.S. Pat. No. 6,445,363; U.S. Pat. No. 6,424,321; U.S. Pat. No. 6,421,183; U.S. Pat. No. 6,417,820; U.S. Pat. No. 6,388,814; U.S. Pat. No. 6,388,640; U.S. Pat. No. 6,369,952; U.S. Pat. No. 6,359,603; U.S. Pat. No. 6,359,602; U.S. Pat. No. 6,356,392; U.S. Pat. No. 6,353,503; U.S. Pat. No. 6,349,001; U.S. Pat. No. 6,329,965; U.S. Pat. No. 6,304,303; U.S. Pat. No. 6,271,808; U.S. Pat. No. 6,246,383; U.S. Pat. No. 6,239,771; U.S. Pat. No. 6,232,934; U.S. Pat. No. 6,222,675; U.S. Pat. No. 6,219,186; U.S. Pat. No. 6,204,974; U.S. Pat. No. 6,181,304; U.S. Pat. No. 6,160,666; U.S. Pat. No. 6,157,291; U.S. Pat. No. 6,147,807; U.S. Pat. No. 6,147,805; U.S. Pat. No. 6,140,980; U.S. Pat. No. 6,127,990; U.S. Pat. No. 6,124,837; U.S. Pat. No. 6,115,007; U.S. Pat. No. 6,097,543; U.S. Pat. No. 6,094,309; U.S. Pat. No. 6,094,242; U.S. Pat. No. 6,091,546; U.S. Pat. No. 6,084,556; U.S. Pat. No. 6,072,445; U.S. Pat. No. 6,055,110; U.S. Pat. No. 6,055,109; U.S. Pat. No. 6,050,717; U.S. Pat. No. 6,040,945; U.S. Pat. No. 6,034,653; U.S. Pat. No. 6,023,372; U.S. Pat. No. 6,011,653; U.S. Pat. No. 5,995,071; U.S. Pat. No. 5,991,085; U.S. Pat. No. 5,982,343; U.S. Pat. No. 5,971,538; U.S. Pat. No. 5,966,242; U.S. Pat. No. 5,959,780; U.S. Pat. No. 5,954,642; U.S. Pat. No. 5,949,583; U.S. Pat. No. 5,943,171; U.S. Pat. No. 5,923,476; U.S. Pat. No. 5,903,396; U.S. Pat. No. 5,903,395; U.S. Pat. No. 5,900,849; U.S. Pat. No. 5,880,773; U.S. Pat. No. 5,864,326; U.S. Pat. No. 5,844,656; U.S. Pat. No. 5,844,530; U.S. Pat. No. 5,838,490; U.S. Pat. No. 5,835,279; U.S. Pat. No. 5,822,127; U.S. Pat. No. 5,808,802; U.S. Pat. No. 5,808,801; U.S. Pat. No. 5,774,096; U.S. Pat. No. 5,767,820; U.S. Pat. No. 5,757,339; U.S. Pat. No. 5,751,493; U.S. Pat. No. 5,742,264; U.S. Pat. No. 5,739,955; U.S. Pat. No. 5,739,797; U.S. Pat. No. 5,708,449; U.S. Pat. No. 5,673,059; U.S. Pat. No. 5,670,970; U.S. Pat. No. 5,642,221; U.S. Pat. No. 5,619,377; U.S. Pat. No. 5,619,373; U.S. Pat. No. 5,606,458; U.S. Pat. No. 5,572,229; U.S. Pat. No. 5,546,099; U.S. Pat. No. 5,543,816; U.S. Pat. No. 5,539,422; U.S. Pat. No. 5,537,253; U.S. Pat. No. 5,526,184; U.S. Pat. No. 5,486,841; U.S. Pat. No. 5,483,307; U.S. Pat. No. 5,341,242; U.S. Pat. No. 5,281,957; and U.S. Pat. No. 5,003,300. When Communication Device 200 is in the voice communication mode, the analog audio data input to Microphone 215 is converted to a digital format by A/D 213 and transmitted to another device via Antenna 218 in a wireless fashion after being processed by Signal Processor 208 , and the wireless signal representing audio data which is received via Antenna 218 is output from Speaker 216 after being processed by Signal Processor 208 and converted to analog signal by D/A 204 . For the avoidance of doubt, the definition of Communication Device 200 in this specification includes so-called ‘PDA’. The definition of Communication Device 200 also includes in this specification any device which is mobile and/or portable and which is capable to send and/or receive audio data, text data, image data, video data, and/or other types of data in a wireless fashion via Antenna 218 . The definition of Communication Device 200 further includes any micro device embedded or installed into devices and equipments (e.g., VCR, TV, tape recorder, heater, air conditioner, fan, clock, micro wave oven, dish washer, refrigerator, oven, washing machine, dryer, door, window, automobile, motorcycle, and modem) to remotely control these devices and equipments. The size of Communication Device 200 is irrelevant. Communication Device 200 may be installed in houses, buildings, bridges, boats, ships, submarines, airplanes, and spaceships, and firmly fixed therein. FIG. 2 a illustrates one of the preferred methods of the communication between two Communication Device 200 . In FIG. 2 a , both Device A and Device B represents Communication Device 200 in FIG. 1 . Device A transfers wireless data to Transmitter 301 which Relays the data to Host H via Cable 302 . The data is transferred to Transmitter 308 (e.g., a satellite dish) via Cable 320 and then to Artificial Satellite 304 . Artificial Satellite 304 transfers the data to Transmitter 309 which transfers the data to Host H via Cable 321 . The data is then transferred to Transmitter 307 via Cable 306 and to Device B in a wireless fashion. Device B transfers wireless data to Device A in the same manner. FIG. 2 b illustrates another preferred method of the communication between two Communication Devices 200 . In this example, Device A directly transfers the wireless data to Host H, an artificial satellite, which transfers the data directly to Device B. Device B transfers wireless data to Device A in the same manner. FIG. 2 c illustrates another preferred method of the communication between two Communication Devices 200 . In this example, Device A transfers wireless data to Transmitter 312 , an artificial satellite, which Relays the data to Host H, which is also an artificial satellite, in a wireless fashion. The data is transferred to Transmitter 314 , an artificial satellite, which Relays the data to Device B in a wireless fashion. Device B transfers wireless data to Device A in the same manner. <<Voice Recognition System>> Communication Device 200 ( FIG. 1 ) has a function to operate the device by the user's voice or convert the user's voice into a text format (i.e., the voice recognition). Such function can be enabled by the technologies primarily introduced in the following inventions and the references cited thereof: U.S. Pat. No. 6,282,268; U.S. Pat. No. 6,278,772; U.S. Pat. No. 6,269,335; U.S. Pat. No. 6,269,334; U.S. Pat. No. 6,260,015; U.S. Pat. No. 6,260,014; U.S. Pat. No. 6,253,177; U.S. Pat. No. 6,253,175; U.S. Pat. No. 6,249,763; U.S. Pat. No. 6,246,990; U.S. Pat. No. 6,233,560; U.S. Pat. No. 6,219,640; U.S. Pat. No. 6,219,407; U.S. Pat. No. 6,199,043; U.S. Pat. No. 6,199,041; U.S. Pat. No. 6,195,641; U.S. Pat. No. 6,192,343; U.S. Pat. No. 6,192,337; U.S. Pat. No. 6,188,976; U.S. Pat. No. 6,185,530; U.S. Pat. No. 6,185,529; U.S. Pat. No. 6,185,527; U.S. Pat. No. 6,182,037; U.S. Pat. No. 6,178,401; U.S. Pat. No. 6,175,820; U.S. Pat. No. 6,163,767; U.S. Pat. No. 6,157,910; U.S. Pat. No. 6,119,086; U.S. Pat. No. 6,119,085; U.S. Pat. No. 6,101,472; U.S. Pat. No. 6,100,882; U.S. Pat. No. 6,092,039; U.S. Pat. No. 6,088,669; U.S. Pat. No. 6,078,807; U.S. Pat. No. 6,075,534; U.S. Pat. No. 6,073,101; U.S. Pat. No. 6,073,096; U.S. Pat. No. 6,073,091; U.S. Pat. No. 6,067,517; U.S. Pat. No. 6,067,514; U.S. Pat. No. 6,061,646; U.S. Pat. No. 6,044,344; U.S. Pat. No. 6,041,300; U.S. Pat. No. 6,035,271; U.S. Pat. No. 6,006,183; U.S. Pat. No. 5,995,934; U.S. Pat. No. 5,974,383; U.S. Pat. No. 5,970,239; U.S. Pat. No. 5,963,905; U.S. Pat. No. 5,956,671; U.S. Pat. No. 5,953,701; U.S. Pat. No. 5,953,700; U.S. Pat. No. 5,937,385; U.S. Pat. No. 5,937,383; U.S. Pat. No. 5,933,475; U.S. Pat. No. 5,930,749; U.S. Pat. No. 5,909,667; U.S. Pat. No. 5,899,973; U.S. Pat. No. 5,895,447; U.S. Pat. No. 5,884,263; U.S. Pat. No. 5,878,117; U.S. Pat. No. 5,864,819; U.S. Pat. No. 5,848,163; U.S. Pat. No. 5,819,225; U.S. Pat. No. 5,805,832; U.S. Pat. No. 5,802,251; U.S. Pat. No. 5,799,278; U.S. Pat. No. 5,797,122; U.S. Pat. No. 5,787,394; U.S. Pat. No. 5,768,603; U.S. Pat. No. 5,751,905; U.S. Pat. No. 5,729,656; U.S. Pat. No. 5,704,009; U.S. Pat. No. 5,671,328; U.S. Pat. No. 5,649,060; U.S. Pat. No. 5,615,299; U.S. Pat. No. 5,615,296; U.S. Pat. No. 5,544,277; U.S. Pat. No. 5,524,169; U.S. Pat. No. 5,522,011; U.S. Pat. No. 5,513,298; U.S. Pat. No. 5,502,791; U.S. Pat. No. 5,497,447; U.S. Pat. No. 5,477,451; U.S. Pat. No. 5,475,792; U.S. Pat. No. 5,465,317; U.S. Pat. No. 5,455,889; U.S. Pat. No. 5,440,663; U.S. Pat. No. 5,425,129; U.S. Pat. No. 5,353,377; U.S. Pat. No. 5,333,236; U.S. Pat. No. 5,313,531; U.S. Pat. No. 5,293,584; U.S. Pat. No. 5,293,451; U.S. Pat. No. 5,280,562; U.S. Pat. No. 5,278,942; U.S. Pat. No. 5,276,766; U.S. Pat. No. 5,267,345; U.S. Pat. No. 5,233,681; U.S. Pat. No. 5,222,146; U.S. Pat. No. 5,195,167; U.S. Pat. No. 5,182,773; U.S. Pat. No. 5,165,007; U.S. Pat. No. 5,129,001; U.S. Pat. No. 5,072,452; U.S. Pat. No. 5,067,166; U.S. Pat. No. 5,054,074; U.S. Pat. No. 5,050,215; U.S. Pat. No. 5,046,099; U.S. Pat. No. 5,033,087; U.S. Pat. No. 5,031,217; U.S. Pat. No. 5,018,201; U.S. Pat. No. 4,980,918; U.S. Pat. No. 4,977,599; U.S. Pat. No. 4,926,488; U.S. Pat. No. 4,914,704; U.S. Pat. No. 4,882,759; U.S. Pat. No. 4,876,720; U.S. Pat. No. 4,852,173; U.S. Pat. No. 4,833,712; U.S. Pat. No. 4,829,577; U.S. Pat. No. 4,827,521; U.S. Pat. No. 4,759,068; U.S. Pat. No. 4,748,670; U.S. Pat. No. 4,741,036; U.S. Pat. No. 4,718,094; U.S. Pat. No. 4,618,984; U.S. Pat. No. 4,348,553; U.S. Pat. No. 6,289,140; U.S. Pat. No. 6,275,803; U.S. Pat. No. 6,275,801; U.S. Pat. No. 6,272,146; U.S. Pat. No. 6,266,637; U.S. Pat. No. 6,266,571; U.S. Pat. No. 6,223,153; U.S. Pat. No. 6,219,638; U.S. Pat. No. 6,163,535; U.S. Pat. No. 6,115,820; U.S. Pat. No. 6,107,935; U.S. Pat. No. 6,092,034; U.S. Pat. No. 6,088,361; U.S. Pat. No. 6,073,103; U.S. Pat. No. 6,073,095; U.S. Pat. No. 6,067,084; U.S. Pat. No. 6,064,961; U.S. Pat. No. 6,055,306; U.S. Pat. No. 6,047,301; U.S. Pat. No. 6,023,678; U.S. Pat. No. 6,023,673; U.S. Pat. No. 6,009,392; U.S. Pat. No. 5,995,933; U.S. Pat. No. 5,995,931; U.S. Pat. No. 5,995,590; U.S. Pat. No. 5,991,723; U.S. Pat. No. 5,987,405; U.S. Pat. No. 5,974,382; U.S. Pat. No. 5,943,649; U.S. Pat. No. 5,916,302; U.S. Pat. No. 5,897,616; U.S. Pat. No. 5,897,614; U.S. Pat. No. 5,893,133; U.S. Pat. No. 5,873,064; U.S. Pat. No. 5,870,616; U.S. Pat. No. 5,864,805; U.S. Pat. No. 5,857,099; U.S. Pat. No. 5,809,471; U.S. Pat. No. 5,805,907; U.S. Pat. No. 5,799,273; U.S. Pat. No. 5,764,852; U.S. Pat. No. 5,715,469; U.S. Pat. No. 5,682,501; U.S. Pat. No. 5,680,509; U.S. Pat. No. 5,668,854; U.S. Pat. No. 5,664,097; U.S. Pat. No. 5,649,070; U.S. Pat. No. 5,640,487; U.S. Pat. No. 5,621,809; U.S. Pat. No. 5,577,249; U.S. Pat. No. 5,502,774; U.S. Pat. No. 5,471,521; U.S. Pat. No. 5,467,425; U.S. Pat. No. 5,444,617; U.S. Pat. No. 4,991,217; U.S. Pat. No. 4,817,158; U.S. Pat. No. 4,725,885; U.S. Pat. No. 4,528,659; U.S. Pat. No. 3,995,254; U.S. Pat. No. 3,969,700; U.S. Pat. No. 3,925,761; U.S. Pat. No. 3,770,892. The voice recognition function can be performed in terms of software by using Area 261 , the voice recognition working area, of RAM 206 ( FIG. 1 ) which is specifically allocated to perform such function as described in FIG. 3 , or can also be performed in terms of hardware circuit where such space is specifically allocated in Area 282 of Sound Processor 205 ( FIG. 1 ) for the voice recognition system as described in FIG. 4 . FIG. 5 illustrates how the voice recognition function is activated. CPU 211 ( FIG. 1 ) periodically checks the input status of Input Device 210 ( FIG. 1 ) (S 1 ). If the CPU 211 detects a specific signal input from Input Device 210 (S 2 ) the voice recognition system which is described in FIG. 2 and/or FIG. 3 is activated. As another embodiment, the voice recognition system can also be activated by entering predetermined phrase, such as ‘start voice recognition system’ via Microphone 215 ( FIG. 1 ). <<Voice Recognition—Dialing/Auto-Off During Call Function>> FIG. 6 a and FIG. 6 b illustrate the operation of the voice recognition in the present invention. Once the voice recognition system is activated (S 1 ) the analog audio data is input from Microphone 215 ( FIG. 1 ) (S 2 ). The analog audio data is converted into digital data by A/D 213 ( FIG. 1 ) (S 3 ). The digital audio data is processed by Sound Processor 205 ( FIG. 1 ) to retrieve the text and numeric information therefrom (S 4 ). Then the numeric information is retrieved (S 5 ) and displayed on LCD 201 ( FIG. 1 ) (S 6 ). If the retrieved numeric information is not correct (S 7 ), the user can input the correct numeric information manually by using Input Device 210 ( FIG. 1 ) (S 8 ). Once the sequence of inputting the numeric information is completed and after the confirmation process is over (S 9 ), the entire numeric information is displayed on LCD 201 and the sound is output from Speaker 216 under control of CPU 211 (S 10 ). If the numeric information is correct (S 11 ), Communication Device 200 ( FIG. 1 ) initiates the dialing process by utilizing the numeric information (S 12 ). The dialing process continues until Communication Device 200 is connected to another device (S 13 ). Once CPU 211 detects that the line is connected it automatically deactivates the voice recognition system (S 14 ). As described in FIG. 7 , CPU 211 ( FIG. 1 ) checks the status of Communication Device 200 periodically (S 1 ) and remains the voice recognition system offline during call (S 2 ). If the connection is severed, i.e., user hangs up, then CPU 211 reactivates the voice recognition system (S 3 ). <<Voice Recognition Tag Function>> FIGS. 8 through 12 describes the method of inputting the numeric information in a convenient manner. As described in FIG. 8 , RAM 206 includes Table # 1 ( FIG. 8 ) and Table # 2 ( FIG. 9 ). In FIG. 8 , audio information # 1 corresponds to tag ‘Scott.’ Namely audio information, such as wave data, which represents the sound of ‘Scott’ (sounds like ‘S-ko-t’) is registered in Table # 1 , which corresponds to tag ‘Scott’. In the same manner audio information # 2 corresponds to tag ‘Carol’; audio information # 3 corresponds to tag ‘Peter’; audio information # 4 corresponds to tag ‘Amy’; and audio information # 5 corresponds to tag ‘Brian.’ In FIG. 9 , tag ‘Scott’ corresponds to numeric information ‘(916) 411-2526’; tag ‘Carol’ corresponds to numeric information ‘(418) 675-6566’; tag ‘Peter’ corresponds to numeric information ‘(220) 890-1567’; tag ‘Amy’ corresponds to numeric information ‘(615) 125-3411’; and tag ‘Brian’ corresponds to numeric information ‘(042) 645-2097.’ FIG. 11 illustrates how CPU 211 ( FIG. 1 ) operates by utilizing both Table # 1 and Table # 2 . Once the audio data is processed as described in S 4 of FIG. 6 , CPU 211 scans Table # 1 (S 1 ). If the retrieved audio data matches with one of the audio information registered in Table # 1 (S 2 ), CPU 211 scans Table # 2 (S 3 ) and retrieves the corresponding numeric information from Table # 2 (S 4 ). FIG. 10 illustrates another embodiment of the present invention. Here, RAM 206 includes Table #A instead of Table # 1 and Table # 2 described above. In this embodiment, audio info # 1 (i.e., wave data which represents the sound of ‘Scot’) directly corresponds to numeric information ‘(916) 411-2526.’ In the same manner audio info # 2 corresponds to numeric information ‘(410) 675-6566’; audio info # 3 corresponds to numeric information ‘(220) 890-1567’; audio info # 4 corresponds to numeric information ‘(615) 125-3411’; and audio info # 5 corresponds to numeric information ‘(042) 645-2097.’ FIG. 12 illustrates how CPU 211 ( FIG. 1 ) operates by utilizing Table #A. Once the audio data is processed as described in S 4 of FIG. 6 , CPU 211 scans Table #A (S 1 ). If the retrieved audio data matches with one of the audio information registered in Table #A (S 2 ), it retrieves the corresponding numeric information therefrom (S 3 ). As another embodiment, RAM 206 may contain only Table # 2 and tag can be retrieved from the voice recognition system explained in FIGS. 3 through 7 . Namely, once the audio data is processed by CPU 211 ( FIG. 1 ) as described in S 4 of FIG. 6 and retrieves the text data therefrom and detects one of the tags registered in Table # 2 (e.g., ‘Scot’), CPU 211 retrieves the corresponding numeric information (e.g., ‘(916) 411-2526’) from the same table. <<Voice Recognition Noise Filtering Function>> FIGS. 13 through 15 describes the method of minimizing the undesired effect of the background noise when utilizing the voice recognition system. As described in FIG. 13 , RAM 206 ( FIG. 1 ) includes Area 255 and Area 256 . Sound audio data which represents background noise is stored in Area 255 , and sound audio data which represents the beep, ringing sound and other sounds which are emitted from the Communication Device 200 are stored in Area 256 . FIG. 14 describes the method to utilize the data stored in Area 255 and Area 256 described in FIG. 13 . When the voice recognition system is activated as described in FIG. 5 , the analog audio data is input from Microphone 215 ( FIG. 1 ) (S 1 ). The analog audio data is converted into digital data by A/D 213 ( FIG. 1 ) (S 2 ). The digital audio data is processed by Sound Processor 205 ( FIG. 1 ) (S 3 ) and compared to the data stored in Area 255 and Area 256 (S 4 ). Such comparison can be done by either Sound Processor 205 or CPU 211 ( FIG. 1 ). If the digital audio data matches to the data stored in Area 255 and/or Area 256 , the filtering process is initiated and the matched portion of the digital audio data is deleted as background noise. Such sequence of process is done before retrieving text and numeric information from the digital audio data. FIG. 14 a describes the method of updating Area 255 . When the voice recognition system is activated as described in FIG. 5 , the analog audio data is input from Microphone 215 ( FIG. 1 ) (S 1 ). The analog audio data is converted into digital data by A/D 213 ( FIG. 1 ) (S 2 ). The digital audio data is processed by Sound Processor 205 ( FIG. 1 ) or CPU 211 ( FIG. 1 ) (S 3 ) and the background noise is captured (S 4 ). CPU 211 ( FIG. 1 ) scans Area 255 and if the captured background noise is not registered in Area 255 , it updates the sound audio data stored therein (S 5 ). FIG. 15 describes another embodiment of the present invention. CPU 211 ( FIG. 1 ) routinely checks whether the voice recognition system is activated (S 1 ). If the system is activated (S 2 ), the beep, ringing sound, and other sounds which are emitted from Communication Device 200 are automatically turned off in order to minimize the miss recognition process of the voice recognition system (S 3 ). <<Voice Recognition Auto-Off Function>> The voice recognition system can be automatically turned off to avoid glitch as described in FIG. 16 . When the voice recognition system is activated (S 1 ), CPU 211 ( FIG. 1 ) automatically sets a timer (S 2 ). The value of timer (i.e., the length of time until the system is deactivated) can be set manually by the user. The timer is incremented periodically (S 3 ), and if the incremented time equals to the predetermined value of time as set in S 2 (S 4 ), the voice recognition system is automatically deactivated (S 5 ). <<Voice Recognition Email Function (1)>> FIGS. 17 a and 17 b illustrate the first embodiment of the function of typing and sending e-mails by utilizing the voice recognition system. Once the voice recognition system is activated (S 1 ), the analog audio data is input from Microphone 215 ( FIG. 1 ) (S 2 ). The analog audio data is converted into digital data by A/D 213 ( FIG. 1 ) (S 3 ). The digital audio data is processed by Sound Processor 205 ( FIG. 1 ) or CPU 211 ( FIG. 1 ) to retrieve the text and numeric information therefrom (S 4 ). The text and numeric information are retrieved (S 5 ) and are displayed on LCD 201 ( FIG. 1 ) (S 6 ). If the retrieved information is not correct (S 7 ), the user can input the correct text and/or numeric information manually by using the Input Device 210 ( FIG. 1 ) (S 8 ). If inputting the text and numeric information is completed (S 9 ) and CPU 211 detects input signal from Input Device 210 to send the e-mail (S 10 ), the dialing process is initiated (S 11 ). The dialing process is repeated until Communication Device 200 is connected to Host H (S 12 ), and the e-mail is sent to the designated address (S 13 ). <<Voice Recognition—Speech-to-Text Function>> FIG. 18 illustrates the speech-to-text function of Communication Device 200 ( FIG. 1 ). Once Communication Device 200 receives a transmitted data from another device via Antenna 218 ( FIG. 1 ) (S 1 ), Signal Processor 208 ( FIG. 1 ) processes the data (e.g., wireless signal error check and decompression) (S 2 ), and the transmitted data is converted into digital audio data (S 3 ). Such conversion can be rendered by either CPU 211 ( FIG. 1 ) or Signal Processor 208 . The digital audio data is transferred to Sound Processor 205 ( FIG. 1 ) via Data Bus 203 and text and numeric information are retrieved therefrom (S 4 ). CPU 211 designates the predetermined font and color to the text and numeric information (S 5 ) and also designates a tag to such information (S 6 ). After these tasks are completed the tag and the text and numeric information are stored in RAM 206 and displayed on LCD 201 (S 7 ). FIG. 19 illustrates how the text and numeric information as well as the tag are displayed. On LCD 201 the text and numeric information 702 (‘XXXXXXXXX’) are displayed with the predetermined font and color as well as with the tag 701 (‘John’). <<Voice Recognition—Summary>> The foregoing inventions may be summarized as the following. (1) A communication device which has a function to retrieve text and numeric information from a user's voice input from a microphone wherein said function is deactivated when said communication device is connected to another device in order to avoid undesired operation of said communication device. (2) A communication device which has a function to retrieve text and numeric information from a user's voice input from a microphone wherein said communication device retrieves a numeric information from said user's voice and initiates a dialing process by utilizing said numeric information thereby enabling said user to initiate said dialing process only by his/her voice and/or by without physically contacting said communication device. (3) A communication device which has a function to retrieve text and numeric information from a user's voice input from a microphone wherein said communication device retrieves audio information from which numeric information can not be retrieved from said user's voice and retrieves predetermined corresponding numeric information therefrom thereby enabling said user to initiate a dialing process in a convenient manner and without memorizing said numeric information or without referring to other sources for said information. (4) A communication device which has a function to retrieve text and numeric information from a user's voice input from a microphone wherein said communication device compares audio information retrieved from said user's voice with pre-stored audio data and erases said audio data from said audio information before retrieving text and numeric information therefrom thereby enabling said function to be more accurate and minimizing error in retrieving said text and numeric information. (5) A communication device which has a function to retrieve text and numeric information from a user's voice input from a microphone wherein said communication device retrieves text and numeric information from data transmitted from another device and displays said text and numeric information with predetermined font and color thereby enabling the user to visually confirm the content of conversation by way of observing the said text and numeric information displayed. (6) A wireless communication device comprising a microphone, a display, an input device, an antenna, an alphanumeric data modification means and, a voice recognition system, wherein when said voice recognition system is activated and said wireless communication is in an email producing mode to produce an email, a series of audio data is input from said microphone and said voice recognition system converts said series of audio data into a first series of alphanumeric data which are displayed on said display, said first series of alphanumeric data are modified by said alphanumeric data modification means to a second series of alphanumeric data when said second series of alphanumeric data are input from said input device, said email including said second series of alphanumeric data is transmitted in a wireless manner from said antenna. <<Positioning System>> FIG. 20 a illustrates the simplified block diagram to detect the position of Communication Device 200 ( FIG. 1 ). In FIG. 20 a , Relay R 1 is connected to Cable C 1 , Relay R 2 is connected to Cable C 2 , Relay R 3 is connected to Cable C 3 , and Relay R 4 is connected to Cable C 4 . Cables C 1 , C 2 , C 3 , and C 4 are connected to Transmitter T, which is connected to Host H by Cable C 5 . The Relays (R 1 through R 20 ) are located throughout the predetermined area in the pattern illustrated in FIG. 20 b . The system illustrated in FIG. 20 a and FIG. 20 b is designed to pinpoint the position of Communication Device 200 by using the method so-called ‘global positioning system’ or ‘GPS.’ Such function can be enabled by the technologies primarily introduced in the following inventions and the references cited thereof: U.S. Pat. No. 6,429,814; U.S. Pat. No. 6,427,121; U.S. Pat. No. 6,427,120; U.S. Pat. No. 6,424,826; U.S. Pat. No. 6,415,227; U.S. Pat. No. 6,415,154; U.S. Pat. No. 6,411,811; U.S. Pat. No. 6,392,591; U.S. Pat. No. 6,389,291; U.S. Pat. No. 6,369,751; U.S. Pat. No. 6,347,113; U.S. Pat. No. 6,324,473; U.S. Pat. No. 6,301,545; U.S. Pat. No. 6,297,770; U.S. Pat. No. 6,278,404; U.S. Pat. No. 6,275,771; U.S. Pat. No. 6,272,349; U.S. Pat. No. 6,266,012; U.S. Pat. No. 6,259,401; U.S. Pat. No. 6,243,647; U.S. Pat. No. 6,236,354; U.S. Pat. No. 6,233,094; U.S. Pat. No. 6,232,922; U.S. Pat. No. 6,211,822; U.S. Pat. No. 6,188,351; U.S. Pat. No. 6,182,927; U.S. Pat. No. 6,163,567; U.S. Pat. No. 6,101,430; U.S. Pat. No. 6,084,542; U.S. Pat. No. 5,971,552; U.S. Pat. No. 5,963,167; U.S. Pat. No. 5,944,770; U.S. Pat. No. 5,890,091; U.S. Pat. No. 5,841,399; U.S. Pat. No. 5,808,582; U.S. Pat. No. 5,777,578; U.S. Pat. No. 5,774,831; U.S. Pat. No. 5,764,184; U.S. Pat. No. 5,757,786; U.S. Pat. No. 5,736,961; U.S. Pat. No. 5,736,960; U.S. Pat. No. 5,594,454; U.S. Pat. No. 5,585,800; U.S. Pat. No. 5,554,994; U.S. Pat. No. 5,535,278; U.S. Pat. No. 5,534,875; U.S. Pat. No. 5,519,620; U.S. Pat. No. 5,506,588; U.S. Pat. No. 5,446,465; U.S. Pat. No. 5,434,574; U.S. Pat. No. 5,402,441; U.S. Pat. No. 5,373,531; U.S. Pat. No. 5,349,531; U.S. Pat. No. 5,347,286; U.S. Pat. No. 5,341,301; U.S. Pat. No. 5,339,246; U.S. Pat. No. 5,293,170; U.S. Pat. No. 5,225,842; U.S. Pat. No. 5,223,843; U.S. Pat. No. 5,210,540; U.S. Pat. No. 5,193,064; U.S. Pat. No. 5,187,485; U.S. Pat. No. 5,175,557; U.S. Pat. No. 5,148,452; U.S. Pat. No. 5,134,407; U.S. Pat. No. 4,928,107; U.S. Pat. No. 4,928,106; U.S. Pat. No. 4,785,463; U.S. Pat. No. 4,754,465; U.S. Pat. No. 4,622,557; and U.S. Pat. No. 4,457,006. Relays R 1 through R 20 are preferably located on ground, however, are also permitted to be installed in artificial satellites as described in the foregoing patents and the references cited thereof in order to cover wider geographical range. The Relays may also be installed in houses, buildings, bridges, boats, ships, submarines, airplanes, and spaceships. In addition, Host H may be carried by houses, buildings, bridges, boats, ships, submarines, airplanes, and spaceships. In stead of utilizing Cables C 1 through C 5 , Relays R 1 through R 20 (and other relays described in this specification) may be connected to Transmitter T in a wireless fashion, and Transmitter T may be connected to Host H in a wireless fashion. FIGS. 21 through 26 illustrate how the positioning system is performed. Assuming that Device A, Communication Device 200 , seeks to detect the position of Device B, another Communication Device 200 , which is located somewhere in the matrix of Relays illustrated in FIG. 20 b. As described in FIG. 21 , first of all the device ID of Device B is entered by utilizing Input Device 210 ( FIG. 1 ) or the voice recognition system of Device A installed therein (S 1 ). The device ID may be its corresponding phone number. A request data including the device ID is sent to Host H ( FIG. 20 a ) from Device A (S 2 ). As illustrated in FIG. 22 , Host H ( FIG. 20 a ) periodically receives data from Device A (S 1 ). If the received data is a request data (S 2 ), Host H, first of all, searches its communication log which records the location of Device B when it last communicated with Host H (S 3 ). Then Host H sends search signal from the Relays described in FIG. 20 b which are located within 100-meter radius from the location registered in the communication log. If there is no response from Device B (S 5 ), Host H sends a search signal from all Relays (from R 1 to R 20 in FIG. 20 b ) (S 6 ). As illustrated in FIG. 23 , Device B periodically receives data from Host H ( FIG. 20 a ) (S 1 ). If the data received is a search signal (S 2 ), Device B sends a response signal to Host H (S 3 ). As illustrated in FIG. 24 Host H ( FIG. 20 a ) periodically receives data from Device B (S 1 ). If the data received is a response signal (S 2 ), Host H locates the geographic position of Device B by utilizing the method described in FIGS. 20 a and 20 b (S 3 ), and sends the location data and the relevant map data of the area where Device B is located to Device A (S 4 ). As illustrated in FIG. 25 , Device A periodically receives data from Host H ( FIG. 20 a ) (S 1 ). If the data received is the location data and the relevant map data mentioned above (S 2 ), Device A displays the map based on the relevant map data and indicates the current location of Device B thereon based on the location data received (S 3 ). Device A can continuously track down the current location of Device B as illustrated in FIG. 26 . First, Device A sends a request data to Host H ( FIG. 20 a ) (S 1 ). As soon as Host H receives the request data (S 2 ), it sends a search signal in the manner illustrated in FIG. 22 (S 3 ). As soon as Device B receives the search signal (S 4 ), it sends a response signal to Host H (S 5 ). Based on the response signal, Host H locates the geographic location of Device B with the method described in FIGS. 20 a and 20 b (S 6 ). Then Host H sends to Device A a renewed location data and a relevant map data of the area where Device B is currently located (S 7 ). As soon as these data are received (S 8 ), Device A displays the map based on the relevant map data and indicates the updated location based on the renewed location data (S 9 ). If Device B is still within the specified area Device A may use the original relevant map data. As another embodiment of the present invention, S 1 through S 4 may be omitted and make Device B send a response signal continuously to Host H until Host H sends a command signal to Device B to cease sending the response signal. <<Positioning System—Automatic Silent Mode>> FIGS. 27 a through 32 g illustrate the automatic silent mode of Communication Device 200 ( FIG. 1 ). In FIG. 27 a , Relay R 1 is connected to Cable C 1 , Relay R 2 is connected to Cable C 2 , Relay R 3 is connected to Cable C 3 , and Relay R 4 is connected to Cable C 4 . Cables C 1 , C 2 , C 3 , and C 4 are connected to Transmitter T, which is connected to Host H by Cable C 5 . The Relays (R 1 through R 20 ) are located throughout the predetermined area in the pattern illustrated in FIG. 27 b . The system illustrated in FIGS. 27 a and 27 b is designed to pinpoint the position of Communication Device 200 by using the method so-called ‘global positioning system’ or ‘GPS.’ As stated hereinbefore, such function can be enabled by the technologies primarily introduced in the inventions in the foregoing patents and the references cited thereof. The Relays R 1 through R 20 are preferably located on ground, however, are also permitted to be installed in artificial satellites as described in the foregoing patents and the references cited thereof in order to cover wider geographical range. In addition, Host H may be carried by an artificial satellite and utilize the formation as described in FIGS. 2 a , 2 b , and 2 c. As illustrated in FIG. 28 , the user of Communication Device 200 may set the silent mode by Input Device 210 ( FIG. 1 ) or by utilizing the voice recognition system installed therein. When Communication Device 200 is in the silent mode, (a) the ringing sound is turned off, (b) Vibrator 217 ( FIG. 1 ) activates when Communication Device 200 receives call, and/or (c) Communication Device 200 sends an automatic response to the caller device when a call is received (S 1 ). The user may, at his discretion, select any of these predetermined functions of the automatic silent mode. FIG. 29 illustrates how the automatic silent mode is activated. Communication Device 200 periodically checks its present location with the method so-called ‘global positioning system’ or ‘GPS’ by using the system illustrated in FIGS. 27 a and 27 b (S 1 ). Communication Device 200 then compares the present location and the previous location (S 2 ). If the difference of the two values is more than the specified amount X, i.e., when the moving velocity of Communication Device 200 exceeds the predetermined value (S 3 ), the silent mode is activated and (a) the ringing sound is automatically turned off, (b) Vibrator 217 ( FIG. 1 ) activates, and/or (c) Communication Device 200 sends an automatic response to the caller device according to the user's setting (S 4 ). Here, the silent mode is automatically activated because the user of Communication Device 200 is presumed to be on an automobile and is not in a situation to freely answer the phone, or the user is presumed to be riding a train and does not want to disturb other passengers. As another embodiment of the present invention, the automatic silent mode may be administered by Host H ( FIG. 27 a ). As illustrated in FIG. 30 , the silent mode is set in the manner described in FIG. 28 (S 1 ) and Communication Device 200 sends to Host H a request signal indicating that it is in the silent mode (S 2 ). As described in FIG. 31 , when Host H ( FIG. 27 a ) detects a call to Communication Device 200 after receiving the request signal, it checks the current location of Communication Device 200 (S 1 ) and compares it with the previous location (S 2 ). If the difference of the two values is more than the specified amount X, i.e., when the moving velocity of Communication Device 200 exceeds the predetermined value (S 3 ), Host H sends a notice signal to Communication Device 200 indicating that it has received an incoming call (S 4 ). As illustrated in FIG. 32 , Communication Device 200 receives data periodically from Host H ( FIG. 27 a ) (S 1 ). If the received data is a notice signal (S 2 ), Communication Device 200 activates the silent mode (S 3 ) and (a) the ringing sound is automatically turned off, (b) Vibrator 217 ( FIG. 1 ) activates, and/or (c) Communication Device 200 sends an automatic response to the caller device according to the user's setting. The automatic response may be sent from Host H instead. As another embodiment of the present invention, a train route data may be utilized. As illustrated in FIG. 32 a , a train route data is stored in Area 263 of RAM 206 . The train route data contains three-dimensional train route map including the location data of the train route. FIG. 32 b illustrates how the train route data is utilized. CPU 211 ( FIG. 1 ) periodically checks the present location of Communication Device 200 by the method described in FIGS. 27 a and 27 b (S 1 ). Then CPU 211 compares with the train route data stored in Area 263 of RAM 206 (S 2 ). If the present location of Communication Device 200 matches the train route data (i.e., if Communication Device 200 is located on the train route) (S 3 ), the silent mode is activated in the manner described above (S 4 ). The silent mode is activated because the user of Communication Device 200 is presumed to be currently on a train and may not want to disturb the other passengers on the same train. As another embodiment of the present invention, such function can be delegated to Host H ( FIG. 27 a ) as described in FIG. 32 c . Namely, Host H ( FIG. 27 a ) periodically checks the present location of Communication Device 200 by the method described in FIGS. 27 a and 27 b (S 1 ). Then Host H compares the present location with the train route data stored in its own storage (not shown) (S 2 ). If the present location of communication 200 matches the train route data (i.e., if Communication Device 200 is located on the train route) (S 3 ) Host H sends a notice signal to Communication Device 200 thereby activating the silent mode in the manner described above (S 4 ). Another embodiment is illustrated in FIGS. 32 f and 32 g . As illustrated in FIG. 32 f , Relays R 101 , R 102 , R 103 , R 104 , R 105 , R 106 , which perform the same function to the Relays described in FIG. 27 a and FIG. 27 b , are installed in Train Tr. The signals from these Relays are sent to Host H illustrated in FIG. 27 a . Relays R 101 through R 106 emit inside-the-train signals which are emitted only inside Train Tr. FIG. 32 g illustrates how Communication Device 200 operates inside Train Tr. Communication Device 200 periodically checks the signal received in Train Tr (S 1 ). If Communication Device 200 determines that the signal received is an inside-the-train signal (S 2 ), it activates the silent mode in the manner described above (S 3 ). <<Positioning System—Auto Response Mode>> FIG. 32 d and FIG. 32 e illustrates the method to send an automatic response to a caller device when the silent mode is activated. Assume that the caller device, a Communication Device 200 , intends to call a callee device, another Communication Device 200 via Host H ( FIG. 27 a ). As illustrated in FIG. 32 d , the caller device dials the callee device and the dialing signal is sent to Host H (S 1 ). Host H checks whether the callee device is in the silent mode (S 2 ). If Host H detects that the callee device is in the silent mode, it sends a predetermined auto response which indicates that the callee is probably on a train and may currently not be available, which is received by the caller device (S 3 ). If the user of the caller device still desires to request for connection and certain code is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system (S 4 ), a request signal for connection is sent and received by Host H (S 5 ), and the line is connected between the caller device and the callee device via Host H (S 6 ). As another embodiment of the present invention, the task of Host H ( FIG. 27 a ) which is described in FIG. 32 d may be delegated to the callee device as illustrated in FIG. 32 e . The caller device dials the callee device and the dialing signal is sent to the callee device via Host H (S 1 ). The callee device checks whether it is in the silent mode (S 2 ). If the callee device detects that it is in the silent mode, it sends an predetermined auto response which indicates that the callee is probably on a train and may currently not be available, which is sent to the caller device via Host H (S 3 ). If the user of the caller device still desires to request for connection and certain code is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system (S 4 ), a request signal for connection is sent to the callee device via Host H (S 5 ), and the line is connected between the caller device and the callee device via Host H (S 6 ). <<Positioning System—Summary>> The foregoing inventions may be summarized as the following. (1) A positioning system comprising a first device, a host, and a second device wherein a device ID of said second device is input into said first device, said device ID is sent to said host, said host sends a search signal to which said second device responds, said host sends to the first device location data indicating the location of said second device, and said first device displays the location of said second device thereby enabling said first device to identify the location of said second device. Where said first device is a communication device, said first device includes an antenna, said antenna sends positioning signal to identify the location of said second device, and said antenna also sends communication signal thereby enabling the user of said first device to identify the location of said second device as well as utilizing said communication device for means of communication. (2) A communication device wherein the moving velocity of said communication device is checked and when said moving velocity exceeds a predetermined value said communication device refrains from emitting sound thereby preventing other persons being present near said communication device from being disturbed. (3) A communication device wherein the location of said communication device is compared to a route data and said communication device refrains from emitting sound if said location of said communication device is determined to match said route data thereby preventing other persons being present near said communication device from being disturbed. (4) A communication system comprising a first communication device and a second communication device wherein said first communication device receives an automatic response if said second communication device is in a certain mode and said first communication device is enable to be connected to said second communication device upon said second device sending a request thereby preventing other persons being present near said first communication device from being disturbed. (5) A communication system comprising a communication device and a plurality of signal emitter wherein said communication device refrains from emitting sound upon receiving a certain signal from said signal emitter thereby preventing other persons being present near said communication device from being disturbed. <<Auto Backup System>> FIGS. 33 through 37 illustrate the automatic backup system of Communication Device 200 ( FIG. 1 ). As illustrated in FIG. 33 , RAM 206 ( FIG. 1 ) includes areas to store the data essential to the user of Communication Device 200 , such as Area 278 for a phone list, Area 279 for an address book, Area 280 for email data, Area 281 for software A, Area 282 for software B, Area 283 for software C, Area 284 for Data D, Area 285 for Data E. RAM 206 also includes Area 264 , i.e., the selected data info storage area, which will be explained in details hereinafter. As described in FIG. 34 , the user selects data by utilizing Input Device 210 ( FIG. 1 ) or the voice recognition system which he/she intends to be automatically backed up (S 1 ). The selected data are written in Area 264 , the selected data info storage area (S 2 ). The overall operation of this function is illustrated in FIGS. 35 a and 35 b . First of all, a timer (not shown) is set by a specific input signal produced by Input Device 210 ( FIG. 1 ) or by the voice recognition system (S 1 ). The timer is incremented periodically (S 2 ) and when the incremented value equals the predetermined value (S 3 ), CPU 211 ( FIG. 1 ) initiates the dialing process (S 4 ). The dialing process continues until Communication Device 200 is connected to Host H explained in FIG. 37 (S 5 ). Once the line is connected, CPU 211 reads the information stored in Area 264 (S 6 ) and based on such information it initiates to transfer the selected data from RAM 206 to Host H (S 7 ). The transfer continues until all of the selected data are transferred to Host H (S 8 ), and the line is disconnected thereafter (S 9 ). This backup sequence can be initiated automatically and periodically by using a timer or manually. As another embodiment of the present invention, instead of selecting the data that are to be backed up, all data in RAM 206 ( FIG. 1 ) can be transferred to Host H. FIG. 36 illustrates the basic structure of the data transferred to Host H. Transferred data 601 includes Header 602 , device ID 603 , selected data 604 and Footer 605 . Device ID 603 is the identification number of Communication Device 200 preferably its phone number, and selected data 604 is a pack of data which is transferred from RAM 206 to Host H based on information stored in Area 264 . Header 602 and Footer 605 indicates the beginning and the end of the Transferred Data 601 respectively. FIG. 37 illustrates the basic structure of Host H. Host H includes backup data storage Area 401 which is used to backup all of the backup data transferred from all Communication Devices 200 . Host H stores the Transferred Data 601 ( FIG. 36 ) to the designated area based on the device ID included in Transferred Data 601 . For example, Transferred Data 601 transferred from Device A is stored in Area 412 as Backup Data A. In the same manner Transferred Data 601 transferred from Device B is stored in Area 413 as Backup Data B; Transferred Data 601 transferred from Device C is stored in Area 414 as Backup Data C; Transferred Data 601 transferred from device D is stored in Area 415 as Backup Data D; Transferred Data 601 transferred from device E is stored in Area 416 as Backup Data E; and Transferred Data 601 transferred from device F is stored in Area 417 as Backup Data F. <<Auto Backup—Summary>> The foregoing invention may be summarized as the following. A communication system comprising a host and a plurality of communication device wherein said host includes a plurality of storage areas and each of said plurality of communication device includes a storage area, and data stored in said storage area of said communication device are manually and/or periodically transferred to one of the designated storage areas of said host thereby enabling the users of said plurality of communication device to retrieve data when said plurality of communication device are lost or broken. <<Signal Amplifier>> FIG. 38 illustrates a signal amplifier utilized for automobiles and other transportation carriers, such as trains, airplanes, space shuttles, and motor cycles. As described in FIG. 38 , Automobile 835 includes Interface 503 , an interface detachably connected to Communication Device 200 , which is connected to Amplifier 502 via Cable 505 . Amplifier 502 is connected to Antenna 501 via Cable 504 and Connector 507 as described in this drawing. The signal produced by Communication Device 200 is transferred to Interface 503 . Then the signal is transferred to Amplifier 502 via Cable 505 where the signal is amplified. The amplified signal is transferred to Antenna 501 via Cable 504 and Connector 507 , which transmits the amplified signal to Host H (not shown). The receiving signal is received by Antenna 501 and transferred to Amplifier 502 via Connector 507 and Cable 504 , and then is transferred to Interface 503 via Cable 505 , which transfers the amplified signal to Communication Device 200 . <<Signal Amplifier—Summary>> The foregoing invention may be summarized as the following. A transportation carrier which is primarily designed to carry person or persons comprising an interface which is detachably connectable to a communication device, an amplifier which is connected to said interface and which amplifies the signal produced by said communication device, and an transmitter which is connected to said amplifier and which transmits said signal amplified by said amplifier. <<Audio/Video Data Capturing System>> FIGS. 39 through 44 illustrate the audio/video capturing system of Communication Device 200 ( FIG. 1 ). Assuming that Device A, a Communication Device 200 , captures audio/video data and transfers such data to Device B, another Communication Device 200 , via a host (not shown). Primarily video data is input from CCD Unit 214 ( FIG. 1 ) and audio data is input from Microphone 215 of ( FIG. 1 ) of Device A. As illustrated in FIG. 39 , RAM 206 ( FIG. 1 ) includes Area 267 which stores video data, Area 268 which stores audio data, and Area 265 which is a work area utilized for the process explained hereinafter. As described in FIG. 40 , the video data input from CCD Unit 214 ( FIG. 1 ) (S 1 a ) is converted from analog data to digital data (S 2 a ) and is processed by Video Processor 202 ( FIG. 1 ) (S 3 a ). Area 265 ( FIG. 39 ) is used as work area for such process. The processed video data is stored in Area 267 ( FIG. 39 ) of RAM 206 (S 4 a ) and is displayed on LCD 201 ( FIG. 1 ) (S 5 a ). As described in the same drawing, the audio data input from Microphone 215 ( FIG. 1 ) (S 1 b ) is converted from analog data to digital data by A/D 213 ( FIG. 1 ) (S 2 b ) and is processed by Sound Processor 205 ( FIG. 1 ) (S 3 b ). Area 265 is used as work area for such process. The processed audio data is stored in Area 268 ( FIG. 39 ) of RAM 206 (S 4 b ) and is transferred to Sound Processor 205 and is output from Speaker 216 ( FIG. 1 ) via D/A 204 ( FIG. 1 ) (S 5 b ). The sequences of S 1 a through S 5 a and S 1 b through S 5 b are continued until a specific signal indicating to stop such sequence is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system (S 6 ). FIG. 41 illustrates the sequence to transfer the video data and the audio data via Antenna 218 ( FIG. 1 ) in a wireless fashion. As described in FIG. 41 , CPU 211 ( FIG. 1 ) of Device A initiates a dialing process (S 1 ) until the line is connected to a host (not shown) (S 2 ). As soon as the line is connected, CPU 211 reads the video data and the audio data stored in Area 267 ( FIG. 39 ) and Area 268 ( FIG. 39 ) (S 3 ) and transfer them to Signal Processor 208 ( FIG. 1 ) where the data are converted into a transferring data (S 4 ). The transferring data is transferred from Antenna 218 ( FIG. 1 ) in a wireless fashion (S 5 ). The sequence of S 1 through S 5 is continued until a specific signal indicating to stop such sequence is input from Input Device 210 ( FIG. 1 ) or via the voice recognition system (S 6 ). The line is disconnected thereafter (S 7 ). FIG. 42 illustrates the basic structure of the transferred data which is transferred from Device A as described in S 4 and S 5 of FIG. 41 . Transferred data 610 is primarily composed of Header 611 , video data 612 , audio data 613 , relevant data 614 , and Footer 615 . Video data 612 corresponds to the video data stored in Area 267 ( FIG. 39 ) of RAM 206 , and audio data 613 corresponds to the audio data stored in Area 268 ( FIG. 39 ) of RAM 206 . Relevant Data 614 includes various types of data, such as the identification numbers of Device A (i.e., transferor device) and Device B (i.e., the transferee device), a location data which represents the location of Device A, email data transferred from Device A to Device B, etc. Header 611 and Footer 615 represent the beginning and the end of Transferred Data 610 respectively. FIG. 43 illustrates the data contained in RAM 206 ( FIG. 1 ) of Device B. As illustrated in FIG. 43 , RAM 206 includes Area 269 which stores video data, Area 270 which stores audio data, and Area 266 which is a work area utilized for the process explained hereinafter. As described in FIG. 44 a and FIG. 44 b , CPU 211 ( FIG. 1 ) of Device B initiates a dialing process (S 1 ) until Device B is connected to a host (not shown) (S 2 ). Transferred Data 610 is received by Antenna 218 ( FIG. 1 ) of Device B (S 3 ) and is converted by Signal Processor 208 ( FIG. 1 ) into data readable by CPU 211 (S 4 ). Video data and audio data are retrieved from Transferred Data 610 and stored into Area 269 ( FIG. 43 ) and Area 270 ( FIG. 43 ) of RAM 206 respectively (S 5 ). The video data stored in Area 269 is processed by Video Processor 202 ( FIG. 1 ) (S 6 a ). The processed video data is converted into an analog data (S 7 a ) and displayed on LCD 201 ( FIG. 1 ) (S 8 a ). S 7 a may not be necessary depending on the type of LCD 201 used. The audio data stored in Area 270 is processed by Sound Processor 205 ( FIG. 1 ) (S 6 b ). The processed audio data is converted into analog data by D/A 204 ( FIG. 1 ) (S 7 b ) and output from Speaker 216 ( FIG. 1 ) (S 8 b ). The sequences of S 6 a through S 8 a and S 6 b through S 8 b are continued until a specific signal indicating to stop such sequence is input from Input Device 210 ( FIG. 1 ) or via the voice recognition system (S 9 ). <<Audio/Video Data Capturing System—Summary>> The foregoing invention may be summarized as the following. (1) A communication system comprising a first communication device and a second communication device wherein said first communication consists of a video input means to input video information, a microphone, and a first antenna, said second communication device consists of a display means to output said video information, a speaker, and a second antenna, said first communication device inputs said video information and said audio information from said video input means and said microphone respectively, said video information and said audio information are sent to said second communication device from said first antenna in a wireless fashion, said second communication device receives said video information and said audio information in a wireless fashion from said second antenna, and said video information and said audio information are output from said display means and said speaker of said second communication device respectively thereby enabling the user of said first communication device and the user of said second communication device to communicate at any location wherever they desire. (2) A communication device comprising a video input means to input video information, a microphone, and an antenna wherein said communication device inputs said video information and said audio information from said video input means and said microphone respectively, said video information is sent to another device in a wireless fashion from said antenna, said audio information is also sent to said other device in a wireless fashion from said antenna thereby enabling the user of said communication device to communicate with said other device by utilizing said video information and said audio information in any location wherever he/she desires. <<Digital Mirror Function (1)>> FIGS. 44 c through 44 e illustrate the first embodiment of digital mirror function of Communication Device 200 ( FIG. 1 ). In this embodiment, Communication Device 200 includes Rotator 291 as described in FIG. 44 c . Rotator 291 is fixed to the side of Communication Device 200 and rotates CCD Unit 214 ( FIG. 1 ) and thereby CCD Unit 214 is enabled to face multi-direction. CPU 211 ( FIG. 1 ) reads the video data stored in Area 267 ( FIG. 39 ) from left to right as described in FIG. 44 d when CCD Unit 214 is facing the opposite direction from LCD 201 ( FIG. 1 ). However, when CCD Unit 214 is facing the same direction with LCD 201 , CPU 211 reads the video data stored in Area 267 from right to left as described in FIG. 44 e thereby producing a ‘mirror image’ on LCD 201 . As another embodiment, more than one area in RAM 206 ( FIG. 1 ) may be utilized instead of one area, i.e., Area 267 . The following description is not explained in the drawing figures. First Area and Second Area in RAM 206 ( FIG. 1 ) are utilized in this embodiment. First of all, CPU 211 stores the video data taken from CCD Unit 214 into both First Area and Second Area. Here, the video data stored in First Area and Second Area are identical. CPU 211 reads the video data stored in First Area from left to right as described in FIG. 44 d . CPU 211 reads the video data stored in Second Area from right to left as described in FIG. 44 e . CPU 211 displays the video data stored in First Area on LCD 201 when CCD Unit 214 is facing the opposite direction from LCD 201 . CPU 211 displays the video data stored in Second Area on LCD 201 when CCD Unit 214 is facing the same direction with LCD 201 . As another embodiment of the present invention, more than one CCD unit which face multi-direction may be utilized instead of enabling one CCD unit to rotate in the manner described hereinbefore. The following description is not explained in the drawing figures. First CCD Unit and Second CCD Unit are utilized in this embodiment. Here, First CCD Unit faces the opposite direction from LCD 201 ( FIG. 1 ), and Second CCD Unit faces the same direction with LCD 201 . CPU 211 ( FIG. 1 ) reads the video data stored in Area 267 ( FIG. 39 ) from left to right as described in FIG. 44 d when First CCD Unit is activated. CPU 211 reads the video data stored in Area 267 ( FIG. 39 ) from right to left as described in FIG. 44 e when Second CCD Unit is activated thereby producing a ‘mirror image’ on LCD 201 . Such activations may be rendered automatically by CPU 211 or manually by the user of Communication Device 200 utilizing input device 210 ( FIG. 1 ) or via voice recognition system. As another embodiment, more than one area in RAM 206 ( FIG. 1 ) may be utilized instead of one area, i.e., Area 267 . First Area and Second Area in RAM 206 are utilized in this embodiment. Here, First Area is designed to be read from left to right as described in FIG. 44 d , and Second Area is designed to be read from right to left as described in FIG. 44 e . CPU 211 stores the video data taken from First CCD Unit and Second CCD Unit into First Area and Second Area respectively. CPU 211 displays the video data stored in First Area on LCD 201 when First CCD Unit is activated, and also displays the video data stored in Second Area on LCD 201 when Second CCD Unit is activated. As another embodiment of the present invention, more than one LCD unit which face multi-direction may be utilized instead of one LCD 201 ( FIG. 1 ). The following description is not explained in the drawing figures. First LCD and Second LCD are utilized in this embodiment. Here, First LCD faces the opposite direction from CCD Unit 214 ( FIG. 1 ), and Second LCD faces the same direction with CCD Unit 214 . CPU 211 ( FIG. 1 ) reads the video data stored in Area 267 ( FIG. 39 ) from left to right as described in FIG. 44 d when First LCD is activated. CPU 211 ( FIG. 1 ) reads the video data stored in Area 267 ( FIG. 39 ) from right to left as described in FIG. 44 e when Second LCD is activated thereby producing a ‘mirror image’ thereon. Such activations may be rendered automatically by CPU 211 or manually by the user of Communication Device 200 utilizing input device 210 ( FIG. 1 ) or via voice recognition system. As another embodiment, more than one area in RAM 206 ( FIG. 1 ) may be utilized instead of one area, i.e., Area 267 ( FIG. 39 ). First Area and Second Area in RAM 206 ( FIG. 1 ) are utilized in this embodiment. CPU 211 stores the video data taken from CCD Unit 214 into both First Area and Second Area. Here, the video data stored in First Area and Second Area are identical. CPU 211 reads the video data stored in First Area from left to right as described in FIG. 44 d , and also reads the video data stored in Second Area from right to left as described in FIG. 44 e . The video data stored in First Area is displayed on First LCD, and the video data stored in Second Area is displayed on Second LCD. <<Digital Mirror—Summary>> The foregoing inventions may be summarized as the following. (1) A wireless communication device comprising a camera, a display, an image data producing means, a wireless transmitting means, wherein said camera is capable of facing a first direction and a second direction, said image data producing means is capable of producing a non-inverted image data and an inverted image data, said image data producing means produces said non-inverted image data which is displayed on said display when said camera is facing said first direction and produces said inverted image data which is displayed on said display when said camera is facing said second direction, while said non-inverted image data is transferred in a wireless fashion from said wireless transmitting means. (2) A communication device comprising a display and a video input means wherein said display outputs video image which is input from said video input means and said video image is output in a symmetric fashion when said video input means is facing the same direction with said display thereby enabling the user of said communication device to utilize said communication device as a digital mirror. <<Caller ID System>> FIGS. 45 through 47 illustrate the caller ID system of Communication Device 200 ( FIG. 1 ). As illustrated in FIG. 45 , RAM 206 includes Table C. As shown in the drawing, each phone number corresponds to a specific color and sound. For example Phone # 1 corresponds to Color A and Sound E; Phone # 2 corresponds to Color B and Sound F; Phone # 3 corresponds to Color C and Sound G; and Phone # 4 corresponds to color D and Sound H. As illustrated in FIG. 46 , the user of Communication Device 200 selects or inputs a phone number (S 1 ) and selects a specific color (S 2 ) and a specific sound (S 3 ) designated for that phone number by utilizing Input Device 210 ( FIG. 1 ). Such sequence can be repeated until there is a specific input signal from Input Device 210 ordering to do otherwise (S 4 ). As illustrated in FIG. 47 , CPU 211 ( FIG. 1 ) periodically checks whether it has received a call from other communication devices (S 1 ). If it receives a call (S 2 ), CPU 211 scans Table C ( FIG. 45 ) to see whether the phone number of the caller device is registered in the table (S 3 ). If there is a match (S 4 ), the designated color is output from Indicator 212 ( FIG. 1 ) and the designated sound is output from Speaker 216 ( FIG. 1 ) (S 5 ). For example if the incoming call is from Phone # 1 , Color A is output from Indicator 212 and Sound E is output from Speaker 216 . <<Caller ID—Summary>> The foregoing invention may be summarized as the following. A communication device comprising a color emitting means which outputs more than one type of color and a speaker which outputs more than one audio information wherein said communication device stores information regarding a plurality of phone numbers, a specific color and/or a specific audio information is designated to each phone number respectively, and said specific color is output from said color emitting means and/or said specific audio information is output from said speaker according to the phone number of an incoming call thereby enabling the user of said communication device to perceive the identification of the caller of said incoming call in advance of answering thereto. <<Stock Purchasing Function>> FIGS. 48 through 52 illustrate the method of purchasing stocks by utilizing Communication Device 200 ( FIG. 1 ). FIG. 48 illustrates the data stored in ROM 207 ( FIG. 1 ) necessary to set the notice mode. Area 251 stores the program regarding the vibration mode (i.e., vibration mode ON/vibration mode OFF); Area 252 stores the program regarding sound which is emitted from Speaker 216 ( FIG. 1 ) and several types of sound data, such as Sound Data I, Sound Data J, and Sound Data K are stored therein; Area 253 stores the program regarding the color emitted from Indicator 212 ( FIG. 1 ) and several types of color data, such as Color Data L, Color Data M, and Color Data N are stored therein. As illustrated in FIG. 49 , the notice mode is activated in the manner in compliance with the settings stored in setting data Area 271 of RAM 206 ( FIG. 1 ). In the example illustrated in FIG. 49 , when the notice mode is activated, Vibrator 217 ( FIG. 1 ) is turned on in compliance with the data stored in Area 251 a , Speaker 216 ( FIG. 1 ) is turned on and Sound Data J is emitted therefrom in compliance with the data stored in Area 252 a , and Indicator 212 ( FIG. 1 ) is turned on and Color M is emitted therefrom in compliance with the data stored in Area 253 a . Area 292 stores the stock purchase data, i.e., the name of the brand, the amount of limited price, the name of the stock market (such as NASDAQ and/or NYSE) and other relevant information regarding the stock purchase. As illustrated in FIG. 50 , the user of Communication Device 200 inputs the stock purchase data from Input Device 210 ( FIG. 1 ) or by the voice recognition system, which is stored in Area 292 of RAM 206 ( FIG. 49 ) (S 1 ). By way of inputting specific data from Input Device 210 , the property of notice mode (i.e., vibration ON/OFF, sound ON/OFF and the type of sound, indicator ON/OFF, and the type of color) is set and the relevant data are stored in Area 271 (i.e., Areas 251 a , 252 a , 253 a ) ( FIG. 49 ) of RAM 206 by the programs stored in Areas 251 , 252 , 253 of ROM 207 ( FIG. 48 ) (S 2 ). Communication Device 200 initiates a dialing process (S 3 ) until it is connected to Host H (described hereinafter) (S 4 ) and sends the stock purchase data thereto. FIG. 51 illustrates the operation of Host H (not shown). As soon as Host H receives the stock purchase data from Communication Device 200 (S 1 ), it initiates to monitor the stock markets which is specified in the stock purchase data (S 2 ). If Host H detects that the price of the certain brand specified in the stock purchase data meets the limited price specified in the stock purchase data, (in the present example if the price of brand x is y) (S 3 ), it initiates a dialing process (S 4 ) until it is connected to Communication Device 200 (S 5 ) and sends a notice data thereto (S 6 ). As illustrated in FIG. 52 , Communication Device 200 periodically monitors the data received from Host H (not shown) (S 1 ). If the data received is a notice data (S 2 ), the notice mode is activated in the manner in compliance with the settings stored in setting data Area 271 ( FIG. 49 ) of RAM 206 (S 3 ). In the example illustrated in FIG. 49 , Vibrator 217 ( FIG. 1 ) is turned on, Sound Data J is emitted from Speaker 216 ( FIG. 1 ), and Indicator 212 ( FIG. 1 ) emits Color M. <<Stock Purchase—Summary>> The foregoing invention may be summarized as the following. A communication system comprising a first computer and a second computer wherein said second computer is a wireless communication device including an antenna, a stock purchase data is input to said second computer, said first computer monitors one or more stock markets specified in said stock purchase data and sends a notice to said second computer, and said second computer responds in a specified manner upon receiving said notice from said antenna in a wireless fashion thereby enabling the user of said second computer to receive said notice regarding said stock purchase data in any location wherever he/she desires. <<Timer Email Function>> FIGS. 53 a and 53 b illustrate the method of sending emails from Communication Device 200 ( FIG. 1 ) by utilizing a timer. Address data, i.e., email address is input by utilizing Input Device 210 ( FIG. 1 ) or via voice recognition system explained in FIG. 3 , FIG. 4 , FIG. 5 , FIG. 13 , FIG. 14 , FIG. 14 a , FIG. 15 , FIG. 16 and/or FIG. 17 (S 1 ) and the text data, the text of the email message is input by the same manner (S 2 ). The address data and the text data are automatically saved in RAM 206 ( FIG. 1 ) (S 3 ). The sequence of S 1 through S 3 is repeated (i.e., writing more than one email) until a specified input signal is input from Input Device 210 ( FIG. 1 ) or by utilizing the voice recognition system explained above. Once inputting both the address data and the text data (which also includes numeric data, images and programs) are completed a timer (not shown) is set by Input Device 210 or by utilizing the voice recognition system (S 5 ), and the timer is incremented periodically (S 6 ) until the timer value equals the predetermined value specified in S 5 (S 7 ). A dialing process is continued (S 8 ) until the line is connected (S 9 ) and the text data are sent thereafter to email addresses specified in S 1 (S 10 ). All of the emails are sent (S 11 ) and the line is disconnected thereafter (S 12 ). As another embodiment of the present invention a specific time may be input by Input Device 210 and send the text data on the specific time (i.e., a broad meaning of ‘timer’). <<Timer Email—Summary>> The foregoing invention may be summarized as the following. A communication device comprising a text data input means which inputs one or more text data, a storage means which stores said text data, a sending means which sends said text data which is input by said input means, and a timer means which activates said sending means at a predetermined time wherein said text data input means input said text data, said storage means stores said text data input by said text data input means, said timer means activates said sending means at said predetermined time, and said sending means sends said text data at said predetermined time thereby enabling the user of said communication device to send said text data at said predetermined time at which said user is not able to send said text data. <<Call Blocking Function>> FIGS. 54 through 56 illustrates the so-called ‘call blocking’ function of Communication Device 200 ( FIG. 1 ). As illustrated in FIG. 54 , RAM 206 ( FIG. 1 ) includes Area 273 and Area 274 . Area 273 stores phone numbers that should be blocked. In the example illustrated in FIG. 54 , Phone # 1 , Phone # 2 , and Phone # 3 are blocked. Area 274 stores a message data, preferably a wave data, stating that the phone can not be connected. FIG. 55 illustrates the operation of Communication Device 200 . When Communication Device 200 receives a call (S 1 ), CPU 211 ( FIG. 1 ) scans Area 273 ( FIG. 54 ) of RAM 206 (S 2 ). If the phone number of the incoming call matches one of the phone numbers stored in Area 273 (S 3 ), CPU 211 sends the message data stored in Area 274 ( FIG. 54 ) of RAM 206 to the caller device (S 4 ) and disconnects the line (S 5 ). FIG. 56 illustrates the method of updating Area 273 ( FIG. 54 ) of RAM 206 . Assuming that the phone number of the incoming call does not match any of the phone numbers stored in Area 273 of RAM 206 (see S 3 of FIG. 55 ). In that case, Communication Device 200 is connected to the caller device. However, the user of Communication Device 200 may decide to have such number ‘blocked’ after all. If that is the case, the user dials ‘999’ while the line is connected. Technically CPU 211 ( FIG. 1 ) periodically checks the signals input from Input Device 210 ( FIG. 1 ) (S 1 ). If the input signal represents a numerical data ‘999’ from Input Device 210 (S 2 ), CPU 211 adds the phone number of the pending call to Area 273 (S 3 ) and sends the message data stored in Area 274 ( FIG. 54 ) of RAM 206 to the caller device (S 4 ). The line is disconnected thereafter (S 5 ). FIGS. 57 through 59 illustrate another embodiment of the present invention. As illustrated in FIG. 57 , Host H (not shown) includes Area 403 and Area 404 . Area 403 stores phone numbers that should be blocked to be connected to Communication Device 200 . In the example illustrated in FIG. 57 , Phone # 1 , Phone # 2 , and Phone # 3 are blocked for Device A; Phone # 4 , Phone # 5 , and Phone # 6 are blocked for Device B; and Phone # 7 , Phone # 8 , and Phone # 9 are blocked for Device C. Area 404 stores a message data stating that the phone can not be connected. FIG. 58 illustrates the operation of Host H (not shown). Assuming that the caller device is attempting to connect to Device B, Communication Device 200 . Host H periodically checks the signals from all Communication Device 200 (S 1 ). If Host H detects a call for Device B (S 2 ), it scans Area 403 ( FIG. 57 ) (S 3 ) and checks whether the phone number of the incoming call matches one of the phone numbers stored therein for Device B (S 4 ). If the phone number of the incoming call does not match any of the phone numbers stored in Area 403 , the line is connected to Device B (S 5 b ). On the other hand, if the phone number of the incoming call matches one of the phone numbers stored in Area 403 , the line is ‘blocked,’ i.e., not connected to Device B (S 5 a ) and Host H sends the massage data stored in Area 404 ( FIG. 57 ) to the caller device (S 6 ). FIG. 59 illustrates the method of updating Area 403 ( FIG. 57 ) of Host H. Assuming that the phone number of the incoming call does not match any of the phone numbers stored in Area 403 (see S 4 of FIG. 58 ). In that case, Host H allows the connection between the caller device and Communication Device 200 , however, the user of Communication Device 200 may decide to have such number ‘blocked’ after all. If that is the case, the user simply dials ‘999’ while the line is connected. Technically Host H ( FIG. 57 ) periodically checks the signals input from Input Device 210 ( FIG. 1 ) (S 1 ). If the input signal represents ‘999’ from Input Device 210 ( FIG. 1 ) (S 2 ), Host H adds the phone number of the pending call to Area 403 (S 3 ) and sends the message data stored in Area 404 ( FIG. 57 ) to the caller device (S 4 ). The line is disconnected thereafter (S 5 ). As another embodiment of the method illustrated in FIG. 59 , Host H ( FIG. 57 ) may delegate some of its tasks to Communication Device 200 (this embodiment is not shown in drawings). Namely, Communication Device 200 periodically checks the signals input from Input Device 210 ( FIG. 1 ). If the input signal represents a numeric data ‘999’ from Input Device 210 , Communication Device 200 sends to Host H a block request signal as well as with the phone number of the pending call. Host H, upon receiving the block request signal from Communication Device 200 , adds the phone number of the pending call to Area 403 ( FIG. 57 ) and sends the message data stored in Area 404 ( FIG. 57 ) to the caller device. The line is disconnected thereafter. <<Call Blocking—Summary>> The foregoing invention may be summarized as the following. (1) A communication system comprising a communication device and a blocked number storage means wherein an incoming call is prevented from being connected to said communication device if the phone number of said incoming call is included in said blocked number storage means thereby preventing the user of said communication device from being disturbed from unnecessary calls. (2) A communication system comprising a communication device and a blocked number storage means wherein a pending call is disconnected from said communication device if a predetermined signal is input to said communication device and the phone number of said pending call is included in said blocked number storage means thereby preventing the user of said communication device from being disturbed from unnecessary calls. <<Online Payment Function>> FIGS. 60 through 64 illustrate the method of online payment by utilizing Communication Device 200 ( FIG. 1 ). As illustrated in FIG. 60 , Host H includes account data storage Area 405 . All of the account data of the users of Communication Device 200 who have signed up for the online payment service are stored in Area 405 . In the example described in FIG. 60 , Account A stores the relevant account data of the user using Device A; Account B stores the relevant account data of the user using Device B; Account C stores the relevant account data of the user using Device C; and Account D stores the relevant account data of the user using device D. Here, Devices A, B, C, and D are Communication Device 200 . FIGS. 61 a and 61 b illustrate the operation of the payer device, Communication Device 200 . Assuming that Device A is the payer device and Device B is the payee device. Account A explained in FIG. 60 stores the account data of the user of Device A, and Account B explained in the same drawing stores the account data of the user of Device B. As illustrated in FIG. 61 a , LCD 201 ( FIG. 1 ) of Device A displays the balance of Account A by receiving the relevant data from Host H ( FIG. 60 ) (S 1 ). From the signal input from Input Device 210 ( FIG. 1 ), the payer's account and the payee's account are selected (in the present example, Account A as the payer's account and Account B as the payee's account are selected), and the amount of payment and the device ID (in the present example, Device A as the payer's device and Device B as the payee's device) are input via Input Device 210 (S 2 ). If the data input from Input Device 210 is correct (S 3 ), CPU 211 ( FIG. 1 ) of Device A prompts for other payments. If there are other payments to make, the sequence of S 1 through S 3 is repeated until all of the payments are made (S 4 ). The dialing process is initiated and repeated thereafter (S 5 ) until the line is connected to Host H ( FIG. 60 ) (S 6 ). Once the line is connected, Device A sends the payment data to Host H (S 7 ). The line is disconnected when all of the payment data including the data produced in S 2 are sent to Host H (S 8 and S 9 ). FIG. 62 illustrates the payment data described in S 7 of FIG. 61 b . Payment data 620 is composed of Header 621 , Payer's Account Information 622 , Payee's Account Information 623 , amount data 624 , device ID data 625 , and Footer 615 . Payer's Account Information 622 represents the information regarding the payer's account data stored in Host H ( FIG. 60 ) which is, in the present example, Account A. Payee's Account Information 623 represents the information regarding the payee's account data stored in Host H which is, in the present example, Account B. Amount Data 624 represents the amount of monetary value either in the U.S. dollars or in other currencies which is to be transferred from the payer's account to the payee's account. The device ID data represents the data of the payer's device and the payee's device, i.e., in the present example, Device A and Device B. FIG. 63 illustrates the basic structure of the payment data described in S 7 of FIG. 61 b when multiple payments are made, i.e., when more than one payment is made in S 4 of FIG. 61 a . Assuming that three payments are made in S 4 of FIG. 61 a . In that case, Payment Data 630 is composed of Header 631 , Footer 635 , and three data sets, i.e., Data Set 632 , Data Set 633 , Data Set 634 . Each data set represents the data components described in FIG. 62 excluding Header 621 and Footer 615 . FIG. 64 illustrates the operation of Host H ( FIG. 60 ). After receiving payment data from Device A described in FIGS. 62 and 63 , Host H retrieves therefrom the payer's account information (in the present example Account A), the payee's account information (in the present example Account B), the amount data which represents the monetary value, and the device IDs of both the payer's device and the payee's device (in the present example Device A and Device B) (S 1 ). Host H, based on such data, subtracts the monetary value represented by the amount data from the payer's account (in the present example Account A) (S 2 ), and adds the same amount to the payee's account (in the present example Account B) (S 3 ). If there are other payments to make, i.e., if Host H received a payment data which has a structure of the one described in FIG. 63 , the sequence of S 2 and S 3 is repeated as many times as the amount of the data sets are included in such payment data. <<Online Payment—Summary>> The foregoing invention may be summarized as the following. An online payment system comprising a host and a first device and a second device wherein said host and said first device are connected in a wireless fashion; said host and said second device are also connected in a wireless fashion; said host stores a first account data of said first device and a second account data of said second device; a payment data which includes an amount data representing monetary value, said first account data, and said second account data is input into said first device; said payment data is sent to said host in a wireless fashion; and said host subtracts the value represented by said amount data from said first account data and adds the same value to said second account data thereby enables the users of said first device and said second device to initiate transactions and payments at any location wherever they desire. <<Navigation System>> FIGS. 65 through 74 illustrate the navigation system of Communication Device 200 ( FIG. 1 ). As illustrated in FIG. 65 , RAM 206 ( FIG. 1 ) includes Area 275 , Area 276 , Area 277 , and Area 295 . Area 275 stores a plurality of map data, two-dimensional (2D) image data, which are designed to be displayed on LCD 201 ( FIG. 1 ). Area 276 stores a plurality of object data, three-dimensional (3D) image data, which are also designed to be displayed on LCD 201 . The object data are primarily displayed by a method so-called ‘texture mapping’ which is explained in details hereinafter. Here, the object data include the three-dimensional data of various types of objects that are displayed on LCD 201 , such as bridges, houses, hotels, motels, inns, gas stations, restaurants, streets, traffic lights, street signs, trees, etc. Area 277 stores a plurality of location data, i.e., data representing the locations of the objects stored in Area 276 . Area 277 also stores a plurality of data representing the street address of each object stored in Area 276 . In addition, Area 277 stores the current position data of Communication Device 200 and the Destination Data which are explained in details hereafter. The map data stored in Area 275 and the location data stored in Area 277 are linked each other. Area 295 stores a plurality of attribution data attributing to the map data stored in Area 275 and location data stored in Area 277 , such as road blocks, traffic accidents, and road constructions, and traffic jams. The attribution data stored in Area 295 is updated periodically by receiving an updated data from a host (not shown). As illustrated in FIG. 66 , Video Processor 202 ( FIG. 1 ) includes texture mapping processor 290 . Texture mapping processor 290 produces polygons in a three-dimensional space and ‘pastes’ textures to each polygon. The concept of such method is described in the following patents and the references cited thereof: U.S. Pat. No. 5,870,101, U.S. Pat. No. 6,157,384, U.S. Pat. No. 5,774,125, U.S. Pat. No. 5,375,206, and/or U.S. Pat. No. 5,925,127. As illustrated in FIG. 67 , the voice recognition system is activated when the CPU 211 ( FIG. 1 ) detects a specific signal input from Input Device 210 ( FIG. 1 ) (S 1 ). After the voice recognition system is activated, the input current position mode starts and the current position of Communication Device 200 is input by voice recognition system explained in FIG. 3 , FIG. 4 , FIG. 5 , FIG. 13 , FIG. 14 , FIG. 14 a , FIG. 15 , FIG. 16 and/or FIG. 17 (S 2 ). The current position can also be input from Input Device 210 . As another embodiment of the present invention, the current position can automatically be detected by the method so-called ‘global positioning system’ or ‘GPS’ as illustrated in FIGS. 20 a through 26 and input the current data therefrom. After the process of inputting the current data is completed, the input destination mode starts and the destination is input by the voice recognition system explained above or by the Input Device 210 (S 3 ), and the voice recognition system is deactivated after the process of inputting the Destination Data is completed by utilizing such system (S 4 ). FIG. 68 illustrates the sequence of the input current position mode described in S 2 of FIG. 67 . When analog audio data is input from Microphone 215 ( FIG. 1 ) (S 1 ), such data is converted into digital audio data by A/D 213 (FIG. 1 ) (S 2 ). The digital audio data is processed by Sound Processor 205 ( FIG. 1 ) to retrieve text and numeric data therefrom (S 3 ). The retrieved data is displayed on LCD 201 ( FIG. 1 ) (S 4 ). The data can be corrected by repeating the sequence of S 1 through S 4 until the correct data is displayed (S 5 ). If the correct data is displayed, such data is registered as current position data (S 6 ). As stated above, the current position data can be input manually by Input Device 210 ( FIG. 1 ) and/or can be automatically input by utilizing the method so-called ‘global positioning system’ or ‘GPS’ as described hereinbefore. FIG. 69 illustrates the sequence of the input destination mode described in S 3 of FIG. 67 . When analog audio data is input from Microphone 215 ( FIG. 1 ) (S 1 ), such data is converted into digital audio data by A/D 213 ( FIG. 1 ) (S 2 ). The digital audio data is processed by Sound Processor 205 ( FIG. 1 ) to retrieve text and numeric data therefrom (S 3 ). The retrieved data is displayed on LCD 201 ( FIG. 1 ) (S 4 ). The data can be corrected by repeating the sequence of S 1 through S 4 until the correct data is displayed on LCD 201 (S 5 ). If the correct data is displayed, such data is registered as Destination Data (S 6 ). FIG. 70 illustrates the sequence of displaying the shortest route from the current position to the destination. CPU 211 ( FIG. 1 ) retrieves both the current position data and the Destination Data which are input by the method described in FIGS. 67 through 69 from Area 277 ( FIG. 65 ) of RAM 206 ( FIG. 1 ). By utilizing the location data of streets, bridges, traffic lights and other relevant data, CPU 211 calculates the shortest route to the destination (S 1 ). CPU 211 then retrieves the relevant two-dimensional map data which should be displayed on LCD 201 from Area 275 ( FIG. 65 ) of RAM 206 (S 2 ). As another embodiment of the present invention, by way of utilizing the location data stored in Area 277 , CPU 211 may produce a three-dimensional map by composing the three dimensional objects (by method so-called ‘texture mapping’ as described above) which are stored in Area 276 (FIG. 65 ) of RAM 206 . The two-dimensional map and/or the three dimensional map is displayed on LCD 201 ( FIG. 1 ) (S 3 ). As another embodiment of the present invention, the attribution data stored in Area 295 ( FIG. 65 ) of RAM 206 may be utilized. Namely if any road block, traffic accident, road construction, and/or traffic jam is included in the shortest route calculated by the method mentioned above, CPU 211 ( FIG. 1 ) calculates the second shortest route to the destination. If the second shortest route still includes road block, traffic accident, road construction, and/or traffic jam, CPU 211 calculates the third shortest route to the destination. CPU 211 calculates repeatedly until the calculated route does not include any road block, traffic accident, road construction, and/or traffic jam. The shortest route to the destination is highlighted by a significant color (such as red) to enable the user of Communication Device 200 to easily recognize such route on LCD 201 ( FIG. 1 ). As another embodiment of the present invention, an image which is similar to the one which is observed by the user in the real world may be displayed on LCD 201 ( FIG. 1 ) by utilizing the three-dimensional object data. In order to produce such image, CPU 211 ( FIG. 1 ) identifies the present location and retrieves the corresponding location data from Area 277 ( FIG. 65 ) of RAM 206 . Then CPU 211 retrieves a plurality of object data which correspond to such location data from Area 276 ( FIG. 65 ) of RAM 206 and displays a plurality of objects on LCD 201 based on such object data in a manner the user of Communication Device 200 may observe from the current location. FIG. 71 illustrates the sequence of updating the shortest route to the destination while Communication Device 200 is moving. By way of periodically and automatically inputting the current position by the method so-called ‘global positioning system’ or ‘GPS’ as described hereinbefore, the current position is continuously updated (S 1 ). By utilizing the location data of streets and traffic lights and other relevant data, CPU 211 ( FIG. 1 ) recalculates the shortest route to the destination (S 2 ). CPU 211 then retrieves the relevant two-dimensional map data which should be displayed on LCD 201 from Area 275 ( FIG. 65 ) of RAM 206 (S 3 ). Instead, by way of utilizing the location data stored in Area 277 ( FIG. 65 ), CPU 211 may produce a three-dimensional map by composing the three dimensional objects by method so-called ‘texture mapping’ which are stored in Area 276 ( FIG. 65 ) of RAM 206 . The two-dimensional map and/or the three-dimensional map is displayed on LCD 201 ( FIG. 1 ) (S 4 ). The shortest route to the destination is re-highlighted by a significant color (such as red) to enable the user of Communication Device 200 to easily recognize the updated route on LCD 201 . FIG. 72 illustrates the method of finding the shortest location of the desired facility, such as restaurant, hotel, gas station, etc. The voice recognition system is activated in the manner described in FIG. 67 (S 1 ). By way of utilizing the voice recognition system, a certain type of facility is selected from the options displayed on LCD 201 ( FIG. 1 ). The prepared options can be a) restaurant, b) lodge, and c) gas station (S 2 ). Once one of the options is selected, CPU 211 ( FIG. 1 ) calculates and inputs the current position by the method described in FIG. 68 and/or FIG. 71 (S 3 ). From the data selected in S 2 , CPU 211 scans Area 277 ( FIG. 65 ) of RAM 206 and searches the location of the facilities of the selected category (such as restaurant) which is the closest to the current position (S 4 ). CPU 211 then retrieves the relevant two-dimensional map data which should be displayed on LCD 201 from Area 275 of RAM 206 ( FIG. 65 ) (S 5 ). Instead, by way of utilizing the location data stored in 277 ( FIG. 65 ), CPU 211 may produce a three-dimensional map by composing the three dimensional objects by method so-called ‘texture mapping’ which are stored in Area 276 ( FIG. 65 ) of RAM 206 . The two-dimensional map and/or the three dimensional map is displayed on LCD 201 ( FIG. 1 ) (S 6 ). The shortest route to the destination is re-highlighted by a significant color (such as red) to enable the user of Communication Device 200 to easily recognize the updated route on LCD 201 . The voice recognition system is deactivated thereafter (S 7 ). FIG. 73 illustrates the method of displaying the time and distance to the destination. As illustrated in FIG. 73 , CPU 211 ( FIG. 1 ) calculates the current position wherein the source data can be input from the method described in FIG. 68 and/or FIG. 71 (S 1 ). The distance is calculated from the method described in FIG. 70 (S 2 ). The speed is calculated from the distance which Communication Device 200 has proceeded within specific period of time (S 3 ). The distance to the destination and the time left are displayed on LCD 201 ( FIG. 1 ) (S 4 and S 5 ). FIG. 74 illustrates the method of warning and giving instructions when the user of Communication Device 200 deviates from the correct route. By way of periodically and automatically inputting the current position by the method so-called ‘global positioning system’ or ‘GPS’ as described hereinbefore, the current position is continuously updated (S 1 ). If the current position deviates from the correct route (S 2 ), a warning is given from Speaker 216 ( FIG. 1 ) and/or on LCD 201 ( FIG. 1 ) (S 3 ). The method described in FIG. 74 is repeated for a certain period of time. If the deviation still exists after such period of time has passed, CPU 211 ( FIG. 1 ) initiates the sequence described in FIG. 70 and calculates the shortest route to the destination and display it on LCD 201 . The details of such sequence is as same as the one explained in FIG. 70 . FIG. 74 a illustrates the overall operation of Communication Device 200 regarding the navigation system and the communication system. When Communication Device 200 receives data from Antenna 218 ( FIG. 1 ) (S 1 ), CPU 211 ( FIG. 1 ) determines whether the data is navigation data, i.e., data necessary to operate the navigation system (S 2 ). If the data received is a navigation data, the navigation system described in FIGS. 67 through 74 is performed (S 3 ). On the other hand, if the data received is a communication data (S 4 ), the communication system, i.e., the system necessary for wireless communication which is mainly described in FIG. 1 is performed (S 5 ). <<Navigation System—Summary>> The foregoing inventions may be summarized as the following. (1) A GPS navigation device comprising a display, a microphone, a GPS navigation system which identifies the present location of said GPS navigation device, and a voice recognition system which retrieves a text and numeric data from an analog audio input from said microphone wherein said analog audio is input to said microphone, said voice recognition system retrieves said text and numeric data from said analog audio, said text and numeric data is input to said GPS navigation system thereby enabling the user of said GPS navigation device to input necessary data therein without using his/her hands and/or without physically contacting said GPS navigation device and utilizing said GPS navigation system. (2) A communication device comprising a GPS navigation system, a wireless communication system, and an antenna wherein said antenna receives navigation data which is necessary to operate said GPS navigation system, and said antenna also receives communication data which is necessary to operate said wireless communication system thereby enabling said communication device to be compact and also enabling the user of said communication device to find directions by utilizing said GPS navigation system as well as using said wireless communication system. (3) A GPS navigation device comprising a display means, a navigation system which identifies the present location of said GPS navigation device, a storage means which stores a plurality of object data which is a three-dimensional data of object that is displayed on said display means and a plurality of location data which represents the location of said object wherein based on a specific information produced by said navigation system a specific location data is selected from said storage means, a plurality of said object data which corresponds to said location data is retrieved from said storage means, and said plurality of said object data is displayed on said display means in a manner the user of said GPS navigation device observes from the current location of said GPS navigation device thereby enables said user of said GPS navigation device to have a realistic view from said current location on said display means. (4) A GPS navigation device comprising a display means, a navigation system which identifies the shortest route from a first location to a second location, a storage means which stores a plurality of location data which is categorized in one or more groups wherein when a certain group is selected, said navigation system retrieves a plurality of location data pertaining to said certain group, and identifies the shortest route to one of the location data pertaining to said certain group thereby enables the user of said GPS navigation device to take the shortest route from said user's present location to the location of said certain group. (5) A GPS navigation device comprising a display means, a navigation system which identifies the shortest route from a first location to a second location, a storage means which stores a plurality of attribution data wherein said shortest route is calculated by referring to said plurality of attribution data thereby enabling the user of said GPS navigation device to reach said second location within shorter period time by way of avoiding road blocks, traffic accidents, road constructions, and traffic jams. <<Remote Controlling System>> FIGS. 75 through 83 illustrate the remote controlling system utilizing Communication Device 200 ( FIG. 1 ). As illustrated in FIG. 75 , Communication Device 200 is connected to Network NT. Network NT may be the internet or have the same or similar structure described in FIG. 2 a , FIG. 2 b and/or FIG. 2 c except ‘Device B’ is substituted to ‘Sub-host SH’ in these drawings. Network NT is connected to Sub-host SH in a wireless fashion. Sub-host SH administers various kinds of equipment installed in building 801 , such as TV 802 , Microwave Oven 803 , VCR 804 , Bathroom 805 , Room Light 806 , AC 807 , Heater 808 , Door 809 , and CCD camera 810 . Communication Device 200 transfers a control signal to Network NT in a wireless fashion via Antenna 218 ( FIG. 1 ), and Network NT forwards the control signal in a wireless fashion to Sub-host SH, which controls the selected equipment based on the control signal. Communication Device 200 is also capable to connect to Sub-host SH without going through Network NT and transfer directly the control signal to Sub-host SH in a wireless fashion via Antenna 218 . As illustrated in FIG. 76 , Communication Device 200 is enabled to perform the remote controlling system when the device is set to the home equipment controlling mode. Once Communication Device 200 is set to the home equipment controlling mode, LCD 201 ( FIG. 1 ) displays all pieces of equipment which are remotely controllable by Communication Device 200 . Each equipment can be controllable by the following method. FIG. 77 illustrates the method of remotely controlling TV 802 . In order to check the status of TV 802 , a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of TV 802 , i.e., the status of the power (ON/OFF), the channel, and the timer of TV 802 (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH turns the power on (or off) (S 3 a ), selects the channel (S 3 b ), and/or sets the timer of TV 802 (S 3 c ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 78 illustrates the method of remotely controlling Microwave Oven 803 . In order to check the status of Microwave Oven 803 , a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of Microwave Oven 803 , i.e., the status of the power (ON/OFF), the status of temperature, and the timer of Microwave Oven 803 (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH turns the power on (or off) (S 3 a ), selects the temperature (S 3 b ), and/or sets the timer of Microwave Oven 803 (S 3 c ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 79 illustrates the method of remotely controlling VCR 804 . In order to check the status of VCR 804 , a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of VCR 804 , i.e., the status of the power (ON/OFF), the channel, the timer, and the status of the recording mode (e.g., one day, weekdays, or weekly) of VCR 804 (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH turns the power on (or off) (S 3 a ), selects the TV channel (S 3 b ), sets the timer (S 3 c ), and/or selects the recording mode of VCR 804 (S 3 d ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 80 illustrates the method of remotely controlling Bathroom 805 . In order to check the status of Bathroom 805 , a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of Bathroom 805 , i.e., the status of the bath plug (or the stopper for bathtub) (OPEN/CLOSE), the temperature, the amount of hot water, and the timer of Bathroom 805 (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH opens (or closes) the bath plug (S 3 a ), selects the temperature (S 3 b ), selects the amount of hot water (S 3 c ), and/or sets the timer of Bathroom 805 (S 3 d ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 81 illustrates the method of remotely controlling AC 807 and Heater 808 . In order to check the status of AC 807 and/or Heater 808 a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of AC 807 and/or Heater 808 , i.e., the status of the power (ON/OFF), the status of temperature, and the timer of AC 807 and/or Heater 808 (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH turns the power on (or off) (S 3 a ), selects the temperature (S 3 b ), and/or sets the timer of AC 807 and/or Heater 808 (S 3 c ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 82 illustrates the method of remotely controlling Door 809 . In order to check the status of Door 809 a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of Door 809 , i.e., the status of the door lock (LOCKED/UNLOCKED), and the timer of door lock (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH locks (or unlocks) the door (S 3 a ), and/or sets the timer of the door lock (S 3 b ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 83 illustrates the method of CCD Camera 810 . In order to check the status of CCD Camera 810 a specific signal is input from Input Device 210 ( FIG. 1 ) or by the voice recognition system, and Communication Device 200 thereby sends a check request signal to Sub-host SH via Network NT. Sub-host SH, upon receiving the check request signal, checks the status of CCD Camera 810 , i.e., the status of the camera angle, zoom and pan, and the timer of CCD Camera 810 (S 1 ), and returns the results to Communication Device 200 via Network NT, which are displayed on LCD 201 ( FIG. 1 ) (S 2 ). Based on the control signal produced by Communication Device 200 , which is transferred via Network NT, Sub-host SH selects the camera angle (S 3 a ), selects zoom or pan (S 3 b ), and/or sets the timer of CCD Camera 810 (S 3 c ). The sequence of S 2 and S 3 can be repeated (S 4 ). FIG. 84 illustrates the overall operation of Communication Device 200 regarding the remote controlling system and communication system. CPU 211 ( FIG. 1 ) periodically checks the input signal from Input Device 210 ( FIG. 1 ) (S 1 ). If the input signal indicates that the remote controlling system is selected (S 2 ), CPU 211 initiates the process for the remote controlling system (S 3 ). On the other hand, if the input signal indicates that the communication system is selected (S 4 ), CPU 211 initiates the process for the communication system (S 5 ). FIG. 85 is a further description of the communication performed between Sub-host SH and Door 809 which is described in FIG. 82 . When Sub-host SH receives a check request signal as described in FIG. 82 , Sub-host SH sends a check status signal which is received by Controller 831 via Transmitter 830 . Controller 831 checks the status of Door Lock 832 and sends back a response signal to Sub-host SH via Transmitter 830 in a wireless fashion indicating that Door Lock 832 is locked or unlocked. Upon receiving the response signal from Controller 832 , Sub-host SH sends a result signal to Communication Device 200 in a wireless fashion as described in FIG. 82 . When Sub-host SH receives a control signal from Communication Device 200 in a wireless fashion as described in FIG. 82 , it sends a door control signal which is received by Controller 831 via Transmitter 830 . Controller 831 locks or unlocks Door Lock 832 in conformity with the door control signal. As another embodiment of the present invention, Controller 831 may owe the task of both Sub-host SH and itself and communicate directly with Communication Device 200 via Network NT. As another embodiment of the present invention each equipment, i.e., TV 802 , Microwave Oven 803 , VCR 804 , Bathroom 805 , Room Light 806 , AC 807 , Heater 808 , Door Lock 809 , and CCD Camera 810 , may carry a computer which directly administers its own equipment and directly communicates with Communication Device 200 via Network NT instead of Sub-host SH administering all pieces of equipment and communicate with Communication Device 200 . The above-mentioned invention is not limited to equipment installed in building 801 ( FIG. 75 ), i.e., it is also applicable to the ones installed in all carriers in general, such as automobiles, airplanes, space shuttles, ships, motor cycles and trains. <<Remote Controlling System—Summary>> The foregoing inventions may be summarized as the following. (1) A remote controlling system comprising a wireless communication device, an administration device which is capable of communicating with said communication device in a wireless fashion, a plurality of equipment which are subject to control of said administration device wherein said communication device sends a controlling signal to said administration device, said administration device controls said plurality of equipment in conformity with said control signal thereby enabling the user of said remote controlling system to remotely control one or more of said equipment in a wireless fashion from any location he/she desires and enabling said user to remotely control one or more said equipment as well as using said remote controlling system to communicate with other devices. (2) A communication device comprising a remote controlling system which locks or unlocks a door, a wireless communication system, and an antenna wherein said antenna sends a door control signal which is necessary to lock or unlock said door, and said antenna also sends a communication signal which is necessary to operate said wireless communication system thereby enabling said communication device to be compact and also enabling the user of said communication device to lock or unlock said door as well as using said wireless communication system. <<Auto Emergency Calling System>> FIGS. 86 and 87 illustrate the automatic emergency calling system utilizing Communication Device 200 ( FIG. 1 ). FIG. 86 illustrates the overall structure of the automatic emergency calling system. Communication Device 200 is connected to Network NT in a wireless fashion. Network NT may be the Internet or have the same or similar structure described in FIGS. 2 a , and/or 2 c . Network NT is connected to Automobile 835 thereby enabling Automobile 835 to communicate with Communication Device 200 in a wireless fashion. Emergency Center EC, a host computer, is also connected to Automobile 835 in a wireless fashion via Network NT. Airbag 838 which prevents persons in Automobile 835 from being physically injured or minimizes such injury in case traffic accidents occur is connected to Activator 840 which activates Airbag 838 when it detects an impact of more than certain level. Detector 837 sends an emergency signal via Transmitter 836 in a wireless fashion when Activator 840 is activated. The activation signal is sent to both Emergency Center EC and Communication Device 200 . In lieu of Airbag 838 any equipment may be used so long as such equipment prevents from or minimizes physical injuries of the persons in Automobile 835 . FIG. 87 illustrates the overall process of the automatic emergency calling system. Detector 837 ( FIG. 86 ) periodically checks the status of Activator 840 ( FIG. 86 ) (S 1 ). If the Activator 840 is activated (S 2 ), Detector 837 transmits an emergency signal via Transmitter 836 in a wireless fashion (S 3 a ). The emergency signal is transferred via Network NT and received by Emergency Center EC ( FIG. 86 ) and by Communication Device 200 in a wireless fashion (S 3 b ). As another embodiment of the present invention, the power of Detector 837 ( FIG. 86 ) may be usually turned off, and Activator 840 ( FIG. 86 ) may turn on the power of Detector 837 by the activation of Activator 840 thereby enabling Detector 837 to send the emergency signal to both Emergency Center EC ( FIG. 86 ) and to Communication Device 200 as described above. This invention is also applicable to any carriers including airplanes, space shuttles, ships, motor cycles and trains. Having thus described a presently preferred embodiment of the present invention, it will not be appreciated that the aspects of the invention have been fully achieved, and it will be understood by those skilled in the art that many changes in construction and circuitry and widely differing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the present invention. The disclosures and the description herein are intended to be illustrative and are not in any sense limiting of the invention, more preferably defined in scope by the following claims.
The communication device which implements the target device location indicating function, the motion visual image producing function, the non-motion visual image producing function, and the auto backing up function. The target device location indicating function indicates the current location of the target device, the motion visual image producing function retrieves the motion visual image data from the camera, the non-motion visual image producing function retrieves the non-motion visual image data from the camera, and the auto backing up function transfers the data stored in the communication device to another computer for purposes of storing backup data therein.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to an evaporator, and in particular to a portable evaporator for use in the mining industry. Specifically, the invention relates to an evaporator for use in the mining industry to reduce the volume of water in tailings ponds during reclamation. In order to keep the volume of water in tailings ponds to a minimum, it is necessary to supplement natural evaporation using a mechanical spraying device or evaporator. The evaporator jets fine streams of liquid from a tailings pond into a stream of air under pressure to effect evaporation of large volumes of liquid. It will be appreciated that the evaporator can be used for other purposes, i.e. for evaporating water other than that taken from tailings ponds. 2. Discussion of the Prior Art Spraying devices or evaporators of the types disclosed herein are by no means new. Examples of such apparatus are disclosed by U.S. Pat. No. 3,069,091, issued to R. C. Giesse et al on Dec. 18, 1962; U.S. Pat. No. 3,269,657, issued to V. P. M. Ballu on Aug. 30, 1966; U.S. Pat. No. 3,319,890, issued to D. E. Wolford on May 16, 1967; U.S. Pat. No. 3,883,073, issued to V. P. M. Ballu on May 13, 1975; U.S. Pat. No. 5,269,461, issued to J. F. Davis on Dec. 14, 1993 and U.S. Pat. No. 5,299,737, issued to C. D. McGinnis et al on Apr. 5, 1994. In general, while existing devices perform the desired function in varying degrees of efficiency, it has been found that a need still exists for an evaporator which can be used on virtually any terrain for quickly evaporating large volumes of liquid. GENERAL DESCRIPTION OF THE INVENTION The object of the present invention is to meet the above defined need by providing a relatively simple, efficient, portable evaporator, which can be used on uneven terrain. Accordingly, the present invention relates to an evaporator for quickly evaporating large volumes of liquid comprising: (a) a stand for supporting the evaporator in a fixed position; (b) a frame rotatable on said stand for rotation around a vertical axis; (c) a tubular horizontal housing on said frame, said housing having first and second open ends; (d) a fan in said housing; (e) a motor on said frame at the first open end of said housing for driving said fan to move air through said housing from said first open end to the second open end thereof; (f) an elongated tubular nozzle extending upwardly and outwardly from said second open end of said housing for discharging a stream of air from the evaporator; (g) a manifold around an upper outlet end of said nozzle for receiving liquid from a source thereof; and (h) a plurality of jets in said manifold for discharging atomized liquid into the stream of air exiting said nozzle, whereby evaporation of the liquid is facilitated. BRIEF DESCRIPTION OF THE DRAWINGS The invention is described below in greater detail with reference to the accompanying drawings, which illustrate a preferred embodiment of the invention, and wherein: FIG. 1 is a perspective view of an evaporator in accordance with the present invention; FIG. 2 is a side view of the evaporator of FIG. 1; FIG. 3 is a schematic front view of the evaporator of FIGS. 1 and 2; FIG. 4 is a top view of a stand and frame used in the evaporator of FIGS. 1 to 3 ; FIG. 5 is a partly exploded, cross-sectional view of the stand and the frame of FIG. 4; FIG. 6 is a longitudinal sectional view of a housing and nozzle used in the evaporator of FIGS. 1 to 3 ; FIG. 7 is an exploded view of a turbine assembly used in the evaporator of FIGS. 1 to 3 ; FIG. 8 is a top view of a louver used in the nozzle of FIG. 6; and FIG. 9 is a cross section of the louver taken generally along line 9 — 9 of FIG. 8 . DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIGS. 1 and 2, the basic elements of the evaporator include a stand generally indicated at 1 , a frame 2 rotatably mounted on the stand 1 carrying a motor 3 and a housing horizontal 4 , and a discharge nozzle 6 for discharging a stream of air and fine water droplets from the evaporator. The stand 1 is defined by four extensible legs 7 supporting a pair of crossbars 8 at their upper ends. Each leg 7 includes a tubular top section 9 with a smaller diameter, tubular bottom section 10 telescopically mounted in the top section 9 . The sections 9 and 10 are releasably locked in one position by pins 11 extending through diametrically opposed holes 12 (FIGS. 3 and 5) in the top and bottom sections 9 and 10 , respectively. As shown in FIG. 5, a plurality of spaced apart, opposed holes 12 in the bottom section 10 permit individual adjustment of the length of the legs 7 so that the evaporator can be stabilized on uneven terrain. Stops defined by rectangular projections 13 are provided near the bottom end of each leg 7 for limiting movement of the bottom section 10 into the top section 9 . Rectangular feet 14 are welded to the bottom ends of the legs 7 at an angle of 45° to the longitudinal axes of the legs for penetrating the ground, thus providing additional stability. The crossbars 8 are defined by rectangular cross section, steel tubes. Square cross section tubes 15 (FIGS. 2 to 5 ) are welded to the crossbars 8 to define a support for a rectangular top plate 16 . A cylindrical tubular post 17 (FIGS. 2, 3 and 5 ) is welded to the two crossbars 8 at the center of the stand 1 . The post 17 extends upwardly beyond the top of the stand 1 for rotatably supporting the frame 2 for rotation around a vertical axis. A reinforcing plate 19 with a semicircular notch (not shown) in one side thereof for receiving the post 17 is welded to the bottom of the crossbars 8 and to the post 17 for added strength. The post 17 extends upwardly through a turntable defined by a circular plate 20 on the bottom of the frame 2 and a sleeve 21 carried by the plate 20 . The frame 2 is secured in position by a tubular cap 23 (FIGS. 4 and 5) on the top end of the tube 17 , and a pin (not shown) which extends through diametrically opposed, aligned holes 25 and 26 in the post 17 and the sleeve 21 , respectively. With reference to FIGS. 4 and 5, the skeletal frame 2 includes a pair of parallel, spaced apart sides 28 interconnected at the center by a bottom crossbar 29 , which is welded to the turntable 20 and receives the sleeve 21 , and a top crossbar 30 . Additional crossbars 32 and 33 are provided at the top of the rear end of the frame 2 , and at the rear end of the frame, respectively. The crossbars 32 are large angle irons for supporting the motor 3 . A pair of inverted L-shaped ledges 35 (FIGS. 4 and 5) are welded to the interior of the sides 28 at the front end of the frame 2 for supporting a cradle 36 (FIG. 1) carrying the fan housing 4 . The motor 3 is held in position by triangular braces 38 (FIGS. 1 and 2 ), and is protected from the elements by an arcuate cover 39 cantilevered from a generally triangular stand 40 mounted on the sides 28 of the frame 2 . Side shields 41 are mounted on the stand 40 limiting access to the moving parts at the air inlet end of the machine. The flared rear or inlet end 42 of the horizontal fan housing 4 is protected by a cage 43 , the bottom ends of which are bolted to the sides 28 of the frame 2 . Referring to FIGS. 2 and 6, a generally C-shaped handle 44 is provided on the top of the housing 4 to facilitate lifting of the evaporator. The nozzle 6 includes a cylindrical, horizontal bottom arm 46 , which is rotatably connected to the front or outlet end 47 of the housing 4 , and an upwardly tapering top arm 48 inclined 45° to the horizontal through which a stream of air is discharged from the evaporator. Rings 50 and 51 (FIG. 6) of generally U-shaped cross section are welded to the outlet end 47 of the housing 4 and to the inlet end 52 of the nozzle 6 , respectively. The sides of a split ring 53 with a cross section which is the reverse of that of rings 50 and 51 embraces the abutting outer sides of the rings 50 and 51 . Outwardly extending flanges 55 (FIG. 1) on the free ends of the ring 53 are releasably interconnected by a T-shaped bolt 56 . When the bolt 56 is manually rotated to loosen the ring 53 , the nozzle 6 can be rotated using a handle 57 (FIG. 2) on the bottom of the horizontal arm 46 of the nozzle 6 . The bolt 56 is tightened to lock the nozzle 6 in the desired position. A turbine 58 (FIGS. 6 and 7) is fixedly mounted in the inlet end 42 of the housing 4 . The turbine 58 includes a hollow, cylindrical hub 59 with closed ends, and blades 60 extending radially outwardly from the hub 59 to the housing 4 . The outer ends of the blades 60 are connected to the interior of the housing 4 . Thus, the turbine acts as a stator for cutting and directing air entering the inlet end 42 of the housing 4 . A pair of bearings 62 in the ends of the turbine hub 59 rotatably support a shaft 63 , which is connected to the shaft 64 of the motor 3 by a flexible coupler 65 (FIG. 7) available from T. B. Woods, Chambersburg, Pa. A fan 67 and a generally hemispherical nose cone 68 are mounted on the outer end of the shaft 63 for rotation therewith. Actuation of the motor 3 results in the drawing of air into the rear end 42 of the housing 4 for discharge through the nozzle 6 . With reference to FIGS. 6, 8 and 9 , a plurality of parallel louvers 70 extend across the nozzle 6 at the elbow 72 between the horizontal and inclined arms 46 and 48 , respectively of the nozzle 6 . Each louver 70 includes a horizontal lower section 73 , an intermediate section 74 bent 22.5° with respect to the lower section 73 , and an upper section 75 bent 22.5° with respect to the intermediate section, i.e. 45° from the horizontal. The louvers 70 redirect air entering the inlet end 52 of the nozzle 4 upwardly through the inclined arm 48 to the outlet end 77 thereof. An annular manifold 80 is mounted on the upper, outlet end 77 of the nozzle 6 using brackets 81 . An inlet tube 83 in the bottom of the manifold 80 introduces water pumped from a tailings pond through a hose 84 (FIG. 2) connected to the inlet tube. The water is discharged through a plurality of atomizing jets or nozzles 85 into the stream of air exiting the nozzle 6 . The jets 85 extend radially upwardly and inwardly for providing a fine mist of water particles, which are picked up by the air under pressure to accelerate evaporation. The nozzle 6 can readily be rotated to a plurality of positions (FIG. 5) so that residual spray does not land in the same place each time and cause erosion.
A relatively simple portable evaporator for quickly evaporating large volumes of water includes a stand with adjustable legs, a frame carrying a tubular housing and a motor rotatably mounted on the stand for rotation around a vertical axis, a fan in the housing driven by the motor, a nozzle rotatably mounted on one end of the housing for directing air from the fan upwardly and outwardly from the housing, and a manifold carrying a plurality of jets for receiving water from a tailings pond or other source and spraying the water into a stream of air exiting the nozzle for expediting evaporation.
8
FIELD OF THE INVENTION [0001] This invention relates to well servicing and more particularly to a method for the auxiliary use of ultrasonic energy in the case of differential sticking of pipe to reduce the contact area of a filtercake prior to applying freeing force. BACKGROUND OF THE INVENTION [0002] During the drilling of oil and gas wells, drilling fluid is circulated through the interior of the drill string and then back up to the surface through the annulus between the drill string and the wall of the borehole. The drilling fluid serves various purposes including lubricating the drill bit and pipe, carrying cuttings from the bottom of the well borehole to the rig surface, and imposing a hydrostatic head on the formation being drilled to prevent the escape of oil, gas, or water into the well borehole during drilling operations. [0003] There are numerous possible causes for the drill string to become stuck during drilling. Differential sticking, one of the causes for stuck pipe incidents, usually occurs when drilling permeable formations where borehole pressures are greater than formation pressures. Under those conditions, when the drill pipe remains at rest against the wall of the borehole for enough time, mud filter cake builds up around the pipe. The pressure exerted by drilling fluid will then hold the pipe against the cake wall. [0004] Some warning signs that put one on notice of the possibility of differential sticking are the presence of prognosed low pressure along with depleted sands; long, unstabilized bottom-hole assembly (hereafter BHA) sections in a deviated hole; loss of fluid loss control and increased sand content; and increasing overpull, slack off or torque to start string movement. [0005] Indications of the actual presence of differential sticking include a period of no string movement; the string cannot be rotated or moved, but circulation is unrestricted. [0006] Methods of freeing differentially stuck drill string include applying torque and jar down with maximum torque load; using a spot pipe releasing pill if jarring is unsuccessful; and lowering mud weight, which may have implications with respect to hole stability. The overpull required to release the pipe may exceed rig capacity, and even cause collapse of the rig. It would be very beneficial if a method were available to reduce the required freeing force so that the existing rig would be adequate for overpull without possibly causing collapse. [0007] Application of wave energy in the oil industry is known, however the most common application of ultrasonic energy is cleaning of electronic microchips in the semiconductor industry and daily household cleaning of jewelry. [0008] In addition to the use of acoustic and ultrasonic methods for core measurements in the laboratory, logging, and seismic applications in the field, acoustic energy has been shown by Tutuncu and Sharma to reduce the lift-off pressure of mud filter cakes by a factor of five. See Tutuncu A. N. and Sharma M. M., 1994, “Mechanisms of Colloidal Detachment in a Sonic Field”, 1st AIChE International Particle Technology Forum, Paper No 63e, 24-29. [0009] Other uses of ultrasonic energy include supplying the energy through downhole tools into hydrocarbons to facilitate the extraction of the oil from the well by reducing the viscosity of the oil. See, for example, U.S. Pat. Nos. 5,109,922 and 5,344,532. U.S. Pat. No. 5,727,628 discloses the use of ultrasonic to clean water wells. [0010] Freeing pipe using vibrational energy has also been tried in recent years. U.S. Pat. No. 4,913,234 discloses a system for providing vibrational energy to effect the freeing of a section of well pipe which comprises: a) an orbital oscillator including a housing; b) an elongated screw shaped stator mounted in said housing and an elongated screw shaped rotor mounted for precessionally rolling rotation freely in said stator; c) means for suspending said oscillator for rotation within said drill pipe about the longitudinal axis of the drill pipe in close proximity to the stuck portion thereof; and d) drive means for rotatably driving said rotor to effect orbital lateral sonic vibration of said housing such that said housing precesses laterally around the inner wall of said pipe, thereby generating lateral quadrature vibrational forces in said pipe to effect the freeing thereof from said well bore. [0011] U.S. Pat. No. 5,234,056 discloses a method for freeing a drill string which comprises a) resiliently suspending a mechanical oscillator from a support structure on an elastomeric support having a linear constant spring rate; b) coupling said oscillator to the top end of the drill string, the elastomeric support creating a low impedance condition for vibratory energy at said drill string top end; c) driving said oscillator to generate high level sonic vibratory energy in a longitudinal vibration mode so as to effect high longitudinal vibratory displacement of the top end of the drill string; and d) the drill string acting as an acoustic lever which translates the high vibrational displacement at the top end of the drill string into a high vibrational force at the point where the drill string is stuck in the bore hole, thereby facilitating the freeing of the drill string. [0012] Often when a drill pipe is differentially stuck the result is that it has to be cut and the target zone cannot be reached by the optimal route. It would be extremely desirable in the art if a method were available which provided a means of reducing the amount of force required for freeing a stuck drill pipe. Such a method could potentially save enormous amounts of time and money in drilling operations. [0013] In the present invention, it has been discovered that the auxiliary use of ultrasonic energy can help reduce the pipe contact area, thus reducing the required freeing force and often permitting the existing rig to be sufficient for use in the overpull. The present invention will save rig time and prevent sidetracking of the well, a high cost operation especially in offshore deepwater environments. SUMMARY [0014] In accordance with the foregoing the present invention provides a method for reducing the amount of force necessary to free a stuck drill pipe which comprises an auxiliary method which provides a reduction in the amount of force required to free said pipe. BRIEF DESCRIPTION OF THE DRAWINGS [0015] [0015]FIG. 1 is a diagram of one possible position of a differentially stuck drill pipe. [0016] [0016]FIG. 2 is a schematic diagram of the hollow cylinder filtration cell used in the experimental work. [0017] [0017]FIG. 3 is a graph showing the reduction in pull out (freeing) force as a function of sonification time for an aloxite hollow cylinder sample damaged by drill-in fluid, where the filter cake was built at an elevated pressure and room temperature. [0018] [0018]FIG. 4 is a graph showing the reduction in pull out (freeing) force as a function of sonification time for a Berea sandstone hollow cylinder sample. DETAILED DESCRIPTION OF THE INVENTION [0019] The present invention describes a method of freeing stuck drill pipe, particularly in the case of differential sticking, by the auxiliary use of ultrasonic energy to reduce the amount of freeing force necessary. [0020] [0020]FIG. 1 is a diagram representing one example of the position of a differentially stuck drill pipe. The drill string, 4 , becomes embedded in filter cake, 3 , opposite the permeable zone, 2 , at high differential mud pressure overbalance, leading to stuck pipe in the contact zone. Under dynamic circulating conditions, the filter cake is eroded both by hydraulic flow and by the mechanical action of the drill string. When the well is left static with no pipe rotation, a static filter cake may build up, which increases the overall cake thickness. The string may now become embedded in the thick filter cake, particularly when the wellbore, 1 , is at high deviation and/or the BHA is not properly stabilized. The static filter cake seals the wellbore pressure (at overbalance) from the backside of the pipe. An area of low pressure develops behind the backside of the string/BHA and starts to equilibrate to the lower formation pressure. A differential pressure starts to build up across the pipe/BHA. With time the area of pipe sealed in the filter cake increases. The overbalance pressure times the contact area provides a drag force that may prevent the pipe from being pulled free. The build-up of the drag force is very rapid from the start and will increase with time. [0021] Typical actions used to free the string include applying torque and jarring down with maximum torque load. Circulation is usually not restricted in the case of differential sticking. Therefore, spotting fluids can be circulated across the zone causing the stuck pipe. Spotting fluids contain additives that can dehydrate and crack filter cakes and additives that can lubricate the drill string. Cracking the filter cake will help to transmit the mud pressure to the backside of the string and remove the differential pressure across the string, resulting in minimization of friction. The sticking force then is reduced by an equivalent amount as shown in Equation 1. F s =μAΔP   (1) [0022] where μ is the friction coefficient, A is contact area and ΔP is overbalance. In order to free the pipe the freeing force needs to be equal to or greater than F s . However sometimes it is not possible to generate enough force due to drill string and/or rig limitations, in which case the drill string must be cut, thus causing great financial loss and making it impossible to reach the target zone by the preferred route. Lowering mud weight may be helpful in some cases, but may compromise hole stability. [0023] Design of the drill string is a major consideration. The strength of drill pipe limits the maximum allowable weight and hence the ability to exert overpull. Even if the drill pipe is designed strong enough, the overpull required to release the pipe may exceed rig capacity. It is possible, particularly with small rigs in land operations, for rigs to collapse due to forces applied exceeding the maximum overpull. Downhole jars also allow high impact force to be exerted at the stuck point with relatively low overpull and setdown. However, sometimes the forces exerted are not enough to release the stuck pipe. Jar itself may become stuck as well. In the present invention decrease of contact area of the stuck pipe reduces the amount of overpull required for application. Since A is reduced, sticking force is also reduced (see Equation 1) Hence, the existing difficulties in the release of stuck pipe are minimized. [0024] In the present invention an ultrasonic source is enclosed in a housing of a pipe that permits disposition in the drill string. The ultrasonic source is a high-power sweeping acoustic transducer that operates at either a fixed frequency of approximately 20 KHz, or the frequency can be varied between several Hz and 40 KHz. The tool is made up of a variable number of cylindrical ceramic transducers, which transmit the acoustic energy radially. The transmitter itself is a piece of solid steel to which a piezoelectric driver(s) are attached. The acoustic tool is connected via a normal logging cable to a high power amplifier. The power amplification is related to the ratio of the cross-sectional areas of the tool. [0025] To demonstrate the invention, dynamic filtration experiments were conducted with fully brine-saturated Berea sandstone and aloxite hollow cylinder cores with known pore size distribution. FIG. 2 is a schematic drawing of the dynamic hollow cylinder filtration cell used in the experiments. Hollow core tests represent realistic borehole geometry. The cell is designed and built to handle core samples of 4-inch outside diameter (OD) with 8.3-inch length. Variable internal diameters (ID) for hollow cylinder cores can be used in the cell. For this invention, 0.9-inch ID samples were used. [0026] A Digital Sonifier 450 Model by Branson Ultrasonics Corp. of Danbury, Conn. was used for ultrasonic cleaning purposes. The system consists of the power supply unit, the controls, the converter and a horn. A PC was used to interface with the system and to collect the data off the system. [0027] The hollow cylinder Berea cores were first damaged using drilling and/or drill-in fluids of different formulations under various differential pressures. The drill-in fluid was used to conduct the static filtration. The filtration was performed in the cell at 600-psi pressure difference for about 12 hours. The cake thickness was varied between 2 to 3 mm. Drilling fluid was circulated into the hollow cylinder core and out from an annulus at 500-psi circulation pressure and 50 cc/min. Then the pump was stopped and static filtration was initiated at 500 psi long enough to stick a pipe and static filtrate was collected. Then the ultrasonic horn with 20 KHz central frequency was used to apply sonification from the interior of the pipe that stuck to the wall of the core. The permeability, differential pressure, sonification amplitude, power, and temperature were monitored as a function of sonification treatment time, and the energy requirement for near-complete permeability recovery and pullout force were investigated. [0028] The following examples will serve to illustrate the invention disclosed herein. The examples are intended only as a means of illustration and should not be construed as limiting the scope of the invention in any way. Those skilled in the art will recognize many variations that may be made without departing from the spirit of the, disclosed invention. [0029] Experimental Study [0030] Experiments were designed to demonstrate the usefulness of ultrasonic in reducing pullout force for stuck pipe. A special dynamic hollow cylinder circulation device, described above and shown in FIG. 2 was designed for conducting experiments. The cell pressure, temperature, flow rate, applied horn power and the amplitudes were monitored continuously using data acquisition software. The distance between the damaged surface and the horn was varied to study the effect of distance away from the source. [0031] Again referring to FIG. 2, the system comprises a stainless steel cell, two movable pistons, and an ultrasonic horn holder. It is capable of handling in excess of 5,000 psi pressure and also can be operated at elevated temperature under a specified differential pressure. Two syringe pumps (manufactured by and commercially available from ISCO, Inc. of Nebraska) were used to inject fluid and to control the differential pressure simultaneously with a precision of ±1 psi to measure the permeability of the sample. A data acquisition system was used to record and monitor the real-time pressure, flow rate, and volume of fluid injected. During sonification, the real-time amplitude, power, and time were also recorded and monitored. [0032] Hollow cylinder Berea and aloxite core samples with 4″ OD, 0.9″ ID and 8.3″ length were placed in the dynamic hollow cylinder filtration device, and external filter cakes were built by circulating drilling or drill-in fluid under in situ stress conditions between a casing pipe and walls of the hollow cylinder as shown in FIG. 2. Continuous permeability measurements made it possible to observe when the fluid completely plugged the sample pore spaces. Then the ultrasonic horn was placed into the pipe simulating a stuck pipe scenario in the laboratory as shown in FIG. 2. No sonification was applied in the first test. The application of pulling force was initiated and applied to the stuck pipe in gradually increasing magnitude until the pipe was released. The load required to free the pipe was recorded in this case. Then other identical tests were run with the stuck pipe scenarios, but this time sonification was applied for 1, 3, 5, 10, 15, 20, 25, 30 and 35 minute intervals, respectively. After various-time sonifications, a small pulling force was applied and then the force was gradually increased until the pipe was released. The sonifications were repeated at three energy levels (30% amplitude, 50% amplitude, and 70% amplitude). A summary for the aloxite cylinder at various amplitude and sonification times is presented in FIG. 3. FIG. 3 is a graph showing the reduction in pull out (freeing) force as a function of sonification time for an aloxite hollow cylinder sample damaged by drill-in fluid, where the filter cake was built at an elevated pressure and room temperature. The pullout force ratio is the ratio of freeing force after sonification to freeing force before sonification. [0033] The fastest reduction in the freeing force was observed when 70% (highest power) was applied; however, any amplitude level and timing of sonification helped reduce the freeing force compared to the case of no sonification. The results for Berea hollow cylinder cores are shown in FIG. 4. Different samples were used to test the effect of increasing sonification time. For all the tests except the 40-minute sonification test, a pulling force was applied to free the pipe. However, the longer the sonification time, the smaller was the magnitude of the required force. And, finally, for 40-minute sonification, no pulling force was needed; the release was instantaneous after the sonification. The test results were explained by reduction in the contact area. Because sonification reduced the thickness of the filter cake, it resulted in a reduction in the contact area. Therefore, from equation (1), F s =μAΔP, and ΔP are kept constant, A is smaller, hence F s is smaller. A summary of the pullout force ratios for aloxite and Berea hollow cylinder samples is shown in FIGS. 3 and 4.
Disclosed is an auxiliary method for freeing a drill pipe stuck due to build up of filter cake, which provides a reduction in the amount of force required to free said pipe which comprises: a) Lowering an ultrasonic horn type device down the drill pipe to the point of contact between said drill pipe and mud filter cake; b) Producing ultrasonic energy at the point of contact until the contact area is sufficiently reduced such that substantially less force is required to free the pipe.
4
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a locking device, and more particularly to locking device to secure an inner tube in an outer tube of a telescopic tube assembly. 2. Description of Related Art With reference to FIG. 6 , a conventional locking device ( 50 ) for a telescopic tube assembly having an outer tube ( 40 ) and an inner tube ( 41 ) slidably received in the outer tube ( 40 ) includes a knob ( 51 ) rotatably mounted on a side of the locking device ( 50 ). When the relative position of the inner tube ( 41 ) is to be readjusted, the operator has to hold the inner tube ( 41 ) to prevent the inner tube ( 41 ) from slipping too far into the outer tube ( 40 ). Then the operator is able to unscrew the knob ( 51 ) and change the relative position of the inner tube ( 41 ) to the outer tube ( 40 ). However, when a distal end of the inner tube ( 41 ) is provided with a heavy load, i.e. an illuminating device, the operator has to struggle to hold the weight of the illuminating device. Therefore, assistance from the other operators is essential. That is, it is almost impossible for a lone operator to finish the adjustment of the telescopic tube assembly, especially when a weighty object is on top of the telescopic tube assembly. To overcome the shortcomings, the present invention tends to provide an improved locking device to mitigate the aforementioned problems. SUMMARY OF THE INVENTION The primary objective of the present invention is to provide an improved locking device to enable a lone operator to safely finish the adjustment of the relative position of the inner tube relative to the outer tube. Another objective of the present invention is to eliminate danger to the operator by providing a safety device to prevent excessive movement of the inner tube relative to the outer tube. Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is perspective view of the locking device applied on a telescopic tube assembly; FIG. 2 is schematically cross sectional view of the locking device in FIG. 1 ; FIG. 3 is a schematic view showing the operation of the locking device of the present invention; FIG. 4 is a schematic view showing the application of the locking device; FIG. 5 is a schematic view showing an illuminating device is mounted on the telescopic assembly with the locking device of the present invention applied thereto; and FIG. 6 is side view showing a conventional locking device applied to a telescopic tube assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIGS. 1 and 2 , a telescopic tube assembly includes an outer tube ( 10 ) and an inner tube ( 11 ) slidably received in the outer tube ( 10 ). The inner tube ( 11 ) has multiple adjusting recesses ( 111 ) defined in an outer periphery of the inner tube ( 11 ) and a guiding groove ( 112 ) defined on the outer periphery of the inner tube ( 11 ) along a longitudinal axis of the inner tube ( 11 ). A locking device in accordance with the present invention includes an enclosure ( 20 ) partially securely mounted on a peripheral edge of the outer tube ( 40 ) and having a guide ( 201 ) formed on an inner face of the enclosure ( 20 ), a first space ( 21 ) defined in a side face of the enclosure ( 20 ), a first hole ( 22 ) defined through a bottom face defining the first space ( 21 ), a second hole ( 23 ) defined through the enclosure ( 20 ) to be opposite to the first hole ( 22 ) and a second space ( 24 ) defined to communicate with the second hole ( 23 ). Furthermore, a lever ( 25 ) is received in the first space ( 21 ) and has a proximal end, a distal end, a pivot ( 251 ) and a through hole ( 252 ). The pivot ( 251 ) extends from the lever ( 25 ) and abuts the bottom surface of the first space ( 21 ) to allow the lever ( 25 ) to pivot in the first space ( 21 ). The through hole ( 252 ) is defined through the lever ( 25 ) close to the proximal end. A positioning rod ( 26 ) has a first distal end, a second distal end and a pivot pin ( 263 ). The first distal end is mounted pivotally in the through hole ( 252 ) in the lever ( 25 ). The second distal end of the positioning rod ( 26 ) has a head ( 261 ) corresponding to the adjusting recesses ( 111 ). The pivot pin ( 263 ) extends through the lever ( 25 ) and first distal end of the positioning rod ( 26 ) to allow the positioning rod ( 26 ) to pivot on the lever ( 25 ). A spring ( 262 ) is mounted on the positioning rod ( 26 ) and compressibly received in the first hole ( 22 ) such that when the positioning rod ( 26 ) is moved by the lever ( 25 ), the spring ( 262 ) is able to provide a recoil force to the positioning rod ( 26 ) to return the positioning rod ( 26 ). A knob ( 27 ) having a bolt ( 271 ) integrally formed with the knob ( 27 ) is screwingly extended into the second hole ( 23 ) to abut an abutting block ( 28 ) received in the second space ( 24 ) so that the outer periphery of the inner tube ( 11 ) is engaged by the abutting block ( 28 ). Especially, a safety device is mounted on the outer periphery of the inner tube ( 11 ) to prevent excessive movement of the inner tube ( 11 ) relative to the outer tube ( 10 ). With reference to FIG. 3 , it is noted that before the locking device of the present invention is in application, the head ( 261 ) of the positioning rod ( 26 ) is received in one of the adjusting holes ( 111 ) so as to secure the position of the inner tube ( 11 ) relative to the outer tube ( 10 ). When the lever ( 25 ) is depressed, the positioning rod ( 26 ) leaves the corresponding adjusting recess ( 111 ) to allow the operator to adjust the relative position of the inner tube ( 11 ) to the outer tube ( 10 ). After adjustment of the relative position of the inner tube ( 11 ) to the outer tube ( 10 ), the spring ( 262 ) provides a recoil force to the positioning rod ( 26 ) to force the positioning rod ( 26 ) to return to its original position such that the head ( 261 ) of the positioning rod ( 26 ) is received in a corresponding one of the adjusting recesses ( 111 ) of the inner tube ( 11 ) and the adjustment of the telescopic tube assembly is accomplished. However, during the adjustment of the telescopic tube assembly, the operator is able to use the abutting block ( 28 ) to secure the position of the inner tube ( 11 ) in the outer tube ( 10 ). That is, the operator is able to use the abutting block ( 28 ) to increase the friction between the abutting block ( 28 ) and the outer periphery of the inner tube ( 11 ) by rotating the knob ( 27 ) such that the position of the inner tube ( 11 ) in the outer tube ( 10 ) is temporarily secured. Alternatively, the operator is able to use the abutting block ( 28 ) as an auxiliary securing device to secure the position of the inner tube ( 11 ) relative to the outer tube ( 10 ). Further, the guide ( 201 ) slidable in the guiding groove ( 112 ) is able to smoothen the sliding movement of the inner tube ( 11 ) to the outer tube ( 10 ). Preferably, the safety device ( 12 ) which is mounted on the outer periphery of the inner tube ( 11 ) is a boss. The boss ( 12 ) is integrally formed on the outer periphery of the inner tube ( 11 ) such that excessive sliding movement of the inner tube ( 11 ) relative to the outer tube ( 10 ) is prevented. With reference to FIGS. 4 and 5 , it is noted that when a loudspeaker ( 31 ) or an illuminating device ( 32 ) is mounted on top of the free end of the inner tube ( 11 ), the locking device of the present invention is able to safeguard the operator from possible injury by the sudden falling of the inner tube ( 11 ) due to the weight on top of the telescopic tube assembly. It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
A locking device has an enclosure partially securely mounted on a peripheral edge of the outer tube and having a lever pivotally connected to the enclosure; and a positioning rod securely connected to a side of the lever to be driven by the lever and having a head formed on a free end of the positioning rod to correspond to one of the adjusting recesses of the inner tube such that pivotal movement of the lever is able to drive the head of the positioning rod to selectively move away from the corresponding adjusting recess to allow the inner tube to move relative to the outer tube.
8
CROSS REFERENCE TO RELATED APPLICATIONS This application is related to the following U.S. Patent Applications, each of which was filed on even date herewith and assigned to the assignee of the present application: MEMORY-PROGRAMMABLE CONTROLLER, filed as Ser. No. 568,107 on Jan. 24, 1984 in the name of Dieter Wollscheid, and claiming priority of German Application No. P33 23 824.3 filed July 1, 1983; MEMORY-PROGRAMMABLE CONTROLLER filed as Ser. No. 568,104 on Jan. 24, 1984 in the names of Peter Ninnemann and Dieter Wollscheid, and claiming priority of German Application No. P33 02 902.4 filed Jan. 28, 1983; MEMORY-PROGRAMMABLE CONTROLLER, filed as Ser. No. 568,106 on Jan. 24, 1984 in the names of Peter Ninnemann and Dieter Wollscheid, and claiming priority of German Application No. P33 02 929.6 filed Jan. 28, 1983; MEMORY-PROGRAMMABLE CONTROLLER, filed as Ser. No. 568,115 on Jan. 24, 1984 in the names of Dieter Wollscheid, Peter Ninnemann, Siegfried Stoll and Waldemar Wenzel, and claiming priority of German Application No. P33 02 909.1 filed Jan. 28, 1983. The disclosures of each of the above applications is hereby incorporated by reference. BACKGROUND OF THE INVENTION The present invention relates to the field of memory programmable controllers of the type having cyclically traversed user control programs which operate on process images stored in a data memory of the controller. The process images once the control program has executed a full cycle, are used to control a peripheral process. In particular, the present invention relates to memory-programmable controllers of the multiprocessor type including a word processor which processes operating system and word commands, a bit processor which processes binary interlinking commands, a user program memory in which the control program is stored, an operating system memory in which an operating system program is stored and a data memory wherein the binary process images of the peripheral process under control are stored. Memory-programmable controllers are described in detail, for instance, in Siemens Zeitschrift Energietechnik 1979, no. 2, pages 43 to 47, in no. 4, pages 136 to 139, in European Patent No. 10170 and in U.S. Pat. Nos. 3,921,146 and 3,942,158. Presently popular microprocessors, called word processors in the following because they process data in parallel groupings called words, are as a rule designed, as far as their command sets are concerned, for a broad group of users, i.e., universally. In the course of development, the size and performance of the command sets are increasing steadily. It is also characteristic of this development that more and more information carriers (bits) are combined and processed in parallel, i.e., in word groups, e.g. 8 bits in a word. There are, however, special applications in which largely information one bit wide must be processed. One bit, for instance, independently of others, may carry information on peripheral process conditions, such as whether a switch is "on" or "off", or whether controlled process input conditions are met or not met. A memory-programmable controller of the type mentioned above should preferably be able to carry out bit operations, i.e., logical interlinking of data one bit wide, as well as more complex functions with data one word wide, such as arithmetic functions, data transfer, timing etc. It is therefore advantageous to use within the scope of a memory-programmable controller a multiprocessor system, in which the execution of one bit binary commands is assigned to a separate fast bit processor, while a relatively slow word processor carries out the more complex functions involving words (see, for instance, Siemens-Zeitschrift Energietechnik 1980, no. 9, page 361). Since the word-wide and bit-wide processing of the data is mixed and in part independent of the other, a special arrangement for coupling and synchronizing the processors is required. It must also be taken into consideration that the word processor must additionally execute special routines at definite intervals as well as operate completely asynchronously to the program cycle proper, e.g., word and bit operations. Additionally, the program cycle proper with bit- and word-wise data processing should be loaded as little as possible by these routines, but should have the lowest priority, i.e., as soon as the processing of one of these special routines is required, the latter must be performed immediately and unconditionally. SUMMARY OF THE INVENTION It is an object of the present invention to provide a coupling and synchronization arrangement of the two processors in a memory programmable controller, and especially one which is largely independent of the type of word processor. These and other objects of the present invention are achieved in a memory programmable controller of the type having a cyclically traversed user control program for controlling a peripheral process including a word processor for processing operating system and word commands, a bit processor for processing binary interlinking commands, a user program memory wherein the control program including the word and interlinking commands is stored, an operating system memory wherein an operating system program comprising a plurality of subroutines including the operating systems commands is stored, some of the operating system commands associated with the word commands, each of the subroutines having an entry address, and a data memory wherein binary process image signals are stored, the improvement comprising: that the bit processor sequentially accesses the user program memory and recognizes word commands and interlinking commands in the user program memory, and halts its own operation in response to the recognition of a word command; and further comprising that a generator for generating digital information corresponding to an entry address into a subroutine of the operating system program associated with the recognized word command, is provided whereby the word processor can enter the subroutine at the entry address and execute the subroutine associated with the recognized word command. In a preferred embodiment, the generator for generating comprises a mapping memory for generating the entry addresses corresponding to the respective word commands from the digital information and the bit processor operates so as to produce an addressing signal when the bit processor is processing a binary interlinking command, the addressing signal being coupled to the mapping memory the mapping memory being responsive to the addressing signal and generating an entry address for a subroutine in the operating system memory which continuously interrogates the mapping memory, the bit processor producing, when a word command in the user program memory is recognized, the digital information, the mapping memory being responsive to the digital information and generating the entry address of a subroutine in the operating system program associated with the recognized word command, the word processor being responsive to the entry address and entering into the operating system program at the entry address and executing the subroutine associated with the recognized word command, the bit processor further halting all of its processing operations until the subroutine is executed. Likewise, the bit processor addresses, when a stopping point in the control program is reached, that address in the mapping memory in which the entry address is located at which a subroutine for processing the stopping point in the operating system of the word processor begins. In the above-mentioned manner it is achieved that, for a fixed command code of the word operation in the user program memory, the entry addresses of the corresponding program subroutines can be kept variable. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be explained in greater detail in the following detailed description, with reference to the drawings, in which: FIG. 1 is a block diagram of one embodiment of the memory-programmable controller according to the invention; FIG. 2 is a block diagram of the coupling arrangement between the word processor and the bit processor; FIG. 3 is a flow chart of the command cycle in the word processor; and FIG. 4 is a flow chart of the command cycle in the bit processor. DETAILED DESCRIPTION With reference now to the drawings, the block diagram of one embodiment of a multiprocessor controller according to the invention is shown in FIG. 1. The execution of binary commands is assigned to a separate fast bit processor 3, while a relatively slow word processor 2 carries out more complex functions, involving groups of parallel data, i.e., words. The word processor 2 is coupled to a peripheral bus 21 to which the input and output modules 1 are coupled. The input and output modules interface with the process under control. An internal system bus 22 is coupled to an operating system memory 4 and via data switch 8, to data memory 6 wherein the process image is stored and to user program memory 5 wherein the control program is stored. The bit processor 3 is also connected to the same bus 22 which, via buses 31 and 32 exclusively dedicated to the bit processor and data switches 8, has access to user program memory 5 and data memory 6. Data communication with the peripheral process always occurs by way of the word processor 2 which always stores at the control program cycle limits the state of all input information from the process in the internal data memory 6 and transmits the output signals resulting from the logical interlinking in the data memory 6 to the peripheral process at the end of the control program cycle. While the control program is running, the controller therefore does not operate directly with the actual signals of the peripheral process, but rather with internal process images stored in the data memory 6 (see, for instance, European Patent No. 10170 and U.S. Pat. Nos. 3,942,158 and 3,921,146). The instructions regarding both bit and word operations are encoded in a special programming language and stored in the user program memory 5. These instructions are executed by the bit processor 3 and indirectly by word processor 2 under the control of an operating system program 2 stored permanently in the operating system memory 4 of the word processor 2 in the language of the microprocessor used. In the following, a coupling arrangement will be described which meets the requirements mentioned above, i.e., the common execution of a special programming language by both a word and bit processor, and permits a universal design of the bit processor 3, i.e. independent of the type of word processor 2 coupled thereto. It is characteristic of the overall system that in principle the word processor 2, as a standard microprocessor, and the bit processor 3, each have program counters of their own and at first can operate completely independently of each other and asynchronously. The bit processor 3 itself appears to the word processor 2 like a memory interface or an intelligent peripheral module. It has internal registers, from which the word processor 2 can at any time determine the instantaneous status of the bit processor such as "RUN" or "STOP". Through write access to one of these registers, the bit processor 3 furthermore can be started or stopped by the word processor 2 at any time. The program counter for keeping track of the actual program cycle is located in the bit processor 3. After it has been started, the bit processor 3 fetches instructions D from the user program memory 5 and determines whether they are word or bit operations. After a bit operation is recognized, the bit processor executes it immediately itself. If a word operation is recognized, the bit processor transfers the word operation to the word processor 2 and goes automatically to the status "STOP". The bit processor 3 itself is not capable of accessing or controlling the word processor 2. It merely prepares in its internal registers information for the word processor 2. The control of the overall system must therefore start from the word processor 2. It is achieved by this principle that the bit processor need not be tailored to a specific type of word processor, but can be kept general at its interface and can be handled by any standard microprocessor like a memory or an intelligent peripheral module. As may be seen from FIG. 2, the tasks of the bit processor 3 are therefore to fetch command D in the user program memory 5 at the address A of the program counter of the bit processor and to recognize the type of command (word or bit operation) and to react accordingly. This means that in the case of bit operations, the latter are executed by the bit processor, while if a word operation is recognized, it is transferred to the word processor 2, whereupon the bit processor subsequently stops and waits for a new start by the word processor. The tasks of the word processor 2 include executing certain routines which may be asynchronous or time-controlled, and additionally, controlling the bit processor 3 when executing word operations recognized by the bit processor in special program routines. Each word operation is interpreted by a special program routine through the word processor 2. The entry address into the program routine associated with a given operation is not obtained by the word processor 2 directly from the code of the word operation in the user program memory 5, but preferably from an interposed mapping memory 9. The code of the word operation forms the address A1 for a given memory cell of the memory 9, from which the entry address is generated or mapped into the corresponding program routine as the data D1. In processing this program routine, the word processor can then access further data in the user program memory, such as parameters or operands associated with the word command. It is achieved in this manner that, with a fixed command code of the word operation, the entry addresses of the associated program routines can be kept variable. As indicated, the synchronization between the word and the bit processor is performed by the control signal STOP/START of the bit processor. The program counter of the bit processor 3 can be read and written into by the word processor 2. If the program counter has been written into by the word processor with a defined value, the bit processor 3 then is started. The bit processor 3 starts up freely and assumes the above-mentioned tasks. In the meantime, the word processor 2 processes either routines coming up parallel to the bit processor 3 or is in an active "polling loop" (see FIG. 3) in which it merely addresses two successive 8-bit registers 31 of the bit processor 3, (see FIG. 2) whereupon these registers 31 of the bit processor 3 address the mapping memory 9 in such a way that the latter puts data D1 on the data bus which correspond to the type of the word operation. These data are interpreted as a 16-bit address A2, into which the word processor 2 is then branched. This address A2 is either the entry address for one of the program routines in the operating system memory for word operations or the start of the inactive polling loop itself. As long as no word operation is recognized by the bit processor 3, the registers 31 normally furnish, when addressing the mapping memory, the base address A0 of the mapping memory 9, i.e., the entry or starting address of the polling loop. If the bit processor 3 detects a word operation in the user program memory 5, it connects the code of the word operation as the address A1 to the mapping memory 9 via the correspondingly changed registers 31, and the word processor reads in its loop, determined by the address of the above-mentioned registers, the data D1 of the memory cell of the mapping memory 9 addressed by the bit processor 3, i.e., the entry address A2 into the program routine D2 for this word operation in the operating system memory 4. The word processor 2 therefore always branches off to where the address in the bit processor in the above-mentioned registers 31 point, i.e., to the start of the polling loop or to one of the program routines. After a word operation is recognized, the bit processor 3 stops and must be restarted at the end of the respective program routine of the word processor for the word operation by the word processor 2. Since the program counter in the bit processor 3 is incremented after every complete fetch of an instruction, it already receives the correct continuation address for further cycling through the user program memory 5. If the word operation was a jump command, the word processor must reload the program counter of the bit processor 3 after it is restarted, with the jump destination. The polling loop of the word processor 2 includes, in popular microprocessors, about 2 to 4 commands: Address register of the bit processor, and Jump to the address read from the memory 9. An extremely short reaction time is thereby achieved in recognizing word operations. In addition, the mapping memory 9 makes software-wise branching via a list unnecessary and again, processing time is saved. During the processing of bit operations, the word processor 2 can jump via "interrupts" from its polling loop into the asynchronously or time-controlled routines already mentioned and these can operate in parallel with the bit processor, as is also seen from FIG. 3. If the bit processor then recognizes a word operation, actual execution of these routines continues only until the word processor 2 has returned to its polling loop and can process the word operation. The operation of the word and bit processors as described above are summarized in the flow charts of FIGS. 3 and 4. Besides the fast reaction times, some of the main advantages of the present coupling arrangement are the simple synchronization between the word and bit processors, the possible parallel operation of both processors and the independence of the bit processor design of the type of word processor. The interface to the bit processor is realized as a memory interface and is free of any additional control lines. However, a less costly and instead somewhat less capable solution is also possible. The memory 9 may be omitted. The memory content which transforms the information specifying the type of the word command to the entry address in the program section of the word command, is then within the memory 4 in a constant-data field. The word processor 2 reads in the bit processor only that information which indicates whether a word command occurred, which word command is present and whether a stopping point was reached. The required entry address is then determined for each program through access to the table, i.e., the data field. It is also possible to dispense with recoding the information through memories and have the word processor 2 use the information from the bit processor 3 directly as the entry address, or thereby form this address by logical or arithmetic operations such as masking, shifting or adding etc. In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
A memory-programmable controller of the multiprocessor type, has both a fast bit processor for processing bit oriented operations and a slower word processor for processing word oriented operations. The bit and word operations are stored in a user program memory by the user. These operations are the program which controls the peripheral process controlled by the controller. The bit processor reads the user program memory and sequentially stops when a word command is recognized. The bit processor furnishes information which the word processor uses as the entry address for a program routine associated with the word command in an operating system memory. This provides freedom in the choice of the word processor and in the design of the bit processor to a high degree.
6
[0001] The present invention relates to a plant for manufacturing a rigid pipe for drawing up deep water within an offshore platform. This pipe is used for offshore electricity production in the context of ocean thermal energy. BACKGROUND [0002] An energy production facility of this type generally includes a platform on which means are placed for producing electricity from the temperature difference in the surface and deep water, said platform also being associated with means forming a pipe for drawing cold water up from a depth. [0003] The operating principle of such an OTE (Ocean Thermal Energy) facility consists of using the temperature difference that exists naturally between the surface and deep water of the oceans to run a thermal machine. [0004] Due to the laws of thermodynamics, to have an acceptable efficiency, the implementation of such an OTE facility is only justified with a temperature difference for example greater than 20° C. [0005] Typically, the water can for example be at a temperature of 25° C. on the surface and a temperature of 5° C. at 1000 meters deep. [0006] One can then see that this limits the use of such facilities to specific areas, for example such as tropical areas. [0007] The water must then be pumped at a very significant depth through means forming a suction pipeline associated with the platform, while the hot water is pumped on the surface. [0008] Various attempts to develop OTE-based energy production facilities have already been made. [0009] Efforts were for example made by Georges CLAUDE in the 1930s. [0010] Of course, other operators have made attempts since then. [0011] However, the very large majority of these attempts have failed due to various problems, and in particular problems of the mechanical strength of certain elements of those facilities with the environmental conditions encountered. [0012] It is in fact known that in the geographical areas in which these facilities can be installed, particular meteorological conditions may be encountered such as relatively strong ocean currents, storms, etc., which causes the deterioration or even breakage of certain parts of the facility. [0013] Other problems appear during the manufacture of the rigid pipe for drawing up deep water. [0014] It has in fact already been proposed to produce that pipe in the form of sections jointed together using connecting means. [0015] This nevertheless has a certain number of drawbacks, in particular in terms of the complexity and cost of such a structure. [0016] Other solutions have consisted of producing the pipe on land and towing it to the production site. [0017] The towing and handling operations for such a pipe, which can be several tens or even hundreds of meters long, are also extremely tedious. SUMMARY OF THE INVENTION [0018] It is an object of the present invention to resolve these problems. [0019] The present invention provides a plant for manufacturing a rigid pipe for drawing up deep water for a marine thermal energy facility, characterized in that it includes a floating platform on which continuous production means are installed in the vertical axis of the pipe, and comprising: [0020] a first stage of winding webs of fibers impregnated with resin around a winding roll for the partial crosslinking thereof, [0021] a second stage of complete crosslinking of the resin, [0022] a third stage of mounting functional members on the pipe, [0023] a fourth stage of inspecting the pipe thus manufactured, and [0024] a fifth stage of guiding the pipe. [0025] According to other aspects of the invention, the plant for manufacturing a rigid suction pipe comprises one or more of the following features: [0026] the pipe includes a helical outer rib suitable for cooperating with guiding means of the fifth stage of guiding and driving the lowering to drive the lowering of the pipe into the water, [0027] means for protecting the manufactured pipe from solar radiation are provided between the platform and the water, [0028] the protection means comprise a canvas sheet, and [0029] the second stage of complete crosslinking of the resin includes means for heating the pipe. BRIEF DESCRIPTION OF THE DRAWING [0030] The FIGURE shows a part of a plant for manufacturing a rigid pipe. DETAILED DESCRIPTION [0031] The invention will be better understood in light of the following description, provided solely as an example and done in reference to the appended drawing, which shows a block diagram illustrating the structure and operation of a manufacturing plant according to the invention. [0032] This FIGURE shows part of a plant for manufacturing a rigid pipe for drawing up deep water that is designed to be implemented in a marine thermal energy plant. [0033] This plant for manufacturing the rigid pipe includes a floating platform designated by general reference 1 , on which continuous production means of the suction pipe are installed, said means then making it possible to produce, vertically and continuously, a pipe made from a composite fiber-resin material with a large diameter, for example comprised between 4 and 12 meters, by filamentary winding. [0034] These manufacturing means are designated by general reference 2 in this FIGURE and include a certain number of stages, including a first stage of winding the fibers and pre-curing the impregnating resin, designated by general reference 3 . [0035] This stage then includes various filamentary winding heads around a roll designated by general reference 4 in this FIGURE, for example implementing the “DROSTHOLM” roll technique consisting of a cylindrical surface for receiving the filamentary winding web, advancing axially in a spiral to drive those webs and thereby forming the wall of the pipe, that surface rising through the inside of the roll to renew itself in the upper portion, in a known manner. [0036] This type of roll being well known in the state of the art, it will not be described in more detail hereafter. [0037] This roll is then adapted to drive the pipe in a second stage of post-curing and complete crosslinking of the resin, said second stage being designated by general reference 5 and including heating means 6 making it possible to obtain the desired curing of the resin. [0038] The pipe then enters a third stage of fastening of functional members, such as appendages and helical guiding means for example making it possible to fasten the pipe thus formed on the outer wall, a helical rib forming a screw pitch whereof the function will be described in more detail hereafter. [0039] This third fastening stage is designated by general reference 7 in this FIGURE, while the helical rib is designated by general reference 8 . [0040] The pipe then enters a fourth stage of safety anchoring and material inspection, designated by general reference 9 , in which a certain number of inspections relative to the integrity of the pipe are done. [0041] After this fourth anchoring and inspection step, the pipe enters a fifth stage of supporting, guiding and driving the lowering thereof, that stage being designated by general reference 10 in that FIGURE and then including guide means, designated by general reference 11 , through which the pipe, and in particular the helical guide rib thereof, passes to control the lowering of the pipe. [0042] The pipe then passes through the platform 1 to descend into the water, as designated by general reference 12 in that FIGURE, means for concealing it from solar radiation for example being provided between the lower portion of the platform 1 and the water to avoid any deterioration of the pipe. These concealing means are for example designated by general reference 13 and for example assume the form of a protective canvas sheet. [0043] Other embodiments of the concealing means can of course be considered. [0044] Means in the form of a grate or strainer can also be provided at the lower end of the pipe, those means being designated by general reference 14 in this FIGURE. [0045] One can then see that using such a facility, it is possible to produce a pipe with a large diameter in situ, continuously and vertically. [0046] The basic idea is to use the “DROSTHOLM” continuous piping production technique, which consists of a cylindrical surface for receiving filamentary winding fiber webs. This surface then moves forward axially in a spiral and drives the wound fiber webs, which form the wall of the rigid pipe. This surface then rises through the inside of the roll to renew itself in the upper portion thereof. [0047] Other embodiments can of course be considered. [0048] The first fiber web is then wound on that surface and is driven downward by the hoop of the roll. [0049] If for example the web is one meter wide and the roll consists of a spiral that descends by one meter per revolution, the web then also descends by one meter per revolution. After one revolution, it returns to the initial winding without being superimposed. During that revolution it also descends 10 centimeters for every tenth of a revolution. If there are ten winding stations on a revolution, the web descending by 10 centimeters every tenth of a revolution is then covered with another strip of fibers, and its upper portion has received ten plies of fibers over the complete revolution. It is thus connected to the other layers without notable discontinuities. [0050] One revolution then makes it possible to obtain a wall 5 mm thick with fabrics of 600 grams per square meter. [0051] To create a wall 100 mm thick, it is then necessary to have 20 winding rows over a height of 20 meters. The machinery associated with the roll then consists of 200 winding carriages that must guide and impregnate the fiber webs. [0052] During winding, the first crosslinking is done during deposition of each web so as to avoid a subsequent excessive exothermia due to the large wall thicknesses in the vicinity of 100 mm ultimately considered. By heating to a temperature of 45° to 50° C. for example, that temperature being below the vitreous transition temperature of about 100° C., the crosslinking will for example reach a maximum of 30%. This will thus dissipate 30% of the total exothermia without excessively stiffening the macromolecule matrix, such that the web comports well to the curvature of the surface and adheres thereto. Furthermore, this state of immediate pre-polymerization provides access to compacting of the surface by pressing rollers, bubble rollers, etc. [0053] Once the thickness of 100 mm is reached at the bottom of the twenty winding stages, this intermediate crosslinking state is about 60% complete and provides an initial maintenance stiffness of the wall that then makes it possible to do away with the support of the roll. It is gradually released and rises through the inside of that roll. [0054] The roll being released, the post-curing state must lead to the complete crosslinking of the resin by heating from the outside and inside of the pipe. This complete crosslinking is necessary to avoid aging of the material by reacting humidity. At that point, only 30% of the energy remains to be dissipated. The ratio between the energy generated by chemical reaction and to be dissipated by the thermal pipe is the “DAMKOHLER” number. It must remain below one to avoid a temperature burst, and destruction of the wall of the pipe of the tube that may go as far as the explosion of the pile. [0055] The end-of-crosslinking driving is therefore inseparable from the temperature to ensure the production of such a wall thickness. The speed of rotation is one regulating parameter. [0056] Supporting appendages or devices are attached in the continuation of the previous curing. [0057] By arranging a helical winding path adhered on the crosslinked wall, a complementary roller rolling path will make it possible to support the pipe and contribute to the rotation thereof. The variation in the pitch of that spiral may incorporate the mass of the tube, which increases during manufacturing. This path may reversibly rise partially in the tube if the stratification is not correct or if the wall needs to be corrected. [0058] The manufacturing inspection is done on the resin and fiber components up to the final structure. [0059] Thus, and as regards the resin, the acid number can be monitored, since an excessively high value leads to incomplete crosslinking, the provided resin then being poorly formed. It is also possible to carry out: [0060] a weekly inspection of the styrene content, as its evaporation may lead to a lower crosslinking possibility, [0061] an inspection of the gelatinization duration to validate the inspection of the reactivity of the resin, and [0062] a viscosity inspection, which is necessary to proper wetting of the fibers of the fabrics. [0063] The inspection of the fibers pertains to an inspection of the weight and mechanical integrity of the fabrics. The rolls of fiber provided include a binding method to quickly bind two fabrics by overlapping. [0064] The polymerized material can also be inspected, since for all materials and components involved in the manufacture of the pipe, it should be verified that the minimum values of the defined properties are respected by performing tests. Thus for example, possible non-destructive inspection methods for these assemblies may be: [0065] a visual examination making it possible to verify good bubblizing, good impregnation, good covering of the webs, ambient conditions, etc. [0066] examination by measuring the “BARCOL” hardness, which makes it possible to determine the crosslinking level obtained by comparison. The “BARCOL” hardness measurement being local and the materials being heterogeneous, a great dispersion of the results may be observed. The crosslinking is correct when the material has a satisfactory hardness, for example greater than 40. Only the surface is accessible. Wall samplings should be provided for at the end of crosslinking. [0067] an examination by DSC measurement that relates to the differential calorimetry, which makes it possible to measure the energy remaining to be dissipated after curing on a material sample and to detect sub-polymerization. DSC measurement is a destructive inspection that may be done either on a sample taken from the pipe or on a chip or control sample, [0068] a radiography examination, which may be used to check the accessory assemblies done by adhesion and detect areas lacking adhesive, [0069] an ultrasound examination, which makes it possible to detect unglued surfaces, delamination, empty spaces, and thickness variations, and to monitor fiber levels by burning. [0070] During manufacturing, the environment must be clean and protected from weather. The temperature must not be below 15° C. or above 40° C. As stated above, a temperature of about 40° C. allows pre-crosslinking of the resin by dissipating part of the energy and a limitation of exothermia in the case of large thicknesses, i.e. larger than 30 mm. [0071] A high ambient temperature causes a faster reaction of the resin. It is possible to modulate the reaction time by adding retarding agents into the resin. The physicochemical reactivity characterization makes it possible to control that data. The storage time leads to a curing degree of about 10%. [0072] The ambient hygrometry must also be less than 80%. [0073] During the winding phase, there must not be any water condensation on the wall of the pipe. [0074] Given the thickness of the pipe, the porosities expected from energy absorption also are not too bothersome, as in the case of thin parts, the latter not being subject in its entirety to planar or transverse shearing. [0075] One can thus see that it is possible to manufacture, in situ, a rigid pipe for drawing up cold water that must make it possible to extract cold water at a depth of about 1000 meters. [0076] By manufacturing the pipe in situ, a certain number of problems are eliminated, such as those related to manufacturing it on land and towing it to the exploitation site. This also makes it possible to reduce the cost of such a pipe. [0077] Other embodiments can of course also be considered.
A plant for manufacturing a rigid pipe for drawing up deep water within an offshore platform includes a floating platform on which a continuous production device is installed in the vertical axis of the pipe, and including: a first stage of winding webs of fibers impregnated with resin around a winding roll for the partial crosslinking thereof, a second stage of complete crosslinking of the resin, a third stage of mounting functional members on the pipe, a fourth stage of inspecting the pipe thus manufactured, and a fifth stage of guiding the pipe.
8
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 12/177,813, filed Jul. 22, 2008. U.S. patent application Ser. No. 12/177,813 claims priority to U.S. Provisional Application No. 60/954,749, filed Aug. 8, 2007. The contents of both applications are incorporated herein by reference in their entirety. FIELD OF THE INVENTION The present invention relates generally to the field of valves. More particularly to a diaphragm type flushometer, typically for use in a urinal or water closet or the like. BACKGROUND OF THE INVENTION Prior art flushometers have included a two part diaphragm-disc assembly. The diaphragm plate was typically a rubber component with a metallic core (for support). The diaphragm serves to control the main (primary) water flow through a flushometer by the use of a bypass. The relief valve seat was a separate component that engaged with the diaphragm. In prior art devices, the relief valve seat typically was an additional part also rubber molded around a metallic base. As lower flush volume fixtures have become necessary and popular, there is a need for flushometers to deliver tighter variability to each flush delivered. This requires tighter control over the components which in-turn give tighter control over the flush profile (both total volume per flush and volume per time.) SUMMARY OF THE INVENTION In one embodiment, the invention provides for a reduced part count when assembled as a flush valve, thus providing the associated benefits of reduced parts such as lower cost, ease of maintenance and easy of assembly. The diaphragm of the present invention includes, in one aspect, a plurality of bypasses, in another aspect a singular diaphragm with integrated relief valve seat and in yet another aspect an improved mechanism for sealing the components of the diaphragm kit via the use of retainer. In one embodiment, the invention relates to a flush valve system comprising a flush valve body having a water inlet and a water outlet, the water inlet positioned on a side of the flush valve body and the water outlet positioned at a bottom of the flush valve body. The system further includes a barrel, having a hollow passage, disposed within the flush valve body, the barrel forming a vertical pathway for water from the water inlet to pass to the water outlet, a skirt of the barrel and the flush valve body in communication to form a seal between the water inlet and the water outlet and the flush valve body defining an inlet chamber. A diaphragm is disposed at an upper end of the barrel, sealing the inlet chamber from the hollow passage and the diaphragm defining a control chamber above the diaphragm. The diaphragm has a top surface, a bottom surface, and a side and having a central aperture, the diaphragm further including a plurality of by-pass apertures therethrough. Each of the plurality of by-pass apertures is configured to retain a by-pass, the by-pass providing a passage from the inlet chamber to the control chamber allowing equilibration of pressure. A relief valve retention ring circumscribes the central aperture and extends from the top surface of the diaphragm. The relief valve retention ring has a plurality of relief valve lugs protruding from an inner surface of the relief valve retention ring towards the central aperture. The relief valve seat is positioned on the top surface, and the relief valve seat is positioned between the relief valve retention ring and the central aperture. A relief valve is seated on the diaphragm and has a valve stem extending downward therefrom through the diaphragm into and extending beyond a guide. The guide is coupled to the diaphragm and extending downward from the diaphragm into the barrel, the guide being a generally cylindrical hollow tube in communication with the central aperture. In another embodiment in the form of a flush valve diaphragm kit, the kit comprises a diaphragm having substantially a disk-shape with a top surface, a bottom surface, and a side, with a radius of the diaphragm being substantially greater than a height of the diaphragm. The diaphragm has a central aperture positioned substantially centrally through the diaphragm and a plurality of by-pass apertures are disposed in the diaphragm, the plurality of by-pass apertures comprising passages through the diaphragm. The kit further includes a plurality of by-passes and each by-pass aperture has a by-pass associated therewith and retainably disposable therein. A relief valve retention ring circumscribes the central aperture and extends from the top surface of the diaphragm. The relief valve retention ring has a plurality of relief valve guides protruding from an inner surface of the relief valve retention ring towards the central aperture. A relief valve seat is positioned on the top surface, the relief valve seat positioned between the relief valve retention ring and the central aperture. A retainer is affixed the diaphragm to a guide, the retainer being disposable with the central aperture of the diaphragm and has a flange engagable with the top surface of the diaphragm. A relief valve has a valve stem, the relief valve seatable on the relief valve seat and retained at least partially by the relief valve retention ring, and the valve stem extending through the retainer and the guide away from the diaphragm. In yet another embodiment comprised of an diaphragm assembly for use in a flush valve, the diaphragm assembly comprises a diaphragm having a substantially cylindrical shape with a top surface, a bottom surface, and a side, with a radius of the diaphragm being substantially greater than a height of the diaphragm. The diaphragm has a central aperture positioned substantially centrally through the diaphragm. A plurality of by-pass apertures are disposed in the diaphragm, the plurality of by-pass apertures comprising passages through the diaphragm. A plurality of by-passes is included with each by-pass aperture having a by-pass associated therewith and retainably disposable therein. A relief valve retention ring circumscribes the central aperture and extends from the top surface of the diaphragm. The relief valve retention ring has a plurality of relief valve guides protruding from an inner surface of the relief valve retention ring towards the central aperture. A relief valve seat is positioned on the top surface, the relief valve seat positioned between the relief valve retention ring and the central aperture. The invention includes certain features and combinations of parts hereinafter fully described, illustrated in the accompanying figures, described below, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of a prior art flush valve; FIG. 2 is an exploded view of a flush valve diaphragm assembly; FIG. 3 is a top view of a flush valve diaphragm; and FIG. 4 is a cross-sectional view of a diaphragm assembly including a diaphragm, relief valve, and guide. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Diaphragm-type flushometers having a single bypass orifice and multiple assembled kit parts are well known, as taught in U.S. Pat. Nos. 6,616,119; 5,967,182; 5,887,848; 5,490,659; 5,213,305; and 5,332,192 and incorporated herein by reference. The invention has application for all fixtures utilizing a diaphragm flush valve, including traditional volume fixtures. However, it should be appreciated that the diaphragm assembly described herein has substantial advantages for reduced water consumption fixtures, also referred to as High Efficiency Urinals (“HEU”) and High Efficiency Toilets (“HET”). However, it should be understood that the improved diaphragm of the present invention can likewise improve performance of flushometers of various volumes per flush and is not unique to improvement of low flushing fixtures. While the diaphragm assembly described herein may be used in various flush valves, FIG. 1 illustrates a flush valve system 100 in which the diaphragm assembly 110 described herein may be used. As shown in FIG. 1 , the flush valve includes a flush valve 101 having an inlet 102 and an outlet 104 . A diaphragm assembly 110 is positioned to separate the inlet 102 and outlet 104 and to regulate the flow therebetween. In continued reference to FIG. 1 , a barrel 105 forms a pathway between the inlet 102 and outlet 104 . Typically the flush valve body 101 is elongated along its vertical (longitudinal) axis 114 such that is taller than it is wide. Standard flush valve bodies generally utilize a side-entry inlet 102 (as depicted in FIG. 1 ) such that water enters the flush valve body 101 from the side, substantially parallel with the horizontal (lateral) axis 115 of the flush valve system 100 . As also shown in FIG. 1 , the outlet 104 is typically positioned at the “bottom” of the flush valve body 101 . The barrel 105 forming the pathway between the inlet 102 and the outlet 104 is generally positioned substantially parallel to the vertical axis 114 of the flush valve system 100 . In one embodiment, the inlet 102 feeds water into an inlet chamber 103 that surrounds the barrel 105 and whose communication with the barrel 105 (and thus the outlet 104 ) is controlled by the diaphragm assembly 110 . The diaphragm assembly 110 is positioned on the barrel 105 for controlling the flow of water from the inlet 102 through the outlet 104 . Water from the inlet chamber 103 will flow “over” the top of the barrel 105 and into the interior of the barrel 105 to the outlet 104 when the diaphragm assembly 110 is “open”, i.e. lifted off of the diaphragm seat 106 . In one embodiment of the diaphragm assembly 110 , the diaphragm assembly 110 includes a flexible diaphragm 116 . The diaphragm 116 , in one embodiment, has a substantially disc-like shape with a top surface 116 a , a bottom surface 116 b , and a side or outer periphery 116 c , with the outer diameter of the diaphragm 116 being substantially greater than a height (thickness) of the diaphragm 116 . The diaphragm 116 is secured about its periphery 116 c . In one embodiment, the diaphragm periphery 116 c is secured to the valve body 101 . The diaphragm 116 is seated on a diaphragm seat 106 , which is an uppermost portion of the barrel 105 . The diaphragm 116 , when seated on the diaphragm seat 106 , forms a seal that prevents water from passing from the inlet 102 , via the inlet chamber 103 , into an interior of the barrel 105 (and subsequently out through the outlet 104 ). The operation of the diaphragm assembly 110 is controlled by the balance of pressures between the inlet chamber 103 and a control chamber 107 . The control chamber 107 is defined as a portion of the interior of the flush valve body 101 above the diaphragm assembly 110 and opposite the inlet chamber 103 , such that pressure of the control chamber 107 operates on the diaphragm 116 opposite the pressure from the inlet chamber 103 (typically due to the pressure of the water in the water supply line (not shown) itself). Thus, the inlet chamber 103 pressure operates to push the diaphragm 116 off the diaphragm seat 106 , and the control chamber 107 pressure operates to press the diaphragm 116 to the diaphragm seat 106 . As shown in FIGS. 1 , 2 , and 4 , in certain embodiments, the diaphragm assembly 110 includes a disc 109 integral to the diaphragm and forming a relief valve seat 117 . The diaphragm assembly 110 includes a central aperture 108 . In this embodiment, the relief valve assembly 119 includes a relief valve head 121 seated on the relief valve seat 117 and over the central aperture 108 . The relief valve head 121 has a relief valve stem 122 extending therefrom through the diaphragm 116 and through guide 120 . The guide 120 extends from the diaphragm 116 downwards towards the outlet 104 and is disposed within the barrel 105 . In one embodiment, the guide 120 is affixed to the diaphragm assembly 110 such as via a retainer 112 , which may be, for example, a threaded screw matching the threads on an inner portion of the guide 120 and having a flange 111 for retaining the diaphragm 116 . In this embodiment, the relief valve stem 122 extends through the retainer 112 and the relief valve head 121 is seated over the retainer 112 . The diaphragm 116 forms a seal at the diaphragm seat 106 as previously discussed, and the guide 120 extends downward therefrom through the barrel 105 . The guide 120 is aligned with the aperture 108 of the diaphragm 116 , such that a pathway from the pressure chamber 107 to the barrel 105 is defined. Referencing FIG. 1 , as stated, the relief valve head 121 is positioned within the aperture 108 of the diaphragm 116 for controllably sealing the control chamber 107 from the barrel 105 . The relief valve head 121 seats upon the diaphragm 116 at the relief valve seat 117 to form a seal and includes a valve stem 122 that extends downward, through the guide 120 , to a point where it is engagable with a plunger 124 in communication with a handle 125 . The valve stem 122 is able to move a limited distance along the vertical axis 114 without unseating the relief valve head 121 from the relief valve seat 117 . The valve stem 122 is positioned in the guide 120 and a lower end 122 a of the valve stem 122 is unattached such that movement of the lower end 122 a will pivot the valve stem 122 and exert force on the relief valve head 121 . In one embodiment (best shown in FIG. 1 ), at the upper portion of the barrel 105 , a refill head 130 is disposed about the guide 120 between the barrel 105 and the guide 120 . The refill head 130 has a central aperture 221 , allowing the refill head 130 to be disposed about the guide 120 . The guide 120 includes a refill head retention flange 129 for retaining the refill head 130 to the diaphragm 116 . Thus, the refill head 130 is bounded, before the flush valve system 100 is activated, by the barrel 105 , the guide 120 and the diaphragm 116 . When the flush valve system 100 is activated, the refill head 130 moves up along the vertical axis 114 with the guide 120 (and a central portion of the diaphragm 116 ) such that it is bounded by the guide 120 and the diaphragm 116 , but is substantially exposed to the intake chamber 103 . Thus, as the diaphragm 116 continues its upstroke opening an annular passage 127 underneath the diaphragm 116 , the refill head 130 rises as well. The refill head 130 allows the flow of the water initiated by the upstroke of the diaphragm 116 from the inlet chamber 103 through the barrel 105 and ultimately to the outlet 104 . The shape of the refill head 130 determines the flow path of the water. Actuation of the handle 125 slides the plunger 124 , which engages the lower end of the valve stem 122 , pivoting it, results in movement of the relief valve head 121 (typically tilting it) breaking the seal between the relief valve head 121 and the relief valve seat 117 on the diaphragm 116 . The tilting of the relief valve head 121 vents the pressure in the control chamber 107 above the diaphragm assembly 110 . The release of the pressure in the control chamber 107 releases the seal of the diaphragm 116 against the diaphragm seat 106 , allowing water to flow from the inlet chamber 103 (which is replenished via the inlet 102 ) past the annular passage 127 over the diaphragm seat 106 of the barrel 105 into the interior of the barrel 105 . This unseating of the diaphragm 116 is often referred to as the “upstroke” of the diaphragm 116 , and the downward motion of the diaphragm 116 reseating is referred to as the “downstroke” with the entire cycle referred to as the “stroke” of the diaphragm 116 . The stroke of the diaphragm 116 determines the time period that water can flow into the barrel 105 from the inlet chamber 103 , which is constantly being filled by water from the inlet 102 and ultimately though the barrel 105 to the outlet 104 to accomplish the “flush”. In one embodiment, illustrated in FIG. 2 the diaphragm 116 is provided as part of a kit. The flushometer diaphragm kits are preferably made up of the diaphragm 116 , a relief valve mechanism 119 , diaphragm guide 120 , optionally a refill ring (not shown), a retainer 112 , and refill head 130 . The diaphragm kit of the present invention includes, in one aspect, a plurality of bypasses 206 , in another aspect a singular diaphragm 116 with integrated relief valve seat 117 (disk 109 ), and in yet another aspect an improved mechanism for sealing the components of the diaphragm kit via the use of retainer 112 . FIGS. 2 and 4 best illustrate one embodiment of the structure of the diaphragm assembly 110 . The diaphragm assembly 110 includes a diaphragm 116 having a central aperture 108 , as described above, for allowing passage of the relief valve stem 122 therethrough. In one embodiment, the central aperture 108 is adapted to receive a retainer 112 that engages the guide 120 . As discussed above, in one embodiment the diaphragm 116 further includes a rigid disc 109 that the diaphragm 116 is molded about (best illustrated in cross-sectional FIGS. 1 and 4 ). The material above the disk 109 serves as the relief valve seat 122 . The diaphragm 116 also includes at least two by-pass apertures 205 each for receiving a by-pass 206 . In an alternative embodiment, at least three by-pass apertures 205 are provided. Each by-pass 206 has a passage 207 therethrough. The at least two by-pass aperture 205 in the diaphragm 116 place the control chamber 107 in communication with the inlet chamber 103 . The by-pass apertures 205 are adapted to receive a by-pass 206 . The by-pass 206 includes a housing having a passage 207 therethrough. Each by-pass 206 is shaped to fit the by-pass aperture 205 in the diaphragm 116 . It should be appreciated that various size passages 207 (passage diameter) may be utilized to provide for various flush profiles. The by-pass aperture 205 is spaced from the center aperture 108 of the diaphragm 116 sufficiently to provide sufficient water flow to the pressure chamber even during a flush cycle when the diaphragm 116 flexes upwards. It will also be appreciated that it is preferred, structurally, that the by-pass aperture 205 is spaced sufficiently from the periphery 116 c of the diaphragm 116 and also from the central aperture 108 of the diaphragm 116 . In one embodiment, the multiple by-pass apertures 205 are equally spaced from one another. The equal spacing of the aperture 205 provides for a more even influx of water (and pressure) into the control chamber 107 (via the by-pass body 206 disposed in the aperture 205 ) than with a singular by-pass aperture or unequally spaced multiple apertures. A disadvantage of a single bypass is the angular orientation of the fixed aperture in the diaphragm 116 relative to the inlet 102 . The local pressure within the valve body 101 and flow of the water in the inlet 102 and inlet chamber 103 within the flushometer body annulus can affect performance of the flushometer. This requires careful alignment during assembly and throughout the lifespan of the diaphragm 116 . The uneven flow of water into the control chamber 107 and the pressurization of same can result in an uneven flexing of the diaphragm 116 resulting in increased wear and a shorter useful lifespan for the diaphragm 116 . The bypass aperture 205 provides communication between the control chamber 107 and the inlet chamber 103 . Thus, the bypass orifices 206 , in combination with the relief valve head 121 and relief valve stem 122 , control, the pressure of the pressure chamber 107 , which, in turn, controls the position of the diaphragm 116 and thus the flow of water past the annular passage 127 between the diaphragm 116 and diaphragm seat 106 . Thus, fluid (and, in certain embodiments, some air) pressure above the diaphragm 116 in the control chamber 107 maintains pressure for closing and holding the diaphragm assembly 110 on the diaphragm seat 106 after flush operation. The by-pass passage 207 is sized to allow a rate of fluid flow through the diaphragm 116 before the flush valve closes. For embodiments having more than one bypass 206 , the passages 207 there through are designed to, in total, allow a rate of fluid flow through the diaphragm 116 . In a particular embodiment, shown in FIG. 2 , a diaphragm 116 with multiple by-passes 206 provides for having improvements for a better performing flushometer diaphragm kit assembly 110 . As previously mentioned, in one embodiment shown in FIG. 4 , the diaphragm 116 of the present invention is a singular, or integrated, component including the relief valve seat 117 for the relief valve head 121 . This unitary construction provides for increased control over the total flush volume and the volume per time by eliminating substantial variability that was inherent in prior art two-piece designs. In one embodiment, the diaphragm 116 comprises a disc 109 , for example, constructed, for example, of a metal, which is over-molded with an elastomeric material to form the outer portion 225 . In one embodiment, the disc 109 surrounds the central aperture 108 but extends only to the relief valve retention ring 214 while the elastomeric material overcoats the disc 109 and relief valve retention ring 214 and also forms the extended peripheral portion, which contains the by-pass apertures of the diaphragm 116 . In one embodiment shown in FIG. 4 , the relief valve retention ring 214 and disc 109 both are formed from the same rigid material and over-molded with the elastomeric material to form the outer portion 225 . The relief valve retention ring 214 , against which the relief valve head 121 abuts during use, is backed by a rigid core material, in one embodiment being the same material as the diaphragm core, thus providing for a more supportive cavity to retain the relief valve head 121 . This increased rigidity also results in improved performance as the prior art rubber-only design is prone to being pushed out of shape over time. The diaphragm 116 and relief valve seat 117 also includes an embodiment with a connecting piece extending from the diaphragm 116 opposite the disc. The outer portion of the connecting piece may be threaded to allow engagement with the flush valve. In one embodiment the connecting piece forms a single metallic component with the metallic portion of the diaphragm/disk unitary piece (diaphragm 116 ). In an alternative embodiment the diaphragm/disk unitary piece (diaphragm 116 ) is affixed to the kit with a separate connection component, such as the retainer 112 . This connection component may be of a different material from either the metal or elastomer from the diaphragm/disk unitary piece (diaphragm 116 ), such as a material of plastic. This material selection allows for greater cost control in manufacturing. In addition the use of a separate connection component allows for a simpler metallic portion to be used in the diaphragm/disk unitary piece (diaphragm 116 ), such as one that can be manufactured with, for example, a punch press and again allowing for greater cost control in the manufacturing process. Referring to FIGS. 2 and 3 , the relief valve retention ring 214 includes, in one embodiment, a plurality of lugs 213 for centrally locating a seated relief valve head onto the relief valve seat 117 . In one embodiment, there are at least six lugs 213 . The lugs 213 provide for a snug fit between the relief valve retention ring 214 and relief valve head 121 . It is necessary to retain spacing between the relief valve retention ring 214 and relief valve head 121 in order to allow the relief valve head to be able to tilt sufficiently to allow water to flow out of the upper control chamber. Without sufficient spacing in this area, the relief valve will not function properly when a user activates the flush cycle. Conversely, too much space, i.e. from insufficient lugs or lugs of insufficient size relative to the spaces therebetween, will result in the relief valve head 121 having to much “play” within the seating area. This play will result in an imprecise functioning of the flushometer. Integrating the disc 109 with the diaphragm 116 also eliminates an otherwise large and unreliable sealing area between the top of the diaphragm 116 and the bottom of the disc 109 . With continued reference to FIG. 4 , the lugs 213 have corners which are on the upper and inner portion of the relief valve retention ring 214 . In one embodiment, the left handed corners of the lugs have an angular shape 230 , while the right handed corners have a rounded shape 231 . The angular corners allow the use of the relief valve retention ring 214 to secure the diaphragm to the flushometer by providing an edge for either an automatic tool or a manual tool for engagement. In contrast the rounded corners have the opposite effect, making it more difficult to remove the diaphragm 116 from its original factory setting. Thus, in one embodiment, there are a plurality of equally spaced lugs 213 , each of the equally spaced lugs 213 including a first end proximate a second end of the adjacent lug 213 , one of the first end or the second end having an angular shaped 230 with the other having a rounded shape 231 . The outer portion of the relief valve retention ring 214 has in one embodiment, a slightly slanted or curved lower portion such that it slopes towards the center of the diaphragm 116 . This provides improved component life and performance over time by allowing the elastomeric diaphragm 116 sufficient space to move in response to pressure. In contrast, prior art diaphragms were secured to a disk that presented a flat bottom surface and an annular angular edge. The interaction of the diaphragm 116 against these surfaces over repeated operations and pressure conditions would result in wear and poor performance. Prior art assemblies also had the seat and diaphragm two separate pieces which introduced a potential leak surface between the two parts. The integrated seat and diaphragm 116 removes this sealing area and potential leak because of incompletely assembled parts. The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.
A flush valve diaphragm is provided. The diaphragm includes at least two by-passes orifices. Each by-pass orifice in the diaphragm has a by-pass associated therewith. Each by-pass having a passage therethrough, allows communication with the control chamber above the diaphragm with an inlet chamber below the diaphragm. The diaphragm also integrates the function of locating and providing sealing means to the flush valve system's aux valve mechanism.
5
The present invention relates generally to burner apparatus and more particularly to a valve for controlling the flow of an active substance to a burner. The invention particularly concerns a device for a resonant burner for controlling shutoff of the resonant burner and for controlling the flow of an active substance which is to be atomized and which is discharged from a discharge nozzle that opens in a resonant burner space. More particularly, the invention is directed toward a valve device of the type described which, when a burner is taken out of operation or is turned off, will automatically insure that no active substance issues from a nozzle through which the active substance is delivered to the burner. SUMMARY OF THE INVENTION Briefly, the present invention may be described as a valve assembly for a burner for controlling delivery thereto of an active fluid substance comprising conduit means including nozzle means through which said active substance is delivered to the burner, air intake means for the burner, valve means operating under the influence of said air intake means for controlling flow of the active substance to the conduit means, and spring means operatively associated with the valve means, said valve means operating under the influence of said spring means to create a suction effect in said conduit means when said valve means is moved to a position terminating flow of said active substance thereto. In accordance with the present invention, the objects thereof are achieved in that the device of the invention is characterized by a valve arrangement which by being responsive to the stream of intake air of a resonant burner can be shifted or adjusted against a spring tension. When there occurs a cessation of the air intake stream, the valve arrangement acts under a spring tension to create a suction that draws the active substance back from the nozzle through the pipeline leading to the resonant burner space. In principle, an individual pipeline can be provided having a valve mechanism which may be manually adjusted for feeding the active substance into the resonant burner space. In a preferred embodiment of the invention however the pipeline in which the suction or draft is created when there occurs a cessation of the air intake stream is at the same time the same pipeline through which the active substance is introduced into the resonant burner space. In this case, the embodiment of the invention is characterized in that the pipeline is run from an active substance supply container via the valve arrangement to a resonant burner space and, moreover, is shut by the valve arrangement when there is a cessation of the air intake stream. An embodiment of the invention which is especially simple in its construction is one wherein the valve means comprise a sliding valve of which a slider is arranged to be adjusted by a diaphragm. The diaphragm may be arranged to adjoin a space which has an air inlet opening through which air flows in with a pressure that is dependent upon the strength of the air intake stream of the resonant burner. This space may be formed with a first, small outlet opening through which air flows and which is always open, and with a second outlet opening which may be opened or shut by a manually operable adjusting member. In normal operation, the diaphragm is only under a pressure which is generated due to the small outlet opening which remains constantly open. By opening the second outlet opening by means of operation of the manually operable adjusting member, this pressure on the diaphragm may be reduced whereby the sliding valve may be moved into a position to shut the flow of active substance therethrough. In order to obtain a desired reverse draft or suction effect with this structural arrangement, a preferred arrangement is one in which the slider is coupled with a second diaphragm which adjoins an area through which the active substance flows downstream from the sliding valve. If the sliding valve is shifted into its closed position, this space will thereby automatically be enlarged thereby resulting in the desired suction or reverse draft effect. If at least one of the diaphragms is not of an automatically spring actuated construction, the slider in the sliding valve shut position is preferably prestressed or initially tensioned by means of a spring. If air is conducted into the active substance container with a pressure which is dependent upon the air intake stream, in order to facilitate the issuance of the active substance from the container, the operative surface of the first diaphragm is preferably made larger than the surface of the second disphragm so that the aforesaid space can be securely expanded in order to provide the reverse draft or suction effect upon the active substance. 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 specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention. DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 is a schematic sectional view depicting a first embodiment of the invention wherein the pipeline which serves to convey active substance to a nozzle is at the same time the pipeline within which the draft or suction is created; and FIG. 2 is a schematic sectional view showing a second embodiment of the invention wherein that pipeline in which the draft is generated is an isolated or individual pipeline. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1 wherein there is shown a first embodiment of the invention, the embodiment depicted includes valve means which are essentially composed of a slider 2 forming part of a sliding valve 4 which is situated in a pipeline 6, 8 extending under an active substance supply container (not shown) to a resonant burner space (also not shown). The pipeline 6 is connected on the input side thereof with the active substance supply container. The pipeline 8 has at the terminal end thereof a nozzle 10 which adjoins a resonant burner space. The slider 2 is actuated under the control or influence of a diaphragm 12. Additionally, the diaphragm 12 is arranged to adjoin a space 14 which has an air inlet opening 16 through which air flows with a pressure level that is dependent upon the strength of the intake air stream for the resonant burner. Moreover, this space includes a first, small outlet opening 18 through which air flows outwardly thereof and which is maintained constantly open. A second outlet opening 22 is provided in flow communication with the space 14, with the opening 22 being adapted to be opened and shut by operation of a manually operable adjusting member 20. The adjusting member 20 is provided with a screw member 24 which is threadedly engaged in the valve assembly and which may be turned by means of a knurled grip 26. Rotation of the threaded member 24 for movement thereof in a downward direction will operate to shut the flow through the opening 22. When flow in the opening 22 is closed, pressure in the space 14 will increase thereby causing the diaphragm 12 to be moved downwardly in order to push the slider 2 in a downward direction. This downward movement of the slider 2 will cause the sliding valve 4 to be brought into its open position. A space 28 is provided underneath the diaphragm 12 with this space being connected through openings 30 with the ambient atmosphere. A spring member 32 located beneath the sliding valve member 2 operates to apply an upwardly directed spring force acting against the pressure which exists in the space 14 in order to transfer the sliding member 2 into the shut or closed position. Thus, the spring member 3 acts against the downward force of the diaphragm 12 which may be created by increased pressure in the space 14. The slider valve member 2 extends through a second diaphragm 34 upon which it is affixed by means of a flange 36. The slider valve member 2 has a hollow interior and active substance flowing inwardly through the pipeline 6 may pass through a neck or narrowed portion 38 and through an annular distribution space 42 so as to flow into the interior of the slider valve member 2 when openings 40 formed in the slider valve member 2 are brought to a vertical position which is in alignment with the annular distributor space 42. Thus, in order to shut off flow of the active substance from the pipeline 6 into the pipeline 8, the slider valve member 2 may be raised to bring the openings 40 out of alignment with the annular distributor 42. Flow will be reestablished when, by lowering the slider valve member 2, the openings 40 are brought into alignment with the annular distributor 42. Before the active substance comes into the pipeline 8 it will flow through a space 44 beneath the diaphragm 34. When the slider valve member 2 is brought into the shutoff position, it will cause the diaphragm 34 to be moved upwardly therewith. As a result of this the volume in the space 44 will be enlarged and thereby the active substance within the space 44 will be drawn out of the pipeline 8 by a reverse draft or suction effect created in the space 44 when the second diaphragm 34 is lifted by virtue of the upward movement of the slider valve member 2. The diaphram 34 has a space 46 located thereabove which is in constant communication with the atmosphere by means of an opening 48. A second embodiment of the invention is shown in FIG. 2. In the embodiment of FIG. 2, the construction of the valve assembly is essentially the same as that of the embodiment in FIG. 1 so that only various elements need to be described in connection with the embodiment of FIG. 2. Instead of the slider valve member 2, an adjustable pin 50 is provided which connects the two diaphragms 12, 34. The pipeline 6 leading from the active substance container into the space 46 above the diaphragm 34 has been dispensed with. The pipeline 8 opens into a pipeline 52 which leads to the nozzle 10. The pipeline 52 is connected to the input side via a tap or faucet with the active substance container. While specific embodiments of the invention have been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
A control valve for a resonant burner having a burner space for receiving active substance through a conduit with an atomizing nozzle discharging into the space is disclosed. When the valve is shut off to terminate flow of the active substance through the valve to the burner conduit, a spring action in the valve tends to withdraw the active substance from the conduit by creating a suction effect therein.
5
This is a continuation of U.S. patent application Ser. No. 08/386,007, filed Feb. 9, 1995, which is a continuation of U.S. patent application Ser. No. 08/151,255 filed Nov. 12, 1993, now U.S. Pat. No. 5,600,897; and further wherein this instant application is a continuation of U.S. patent application Ser. No. 08/102,766 filed Aug. 6, 1993, now abandoned. BACKGROUND OF THE INVENTION The present invention relates to a dryer section for the drying of traveling web, preferably as part of a paper manufacturing machine. The invention relates to a dryer section having a mix of single-tier and double-tier dryer groups as known, for example, from U.S. Pat. No. 5,232,554 the contents of which are incorporated by reference herein. Such a dryer section is divided into a plurality of successive dryer groups. Each of these dryer groups comprises a plurality of heatable dryer cylinders which come into contact with the web and which are coupled to a (preferably) common drive. The art distinguishes between double-felt (double-tier) and single-felt (single-tier) dryer groups. A single-felt dryer group has only a single endless felt (or a single endless wire). This felt travels together with the web alternately over the drying cylinders and guide or transfer rolls that are preferably designed as suction rolls and which are located between the drying cylinders. Such single-felt dryer groups are customarily arranged at the starting portion of the dryer section to which the web to be dried is fed in a condition in which the web is still relatively wet (solids content: about 35-55%, depending inter alia on the paper grade and machine speed). On the other hand, one or more double-felt dryer groups are customarily provided in the final region of the dryer section. Each of these dryer groups has an upper row of cylinders and a lower row of cylinders, the web travelling alternately over the upper and lower cylinders. The one or more double-felt dryer groups may be arranged directly behind a single-felt dryer group. As an alternative, an additional device (e.g. a size press or an intermediate calender) may be interposed. Prior art drying sections deploying a mix of single and double-tier dryer groups (hereinafter "mixed drying section") are essentially of two types. In accordance with a first type, the dryer cylinders belonging to the single-tier group or groups constitute a relatively small portion, e.g. about 20% of the total drying surface traversed by the paper web through the entire drying section. In other words, about 80% of the total drying surface is comprised of the dryer cylinders in the double-tier dryer groups. In the second type of a mixed drying section, substantially most of the total drying surface traversed by the paper web, i.e. more than about 75%, is comprised of the surfaces of the dryer cylinders which belong to the single-tier dryer groups. The remaining 25% is located in the double-tier drying cylinders. In other words, prior art mixed drying sections either are overwhelmingly single-tier or overwhelmingly double-tier. The prior art has not focused attention on the question whether there is an optimal mix that should be provided between the number of single-tier drying cylinders and double-tier drying cylinders and, if so, the precise number of cylinders of each type which should be provided. The present invention also relates to a method as well as to a device for transferring a strip of paper, i.e. a paper web foil, from a first treatment station (dryer section) to a second treatment station in a paper machine. The following prior art is known: (1) Federal Republic of Germany 43 28 554 A1 (2) Federal Republic of Germany 39 41 242 A1 Reference (1) shows and describes a dry end of a paper machine. This dry end has, in a first section, a single-row dryer group with a single felt. The felt, with the web resting on it, travels alternately over drying cylinders and guide suction rolls. In a second section, the dry end has two rows of drying cylinders with two felts. In this case, the web travels alternately over the lower and upper cylinders. Upon the starting, i.e. threading, of the paper machine, a narrow edge strip (called a tail) is first passed through the entire dry end. Blast nozzles serve in this connection for the transfer of the foil from one drying cylinder to the other. The blast nozzles produce air jets which extend substantially in the direction of transfer of the edge strip. The air jets thus drive the edge strip in the desired direction, namely from a first (upstream) drying cylinder to a second (downstream) drying cylinder in order to transfer the edge strip from the first drying cylinder to the second drying cylinder. This transfer has always been a problem. It frequently was not possible to directly transfer the edge strip at given places. At times, there is a fluttering of the edge strip so that the entire process of the passing of the edge strip is time-consuming. This, however, means relatively long downtime of the paper machine, and thus reduced production. Reference (2) also shows and describes the transfer of a narrow edge strip in the dry end of a paper machine. In this case, a jet of air is produced which is directed opposite the direction of travel of the web of paper. However, this reference does not describe a free, i.e., open-chain transfer of the paper strip. Rather, the paper strip adheres to the outer surface of a cylinder and is scraped from the latter by a scraper, the blast air supporting the detachment. SUMMARY OF THE INVENTION One aspect of the present invention is concerned with the precise ratio of single-tier and double-tier drying cylinders that are to be provided in a drying section. The inventors herein reject the prior art conventional wisdom which provides too few single-tier drying cylinders, since that approach ignores problems of runnability--too many paper breaks--and greater difficulty in threading. On the other hand, the inventors discovered that configuring a dryer section entirely of single-tier dryer groups, or even overwhelmingly of single-tier groups, ignores significant advantages provided by double-tier dryer groups. Advantages of double-tier dryer groups include: ease of providing a tail cutter function; avoidance of paper bursting at certain dryness levels; achieving shorter building lengths; assuring no felt or fabric tearing and significantly reduced fabric wear; lower machine fabrication costs as compared to a total single-tier or an overwhelmingly single-tier construction; lower operating costs (steam expenditures and the like) than with total single-tier; improved overall paper quality; and enhanced visibility and control of the open draws of the paper. Another aspect of the present invention is concerned with the problem of threading of the web to be dried into the dryer section. As is known, the following is provided for this purpose. The web which is formed and mechanically dewatered in the initial part of the paper manufacturing machine travels during the starting (threading) phase at full operating speed, but temporarily only up to the end of the press section or up to the first dryer cylinder of the dryer section. From there, it passes downward into a broke pulper. A narrow edge strip, referred hereinbelow as a "striplet" or "tail" is now separated from the web. It is passed first of all through the single-felt dryer group or groups (generally several are present). It is known that this can be done without the aid of ropes. In other words, an automatic ropeless tail guide device, i.e., a tail threading device, is present. For example, the tail is detached from the individual cylinders by means of a scraper which is combined with an air-blow nozzle. Furthermore, special edge suction chambers are provided in the transfer suction rolls, a relatively high vacuum being produced in said chambers during the tail threading process, independently of the other part of the guide suction roll. In contrast, in accordance with Federal Republic of Germany 4037661 (which is an equivalent to said U.S. Pat. No. 5,232,554), a rope guide is provided for the threading of the tail in the subsequently located double-felt dryer group or groups. This arrangement has disadvantages. It can cause operational disturbances. The tail can slip off the rope. Further, the tail is not guided with sufficient precision. Tearing of the rope is also possible. It is therefore desirable to completely avoid rope guides in the entire dryer section of modern paper manufacturing machines. This is particularly true at the increasingly greater operating speeds encountered nowadays (on the order of magnitude of 1500 to 2500 m/min). In order to achieve this object, an automatic ropeless tail guide device is provided in accordance with the invention in the double-felt dryer group or groups. Examples of parts of different constructions suitable for this are described in the following publications: Federal Republic of Germany Patent 1 245 278; Federal Republic of Germany Utility Model 8 914 079; and Federal Republic of Germany Utility Model 9 109 313. Experiments have shown that the reliability of pneumatically acting parts is less than Satisfactory when the solids content of the web is still relatively low. Above a certain solids content and taking into account other factors, and depending on the paper grade and other parameters, however, these pneumatically acting parts operate well. The inventors herein have studied the problems encountered in transferring a paper web from a single-tier to a double-tier dryer group and the operational difficulties encountered in threading a paper web through a double-tier dryer group and have found that an optimal transfer from a single-tier dryer group to the double-tier dryer group(s) depends on various parameters including: paper grade; stiffness of the paper web, particularly of the transfer tail; strength of the paper web, particularly of the transfer tail; dryness, i.e., solids content, of the paper web; operating speeds; basis weight of the paper web; desired paper properties in the final paper product; and runnability. The results will be discussed in detail later, in connection with a transfer point table presented in the Detailed Description section of the instant specification. For rebuilds, costs and other considerations should be taken into account. One consideration is machine down time during a machine rebuild. It should be as short as possible, to have the least impact on paper production. Consonant with this objective, only one or perhaps two groups of an old double-tier machine might be converted to single-tier. The desire to keep the down time as short as possible might militate in favor of selecting a transfer point low in the range of possible values, or at the point between the first possible transfer point and the optimal transfer point, shown in the aforementioned transfer point table. According to the invention, with some of the paper grades the transfer of the paper web into the double-felt dryer groups should occur at a point where the paper web has already traversed about 30-60% of the paper web contacting surface of the entire drying section. For example, a drying section including a total of 40 drying cylinders of same diameters, of which 21 are in the single-tier section and 19 in the double-tier section, meets the condition since, at the end of the single-tier dryer groups, the paper web will have traversed more than 50% of the total surface of all the drying cylinders. In order to reliably automatically thread the paper web from the single-tier groups to and through the open draws of the double-tier groups the invention relies on two advantageous factors. First, with the conditions set forth above, the paper web develops a stiffness and firmness that is high enough for threading purposes. Second, again with the conditions set forth above, the paper web will not tend to adhere to the surface of the drying cylinders of the double-tier group or groups because the adhesion force decreases after the wet web has passed approximately 20-30% of the web contacting surface of the dryer section. By operating in accordance with the invention, the paper web is in the double-tier group(s) at a state where its adhesion to the drying cylinders is low enough to assure both good runnability and reliable automatic (ropeless) tail threading. By constructing the drying section to include a mix of single and double-tier groups, the invention significantly shortens the overall length of the drying section, resulting in savings in machine and building costs, compared with a total single-tier configuration. The invention further obtains an optimal and prompt transfer point for the paper web between the single and double dryer groups. In column 7, lines 10-40 of U.S. Pat. No. 4,232,544 measures are described for further conducting the oncoming tail in the known dryer section within the region of the end of the single-felt dryer group, not into the double-felt dryer group but rather temporarily into the cellar or other locations or receiving bins associated with the paper machine. Only after stable travel of the tail through the single-felt dryer group or groups has been obtained is the tail then conducted further into the double-felt dryer group or groups. The contents of U.S. Pat. No. 4,232,544 are incorporated by reference herein. Another aspect of the invention concerns advantageous arrangements of the cylinders and felt guide rolls in the transition region between the last single-felt dryer group and the directly or indirectly following double-felt dryer group. It is particularly favorable if the web passes substantially downward through the place of separation between the two dryer groups. Still another aspect of the invention is concerned with the problem of the removal of broke, which occasionally is produced in the event of a tear in the paper web. This task, which can never be entirely excluded, is present, in particular, in the initial region of the dryer section, i.e. in the region of the single-felt dryer groups. It is best if all single-felt dryer groups are felted on top. In such a case, the paper broke can simply fall downward under the force of gravity, in particular with arrangement of the cylinders in horizontal rows, as generally customary. If, however, in order to obtain the most uniform possible properties on both sides of the finished web of paper, it is desired that both sides of the web of paper alternately contact the dryer cylinders, not only in the double-felt dryer group but also in the region of the single-felt dryer groups, then an arrangement of the cylinders in vertical or V-shaped rows is particularly advantageous. In this connection, reference is made to U.S. Pat. Nos. 5,050,317 and 5,177,880, the contents of which are incorporated by reference herein. The latter describes inter alia a dryer-section configuration having a plurality of V-shaped dryer groups felted on top and having two bottom-felted dryer groups in the shape of a V, and arranged to provide an optional gap that can be opened for the removal of broke between the lowermost cylinders of these two dryer groups. If the above-mentioned transfer rolls required in the single-felt dryer group are designed as suction rolls, they can be provided with an inner stationary suction box which can also serve for defining a desired suction zone for threading. However, a construction is preferred in which the inside of the transfer suction rolls is free of stationary inserts. Furthermore, a hollow journal serving for the drawing-off of air is not necessary in order to provide a vacuum inside the roll. Rather, an external suction box is provided (for example, in the pocket between two adjacent dryer cylinders). A final aspect of the invention is concerned with the problem of the height above a horizontal reference plane at which the axes of rotation of the cylinders and/or guide rolls of the single-felt dryer group or groups are advantageously arranged, for instance with respect to the required free evaporation path for the paper web between two cylinders. Another factor is the arrangement of these axes of rotation relative to the planes in which the axes of rotation of the cylinders of the following double-felt dryer group lie. It is common to all the various embodiments of the invention that at least one double-felt dryer group is always present in the region of the end of the dryer section. The following advantages (some already mentioned) result from this: 1. Uniform quality of the paper, particularly approximately equal properties of the surface on both sides of the paper, which uniform quality is also obtained in the cross machine direction, obtaining improved printability and reduction of curl tendencies in comparison to paper produced with a total single-tier configuration; 2. Even if a very high final solids content is desired (on the order of 98%), there is no danger of tearing (or breaking) of the paper web since longitudinal stresses are relieved in the double-felt group; 3. The tail cutter required at the end of the dryer section can be readily arranged in the traditional manner in the double-felt dryer group; 4. No rope guide for the pulling-in of the tail is required at any place in the entire dryer section; and 5. Wear of the felts (sometimes observed in the end region of known dryer sections which have exclusively single-felt dryer groups) is avoided by the presence of the double-felt dryer groups. The present invention is also concerned with providing a method and a device for transferring a strip of paper from a first treatment station (dryer Section) to a second treatment station, and particularly from a first drying cylinder to a second drying cylinder in order to permit the transfer with greater reliability and higher speed. Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWING FIGS. 1 to 4 show diagrammatic side views of several different dryer section having a plurality of single-felt dryer groups and at least one subsequent double-felt dryer group; FIGS. 5 to 8 show diagrammatic side views (on a larger scale than in FIGS. 1 to 4) of the web transfer zone between a single-felt dryer group and a following double-felt dryer group having a corresponding tail guide means; FIGS. 9 to 11 are similar to FIGS. 5 to 8 and show different vertical distances between the axes of the cylinders or guide rolls and a reference plane; FIGS. 12 and 13 show other embodiments in a diagrammatic side view; FIG. 14 graphically illustrates the transfer air jet directions in the web transfer regions. FIG. 15 illustrates yet another possible planar alignment between single-tier and double-tier groups; and FIG. 16 shows a further embodiment of the invention, in a diagrammatic side view. FIG. 17 graphically illustrates transfer air jets provided between two top-felted single-tier dryer sections. FIGS. 18A-18D illustrate web transfer arrangements between a bottom felted single-tier leading into a double-tier dryer group and further show different vertical alignments between the axes of the cylinders and guide rolls to a reference plane as well as the height alignment between the cylinders and guide rolls in the adjacent single-tier and double-tier dryer groups; DETAILED DESCRIPTION OF THE INVENTION The dryer section shown in FIG. 1 has located first in the path of the paper web six single-felt dryer groups 11-16, arranged one behind the other. Each of these dryer groups has a single endless felt F. For example, in the first dryer group 11, the felt F travels together with the web 9 alternately over dryer cylinders 51 and guide suction rolls 51'. In the first two dryer groups 11 and 12, as well as in the fourth and sixth dryer groups 14 and 16, the bottom of the web comes in contact with the cylinders. Accordingly, the dryer cylinders 51, 52, 54 and 56 lie in this embodiment above the corresponding guide suction rolls 51', 52', 54' and 56', respectively. The cylinders are in this case "top-felted". This is different in the third dryer group 13 and in the fifth dryer group 18. Here the cylinders 53, 55 contact the top side of the web. They are therefore "bottom-felted" and lie' below the corresponding guide suction rolls 53', 55'. Accordingly, the paper web transfer regions between the dryer groups 12 to 16 are developed using web reversal mechanisms. For the details of these web reversal mechanisms, reference is made to U.S. patent application Ser. No. 867,411, filed Apr. 13, 1992, the contents of which are incorporated by reference herein. It can be noted from FIG. 1 that at each of these web regions, the paper web 9 forms a short open draw; i.e. it is temporarily not supported by a felt. In the region of a small suction zone of a transfer roll 58, it travels in each case onto the next felt. In FIG. 1, these transfer rolls 58 are the sole suction rolls having internal stationary suction boxes. The guide suction rolls 51' to 56', on the other hand, do not have inner stationary inserts or direct suction connections. Rather, an external suction box 59 is provided on each of these transfer suction rolls. This box lies in the pocket between two adjacent dryer cylinders and has a ledge 60 (see FIG. 7) at the place where felt F and web 9 leave-together the first of these two cylinders, the ledge 60 stripping off and diverting the layer of boundary air-carried along by the felt. The last single-felt dryer group 16 is followed by a double-felt dryer group 17 having several bottom cylinders 57 and several top cylinders 57', as well as a bottom felt UF and a top felt OF. Here, the web 9 travels meandering between the lower and upper cylinders. In FIG. 1, a tail cutter S is indicated between the last two cylinders. The dryer section shown in FIG. 2 has for instance three (or four or five) single-felt dryer groups 21-23; however, in contrast to FIG. 1, they are all top-felted. In other words, all dryer cylinders 71-73 contact the bottom side of the web. Another difference from FIG. 1 is that the guide suction rolls 71' to 73' have inner stationary suction boxes and are arranged at only a slight distance from the adjacent dryer cylinders. Furthermore, for example, two (or three) double-felt dryer groups 24, 25 are provided with bottom cylinders 74, 75 and with top cylinders 74' and 75'. The dryer sections of FIGS. 1 and 2 have only horizontal rows of cylinders. In FIGS. 3 and 4, however, in order to shorten the overall structural length of the dryer section, the cylinders of the single-felt dryer groups are arranged in several rows which are inclined to the vertical direction, with rows inclined rearward alternating with rows that are inclined forwards. In accordance with FIG. 3, two V-shaped double rows form a first group 31 and a second dryer group 32. The cylinders 81, 82 of these two dryer groups are top-felted. This is followed by two bottom-felted dryer groups 33, 34. For example, the three (or four) cylinders 83 of the third dryer group form a rearward inclined row. On the other hand, the cylinders 84 of the fourth dryer group form a forward inclined row. Between the lowermost cylinders of these two dryer groups 33, 34, a slot or gap can be opened by a swingable felt guide roll 87, in order to remove broke in the downward direction. The fifth dryer group 35 again has solely top-felted dryer cylinders 85, which again form a V-shaped double row. Behind the last cylinder of this dryer group 35, the web is guided obliquely downward to the first lower cylinder 86 of the following double-felt dryer group 36. In accordance with FIG. 4, solely top-felted and V-shaped single-felt dryer groups 41, 42 and 43 are present, followed by two double-felt dryer groups 44 and 45. In both FIGS. 3 and 4 all transfer suction rolls 81' to 85' and 91' to 93' which are located in the corresponding dryer group between two cylinders are arranged at a larger distance from these cylinders and are provided with external suction boxes. This manner of construction does not merely involve less expense. It furthermore also saves drying section energy since a longer free evaporation path is-present between every two cylinders so that the drying is more economical. These latter factors apply also to the arrangement in accordance with FIG. 1. FIG. 5 shows, in the case of another dry end, the transfer region between the last single-felt dryer group and the first double-felt dryer group. There can be noted here the last two drying cylinders 73 of the last single-felt dryer group 23 and the first three cylinders 74, 74' of the double-felt dryer group 24. There can furthermore be noted a guide suction roll 73' provided with inner suction box and, in front of the first lower drying cylinder 74, a transverse suction roll 58, also having a stationary inner suction box. An automatic rope-less edge-strip guide device is formed in the single-felt dryer group 23, for instance in the manner that each guide suction roll 73 has a known edge-suction zone on one of its two ends. Furthermore, airblast devices are provided on a scraper support body 76, which devices are indicated symbolically by arrows, as well as an air blast nozzle 79. At the place where the web 9 and the felt F jointly leave the last cylinder 73, an edge suction box R (active only in the region of the edge strip), web stabilizer, or the like, can be arranged. Or, a short "edge-strip guide scraper" 88 which covers only the region of the edge strip and which may also have an air-blast nozzle, is arranged on the last cylinder 73. The blast nozzles 101, 102, 103, 104 shown in FIG. 5 are absolutely decisive. They serve for the transferring of an edge strip from the first lower drying cylinder 74 of the double-felt dryer group 24 to the first upper drying cylinder 74' thereof. As can be seen, on both sides of the edge strip 9, there are blast nozzles 101, 103, the air jets of which are directed upward, .i.e., in the direction of transfer, as well as blast nozzles 102, 104, the air jets of which are directed downward and thus opposite the direction of transfer. The inventor has found that, in this way, an extremely stable guiding of the edge strip is possible. The air jets of the nozzles 101, 102 produce a conveying action in that they rapidly carry the edge strip along in upward direction to the drying cylinder 74'. The air jets of the two blast nozzles 102, 104, on the other hand, see to it that the edge strip assumes a stable position and, immediately after leaving the first lower drying cylinder 74 of the dryer group 24, assumes the correct direction to the first upper drying cylinder 74'. The two blast nozzles 101, 102, as well as the two blast nozzles 103, 104, can be structurally combined, being thus borne by a single bracket. In FIG. 14 the transfer region is again shown, on a larger scale. Again, the blast nozzles 102, 104 can be noted. The blast nozzles 101, 103 have been omitted for greater clarity of the drawing. As can be seen, air jet 102.1 from blast nozzle 102 has a component 102.2 which is perpendicular to the direction of the edge strip 9, and a component 102.3 which is exactly opposite to the direction of the edge strip 9. Exactly the same is true with respect to the air jets 104.1 from blast nozzle 104 having the components 104.2 and 104.3. It should be appreciated that the rope-less web transfer over an open draw illustrated and described above with reference to FIGS. 5 and 14 can be applied between individual dryers of a double-tier dryer, between single-tier and double-tier dryers and between single-tier dryer groups. In fact, it can be applied anywhere where the paper web encounters an open draw path. See, for example, FIG. 17. In accordance with FIG. 6, the following is provided between the last cylinder 73 of the single-felt dryer group 23 and the first lower cylinder 74 of the double-felt dryer group 24: A guide roll 18 for the felt F and a guide roll 19 for the bottom felt UF are so arranged that the felts overlap each other. During normal operation, a certain distance is present between the felts F and UF so that the web 9 travels freely, i.e., in an open draw, not supported by the felt F, from the cylinder 73 to the felt guide roll 19. During the threading of the tail, the guide roll 18 can be brought into the position shown in dash-dot lines so that the felts F and UF temporarily contact or almost contact each other. A tail guide scraper 88 can furthermore be provided. In FIGS. 7 and 8, the first cylinder 94' of the double-felt dryer group is an upper cylinder. Therefore a guide suction roll or reversing suction roll 96 is provided between it and the last cylinder 93 of the single-felt dryer group. This suction roll 96 can, as shown in FIG. 7, lie in the loop of the felt F of the single-felt dryer group, the felt F being tangent to the upper cylinder 94' and transferring the web 9 to it. In accordance with FIG. 8, the guide suction roll 96' can lie in the top felt of the double-felt dryer group. This felt tangentially contacts the last cylinder 93 of the single-felt dryer group and receives the web from it. An automatic ropeless tail guide device in the form of tail guide scrapers 88 and in the form of blow nozzles (represented symbolically by arrows) which are arranged on scraper support members 77 or on a separate blow pipe 87 can again be clearly noted in FIGS. 7 and 8. In order that the bottom felt UP which travels in the direction towards the first upper cylinder 94' does not unnecessarily convey air into the pocket T, an additional felt guide roll 100 (or an air scraper) can be provided. In FIG. 9 a larger distance H--as compared with FIG. 1--is provided between the planes E1 and E2 whereby an enlarged evaporation path is available for the web 9 between every two cylinders of the single-felt dryer group. The axes of the cylinders lie in plane El, while the axes of the transfer suction rolls, and at least approximately the axes of the lower cylinders of the double-felt dryer group, lie in plane E2. In accordance with FIG. 10 the following is provided, differing from FIGS. 1 and 2. The axes of the cylinders of the single-felt dryer group lie in the same horizontal plane E1 as the axes of the upper cylinders of the double-felt dryer group. Thus uniform stands 89 can be provided for all of these cylinders. Furthermore, in this way, the axes of the cylinders of the single-felt dryer group lie at a greater vertical distance HO above a reference plane EO than, for instance, the cylinders 56 in FIG. 1. It follows from this that the vertical distance H between the transfer suction rolls and the cylinders can be selected to be very large if evaporation paths still larger than in FIG. 9 are necessary between the cylinders. In this connection, the axes of the transfer suction rolls (indicated in dot-dash line) again lie at least approximately in the same horizontal plane E2 as the axes of the lower cylinders of the double-felt dryer group. The advantages described can be further increased if, in accordance with FIG. 11, the axes of the cylinders of the single-felt dryer group (plane El) are arranged above the axes of the upper cylinders of the double-felt dryer groups (plane E3). FIG. 12 shows an alternative to FIG. 1. The double-felt dryer group 17A is developed as follows in accordance with Federal Republic of Germany Patent 3 623 971. The paper web 9 travels first over a lower cylinder 61 and then, in succession, over two top cylinders 62 and then in succession over two bottom cylinders 63 and then, in succession, over the upper cylinders 64 and then in succession over two lower cylinders 65 and finally over an upper cylinder 66. A guide suction roll 62'-65' is arranged between the cylinders of each cylinder pair 62-65. In this way, the number of open draws of the paper web between the two horizontal rows of cylinders is reduced by approximately one half. The threading of the tail can take place automatically in exactly the same manner as described above with reference to FIGS. 5 and 7, and therefore without ropes. Any paper broke obtained is automatically transported to the rear end of the dryer group 17A and pushed out there. FIG. 13 shows that a bottom felted single-felt dryer group 15A can also be arranged directly in front or a double-felt dryer group 16A. In accordance with another alternative, each lower cylinder 67, 68 in the double-felt dryer group 16A has its own felt FA, FB in order to facilitate the discharge of broke. Note that the lower cylinders 67, 68 of the double-felt dryer group are horizontally aligned (same height) with the dryer cylinders of the preceding single-tier group. Different from FIGS. 1-13, further equipment may be disposed between two of the dryer groups, e.g. between the last single-felt and the first double-felt dryer group. With reference to FIGS. 18A-18D, various Web transfer arrangements for transferring a paper web from a bottom felted single-tier to a double-tier dryer group are illustrated. In FIG. 18A, the cylinders of the single-tier dryer groups lie in a plane II, its vacuum rolls in a plane III, and both planes II and II are located between the planes IV and V respectively of the top and bottom dryer cylinders of the succeeding double-tier group. The paper web 208 travels in a generally straight upward path from the last dryer cylinder 200 of the single-tier group to the leading top cylinder 202 of the double-tier group. The felt rolls 204 and 208 (of the single-tier and double-tier groups respectively), are situated close to one another to provide a relatively short open draw for the paper web at the transfer region. Note further that the diameter of the cylinders in the double-tier group is somewhat smaller than the cylinders in the double-tier group. This provides several advantages. It enables easier access to the pocket areas P1, P2, P3 between the top and bottom cylinders in the double-tier group. Further, if desired, it permits placement of the top and bottom cylinders closer to one another to reduce the size of the open draws of the paper web between the upper and lower cylinders in the double-tier dryer group. It also reduces the height above the floor of the upper cylinders 202, enhancing accessibility and servicing of the machine. In accordance with FIG. 18B, the felt 220 of the bottom cylinders 212, 212' of the double-tier group makes a lick-up, tangent contact with the trailing cylinder 200 of the single-tier group at a point LU, where the paper web transfers to the felt 220, and thereafter guided around the vacuum roll 210 toward the leading bottom cylinder 212. During threading, an air nozzle or similar device 216 produces a jet of air to ensure that the leading end, i.e. tail, of the paper web continues with the felt 220. Air nozzle 216 can be supported on an arm which is connected at a pivoting mechanism 218 so that it can be removed from its illustrated location close to the cylinder, for example in order to facilitate the removal of broke from atop the cylinder 200. In accordance with FIG. 18C, the path of the paper web from the trailing cylinder 200 is toward the felt roll 224 and thereafter across a relatively short open draw 226 to a leading vacuum roll 222 toward the leading top cylinder of the double-tier group. The vacuum roll 222 is provided with a relatively short vacuum zone 228 to support the paper web against the felt 230 that is associated with a double-tier group. FIG. 18D has an arrangement of drying cylinders and vacuum rolls as in FIG. 18B but differs therefrom in that the illustrated vacuum roll 232 is felted by the felt of the single-tier group and carriers the paper web to a lick-down, tangent contact with the leading bottom cylinder 212 of the double-tier group. FIG. 15 illustrates an arrangement wherein the paper web travels first through several single-tier dryer groups arranged alternatingly as a top felted single-tier group 240 followed by a bottom felted single-tier group 242, thence a top felted single-tier group 244 and terminating in a double-tier group 246. Note that in this arrangement the dryer cylinders of all of the top felted single-tier groups i.e. in the same plane as the cylinders of the upper tier of cylinders in the double-tier group 246. Similarly, the cylinders of the bottom felted dryer group 242 have their axis of rotation in the same horizontal plane as the axis of rotation of the bottom cylinders of the double-tier group. In FIG. 16, a further aspect of the invention is disclosed. The configuration shown in FIG. 16 is similar to that of FIG. 5 and comprises the last two dryer cylinders 73 of the last single-tier dryer group 23 having one felt and the first six cylinders 74, 75' of the first double-tier dryer group 24 having an upper felt OF and a lower felt UF as well as upper felt rolls 199 and lower felt rolls 198 with each felt roll being positioned between two adjacent dryer cylinders. Either the upper felt rolls 199 or the lower felt rolls 198 are formed as suction rolls. (In a further alternative, all felt rolls 198 and 199 may be formed as suction rolls). In the embodiment shown, only the lower felt rolls 198 are suction rolls and are connected via suction lines 197 (comprising a control valve 196) to a suction blower 195. In operation, the lower suction felt rolls 198 remove moist air from every other pocket 194, namely from the pockets which are below the upper cylinders 74' and which "contact", i.e. which face, the bottom side of the paper web 9. Thus the evaporation of the bottom web side is being enhanced relative to the evaporation of the top web side. That mode of operation is able to eliminate any tendency of curl of the finished paper web which curl may result from the last single-tier dryer groups 23 or from other factors. More specifically, the enhanced evaporation of the bottom side of the web 9 counteracts a tendency of upward-curl, if any. Accordingly, if there is a tendency of downward curl of the finished paper web, then additional moisture removal should be caused from the pockets 193 which are positioned above the lower cylinders 74. For that purpose the upper felt rolls 199 should be suction rolls (not shown in FIG. 16). If one cannot predict, whether there will be the tendency of upward-curl or of downward-curl, then all felt rolls 198 and 199 should be suction rolls in that case, the lower suction felt rolls 198 should be controllable by control valve 196 as shown in FIG. 20 and the upper suction felt rolls 199 should have a separate suction line (not shown) with a further control valve. It is then possible to enhance the evaporation of either the top side or the bottom side of the paper web 9 depending on the type of curl (downward or upward-curl) that occurs. Instead of providing suction felt rolls, there are other possibilities to control the amount of evaporation of the two sides of the paper web. For example, if the drying cylinders are equipped with doctors (see FIG. 5), moist air may be removed through the hollow doctor beams. Another possibility is to blow dry air either into the pockets 194 which are positioned below the upper cylinders 74' or into the pockets 193 which are above the lower cylinders 74. For that purpose, air blowing devices (not shown) will be positioned below the lower felt rolls 198 and/or above the upper felt rolls 199 which devices blow dry air through the lower felt UF and/or the upper felt OF into the respective pockets 193/194. Such blowing devices per se are known to those skilled in the art. The lower suction felt rolls 198 shown in FIG. 16 have a further advantage. If a web breakage occurs, paper broke is automatically transported--with the aid of the negative pressure in the lower suction felt rolls 198 from one lower cylinder 74 to the next lower cylinder 74 up to the end of the double-tier drying group 24. In that case of web breakage, the control valve of upper suction felt rolls, If those are present, should be immediately closed. The suction felt rolls 198 have, as usual, a perforated roll shell and an internal suction which defines a suction zone 190, as schematically depicted. Note that the suction zone 190 is open to the adjacent pocket 194 and that there must be a distance "d" between the normal path of web 9 and the suction zone 190. Thereby it is avoided that the web might travel together with felt UF around the suction felt roll 198. While FIG. 16 depicts one particular position for the lower suction rolls 198, the foregoing advantages are also attained when the felt suction rolls 198 are symmetrically disposed between the lower cylinders 74, as illustrated for example in FIG. 11. Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
In a drying section of a paper making machine, the paper web is conducted through a plurality of single tier dryer sections and then transferred to at least one final double tier dryer section for completing the drying process. The paper web is threaded through the open draw between the single tier dryer sections and the double tier dryer section and through the open draws between the lower cylinders and the upper cylinders in the double tier dryer section by use of air jets which blow at the paper web from opposite sides thereof. The air jets include at least one jet which blows in a direction generally opposite to that of the paper web.
3
This is a divisional of Ser. No. 08/791,814, filed Jan. 30, 1997, now U.S. Pat. No. 5,892,095. BACKGROUND OF THE INVENTION The present invention relates to a novel chemical-sensitization photoresist composition or, more particularly, to a chemical-sensitization photoresist composition used in the photolithographic patterning process for the manufacture of various kinds of electronic devices capable of giving a patterned resist layer having excellent cross-sectional profile and high fidelity as well as high heat resistance of the patterned resist layer with high photosensitivity and exposure dose latitude. The invention also relates to a novel oxime sulfonate compound useful as an acid-generating agent in the chemical-sensitization photoresist composition. It is a trend in recent years in the photolithographic patterning works for the manufacture of various kinds of electronic devices such as semiconductor devices and liquid crystal display panels that the patterning work is performed by using a chemical-sensitization photoresist composition which contains a relatively small amount of a compound capable of releasing an acid by irradiation with actinic rays and a resinous ingredient susceptible to the changes of solubility behavior in a developer solution induced by the acid. Chemical-sensitization photoresist compositions in general are characterized by high sensitivity to actinic rays and excellent pattern resolution. Chemical-sensitization photoresist compositions are classified into positive-working compositions and negative-working compositions depending on the type of the solubility change of the resinous ingredient to an aqueous alkaline developer solution by the radiation-generated acid. Namely, the alkali-solubility of the resist layer of a positive-working photoresist composition is increased while the alkali-solubility is decreased in the negative-working photoresist composition by exposure to actinic rays. The film-forming resinous ingredient in a positive-working photoresist composition is typically an alkali-soluble polyhydroxystyrene resin, of which at least a part of the hydroxy groups are substituted by acid-dissociable substituent groups such as tert-butoxycarbonyl groups, tetrahydropyranyl groups and the like, so as to decrease the solubility of the resin in an alkaline developer solution. In the negative-working photoresist composition, on the other hand, the film-forming resinous ingredient is a combination of an acid-induced crosslinking agent such as melamine resins and urea resins with a polyhydroxystyrene resin, optionally substituted by the above-mentioned acid-dissociable solubility-reducing substituent groups for a part of the hydroxy groups. The other essential ingredient in the chemical-sensitization photoresist compositions is a compound capable of releasing an acid by irradiation with actinic rays, of which various classes of compounds have been heretofore proposed and actually tested. A class of the most promising acid-generating agents includes oxime sulfonate compounds, in particular, having a cyano group in the molecule. Several compositions containing an oxime sulfonate compound and methods using the same are proposed. For example, European Patent Application 44115 A1 discloses a heat-curable coating solution containing an acid-curable amino resin and an oxime sulfonate compound. Japanese Patent Kokai 60-65072 discloses a method in which a bake-finishing composition containing a heat-curable resin and an oxime sulfonate compound is cured by irradiation with short-wavelength light. Japanese Patent Kokai 61-251652 discloses oxime sulfonate compounds having a substituent group such as ethylenically unsaturated polymerizable groups, epoxy group, hydroxy group and the like, and polymers thereof. Japanese Patent Kokai 1-124848 teaches an image-forming method by the use of a photosensitive composition containing a film-forming organic substance, an oxime sulfonate compound and a photosensitive compound having an aromatic group. Japanese Patent Kokai 2-154266 discloses a photoresist composition containing an alkali-soluble resin, oxime sulfonate compound and sensitivity enhancing crosslinking agent. Japanese Patent Kokai 2-161444 teaches a negative-patterning method by the use of an oxime sulfonate compound. Further, Japanese Patent Kokai 6-67433 discloses a photoresist composition for i-line exposure containing an oxime sulfonate compound. The oxime sulfonate compounds having a cyano group in the molecule disclosed in the above-mentioned patent documents include: α-(p-toluenesulfonyloxyimino)phenyl acetonitrile; α-(4-chlorobenzenesulfonyloxyimino)phenyl acetonitrile; α-(4-nitrobenzenesulfonyloxyimino)phenyl acetonitrile; α-(4-nitro-2-trifluoromethylbenzenesulfonyloxyimino)phenyl acetonitrile; α-(benzenesulfonyloxyimino)-4-chlorophenyl acetonitrile; α-(benzenesulfonyloxyimino)-2,4-dichlorophenyl acetonitrile; α-(benzenesulfonyloxyimino)-2,6-dichlorophenyl acetonitrile; α-(benzenesulfonyloxyimino)-4-methoxyphenyl acetonitrile; α-(2-chlorobenzenesulfonyloxyimino)-4-methoxyphenyl acetonitrile; α-(benzenesulfonyloxyimino)-2-thienyl acetonitrile; α-(4-dodecylbenzenesulfonyloxyimino)phenyl acetonitrile; α-(p-toluenesulfonyloxyimino)-4-methoxyphenyl acetonitrile; α-(4-dodecylbenzenesulfonyloxyimino)-4-methoxyphenyl acetonitrile; α-(p-toluenesulfonyloxyimino)-3-thienyl acetonitrile; and the like. The molecules of these sulfonate compounds are susceptible to scission of the sulfonate ester linkage by irradiation with actinic rays to generate a corresponding sulfonic acid so that they are useful as an acid-generating agent in the chemical-sensitization photoresist compositions. It should be mentioned that, while a sulfonic acid is generated from the oxime sulfonate compound by exposure to light, the number of the sulfonic acid molecules released from a molecule of the above-named oxime sulfonate compounds is necessarily limited to one, so that the amount of the acid is also limited. When such an oxime sulfonate compound is used as an acid-generating agent in a negative-working photoresist composition, accordingly, no satisfactory patterned resist layer can be obtained because the width of a line-patterned resist layer cannot be broad enough at the top and the dimensional fidelity and heat resistance of the patterned resist layer cannot be as high as desired along with a relatively low exposure dose latitude. SUMMARY OF THE INVENTION The present invention, accordingly, has a primary object to provide novel and improved positive-working and negative-working chemical-sensitization photoresist compositions capable of giving a patterned resist layer having good cross-sectional profile, high dimensional fidelity and excellent heat resistance with excellent photosensitivity and exposure dose latitude. The present invention further has an object to provide a novel cyano group-containing oxime sulfonate compound which is useful as an acid-generating agent in a chemical-sensitization photoresist composition exhibiting a high efficiency for the generation of an acid upon irradiation with actinic rays. Thus, the cyano group-containing oxime sulfonate compound of the present invention useful as an acid-generating agent in a chemical-sensitization photoresist composition is a novel compound not known in the prior art nor described in any literature as represented by the general formula A[C(CN)═N--O--SO.sub.2 --R].sub.n, (I) in which each R is, independently from the others, an unsubstituted or substituted monovalent hydrocarbon group, A is a divalent or tervalent organic group and the subscript n is 2, when A is a divalent group, or 3, when A is a tervalent group. The positive-working chemical-sensitization photoresist composition provided by the present invention comprises, as a uniform solution in an organic solvent: (a1) an alkali-soluble hydroxy-containing resin, of which at least a part of the hydroxy groups are substituted by acid-dissociable groups so as to decrease the alkali-solubility of the resin in an aqueous alkaline solution; and (b) the cyano group-containing oxime sulfonate compound defined above as an acid-generating agent, of which the subscript n in the general formula (I) is preferably 2. The negative-working chemical-sensitization photoresist composition provided by the present invention, on the other hand, comprises, as a uniform solution in an organic solvent: (a2) an alkali-soluble resin or an alkali-soluble hydroxy-containing resin, of which a part of the hydroxy groups are substituted by acid-dissociable groups; (b) the cyano group-containing oxime sulfonate compound defined above as an acid-generating agent, of which the subscript n in the general formula (I) is preferably 2; and (c) a crosslinking agent which is a compound capable of forming crosslinks in the presence of an acid. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As is described above, each of the positive-working and negative-working photoresist compositions of the invention is characterized by the use of a specific cyano group-containing oxime sulfonate compound as an acid-generating agent, i.e., the component (b). In the positive-working photoresist composition of the invention, an acid is released from the component (b) by exposure to actinic rays so that the acid-dissociable substituent groups in the component (a1) are dissociated so as to increase the solubility of the resist layer in an aqueous alkaline developer solution pattern-wise in the areas exposed to actinic rays. In the negative-working photoresist composition of the invention, on the other hand, the acid-crosslinking ingredient as the component (c) causes crosslinking of the resinous ingredient as the component (a2) when an acid is generated from the acid-generating agent as the component (b) in the resist layer so as to decrease the solubility of the resist layer in an aqueous alkaline developer solution pattern-wise in the areas exposed to actinic rays. The above-mentioned alkali-soluble resin as the component (a2) is exemplified by novolac resins obtained by the condensation reaction of a phenolic compound such as phenol, m- and p-cresols, xylenols, trimethylphenols and the like, with an aldehyde compound such as formaldehyde in the presence of an acidic catalyst, hydroxystyrene-based resins, e.g., homopolymeric polyhydroxystyrene resins, copolymeric resins of hydroxystyrene and other styrene monomers and copolymeric resins of hydroxystyrene and (meth)acrylic acid or a derivative thereof and (meth)acrylic acid-based resins, e.g., copolymeric resins of (meth)acrylic acid and a derivative thereof. The alkali-soluble hydroxy-containing resin from which the component (a1) is derived by substitution of acid-dissociable groups for at least a part of the hydroxy groups is exemplified by homopolymeric polyhydroxystyrene resins, copolymeric resins of hydroxystyrene and other styrene monomers, copolymeric resins of hydroxystyrene and (meth)acrylic acid or a derivative thereof and copolymeric resins of (meth)acrylic acid and a derivative thereof having carboxylic hydroxy groups. The above-mentioned styrene monomers to be copolymerized with hydroxystyrene include styrene, α-methylstyrene, p- and o-methylstyrenes, p-methoxystyrene, p-chlorostyrene and the like. The above-mentioned derivatives of (meth)acrylic acid to be copolymerized with hydroxystyrene or (meth)acrylic acid include methyl (meth)acrylate, ethyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, (meth)acrylamide, (meth)acrylonitrile and the like. The acid-dissociable groups substituting for at least a part of the hydroxy groups in the above-mentioned alkali-soluble hydroxy-containing resins are exemplified by alkoxycarbonyl groups such as tert-butoxycarbonyl group and tert-amyloxycarbonyl group, tertiary alkyl groups such as tert-butyl group, alkoxyalkyl groups such as ethoxyethyl group and methoxypropyl group, acetal groups such as tetrahydropyranyl group and tetrahydrofuranyl group, benzyl group, trimethylsilyl group and so on. The degree of substitution of the above-mentioned acid-dissociable groups for the hydroxy groups in the hydroxy-containing resin is usually in the range from 1 to 60% or, preferably, from 10 to 50%. In the positive-working chemical-sensitization photoresist composition of the present invention, the resinous ingredient as the component (a1) is preferably a polyhydroxystyrene resin substituted by tert-butoxycarbonyl groups, tetrahydropyranyl group or alkoxyalkyl groups such as ethoxyethyl and methoxypropyl groups for a part of the hydroxy groups in the starting polyhydroxystyrene resin or a combination of these resins. In the negative-working chemical-sensitization photoresist composition of the present invention, the alkali-soluble resinous ingredient as the component (a2) used in combination with the acid-crosslinking agent as the component (c) can be selected from the group consisting of novolac resins, hydroxystyrene-based polymeric resins and (meth)acrylic acid-based polymeric resins as well as these resins substituted by acid-dissociable groups for a part of the hydroxy groups in the resins. The component (a2) is preferably a cresol novolac resin, polyhydroxystyrene resin, a copolymeric resin of hydroxystyrene and styrene or a resin obtained by substitution of tert-butoxycarbonyl groups for a part of the hydroxy groups in a polyhydroxystyrene resin. The acid-crosslinking agent as the component (c) compounded in the negative-working chemical-sensitization photoresist composition of the invention in combination with the above-described component (a2) can be selected from those known in the conventional negative-working chemical-sensitization photoresist compositions without particular limitations. Examples of the component (c) include amino resins having hydroxy and/or alkoxy groups such as melamine resins, urea resins, guanamine resins, acetoguanamine resins, benzoguanamine resins, glycoluryl-formaldehyde resins, succinylamide-formaldehyde resins, ethyleneurea-formaldehyde resins and the like. These resins can be easily obtained by the reaction of melamine, urea, guanamine, acetoguanamine, benzoguanamine, glycoluryl, succinylamide or ethyleneurea in boiling water with formaldehyde to effect methylolation optionally followed by an alkoxylation reaction with a lower alcohol. Commercial products of several grades are available for these resins including those sold under the trade names of Nicalacs Mx-750, Mw-30 and Mx-290 (each a product by Sanwa Chemical Co.). Besides the above-mentioned resinous compounds, the component (c) can be selected from the group consisting of benzene compounds having alkoxy groups such as 1,3,5-tris(methoxymethoxy)benzene, 1,2,4-tris(isopropoxymethoxy)benzene and 1,4-bis(sec-butoxymethoxy)benzene and phenol compounds having hydroxy and/or alkoxy groups such as 2,6-di(hydroxymethyl)p-cresol and 2,6-di(hydroxymethyl)-p-tert-butyl phenol. The above-described acid-crosslinking agents can be used in the negative-working photoresist composition of the invention either singly or as a combination of two kinds or more according to need. The amount of the acid-crosslinking agent as the component (c) in the negative-working chemical-sensitization photoresist composition of the invention is usually in the range from 3 to 70 parts by weight or, preferably, in the range from 5 to 50 parts by weight per 100 parts by weight of the component (a2). When the amount of the component (c) is too small, the photoresist composition cannot be imparted with high photosensitivity while, when the amount thereof is too large, the resist layer formed from the photoresist composition on a substrate surface cannot be uniform along with a decrease in the developability not to give a patterned resist layer of high quality. The alkali-soluble resin for the component (a1) or (a2) should preferably have an average molecular weight in the range from 2000 to 20000. Further, it is preferable that the alkali-soluble resin has a molecular weight distribution as narrow as possible in order to obtain a patterned resist layer of high quality in the pattern resolution and heat resistance of the resist layer. The molecular weight distribution of the resin can be represented by the ratio of the weight-average molecular weight Mw to the number-average molecular weight Mn, i.e., Mw:Mn, which should preferably be 3.5 or smaller or, more preferably, 3.0 or smaller for novolac resins and preferably should be 3.5 or smaller or, more preferably, 2.5 or smaller for polyhydroxystyrene-based resins. The inventive chemical-sensitization photoresist composition, which is either of the positive-working type or of the negative-working type, is characterized by the use of a very specific acid-generating agent which is a novel cyano group-containing oxime sulfonate compound represented by the general formula (I) given before, in which R is an unsubstituted or substituted monovalent hydrocarbon group, A is a divalent or tervalent organic group and the subscript n is 2, when A is divalent, or 3, when A is tervalent, or, in particular, 2. The monovalent hydrocarbon group denoted by R is an aryl group having 6 to 14 carbon atoms or a non-aromatic hydrocarbon group including alkyl groups, cycloalkyl groups, alkenyl groups and cycloalkenyl groups having 12 or less carbon atoms. When R is a substituted hydrocarbon group, the substituent group can be a halogen atom, hydroxy group, alkoxy group or acyl group or, in particular, a halogen atom when R is an alkyl group having 1 to 4 carbon atoms. The above-mentioned aryl group having 6 to 14 carbon atoms is exemplified by phenyl, tolyl, methoxyphenyl, xylyl, biphenyl, naphthyl and anthryl groups. The above-mentioned alkyl group, which can be straightly linear or branched, having 1 to 12 carbon atoms is exemplified by methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, n-octyl and n-dodecyl groups. The alkenyl group is exemplified by ethenyl, propenyl, butenyl, butadienyl, hexenyl and octadienyl groups. The cycloalkyl group is exemplified by cyclopentyl, cyclohexyl, cyclooctyl and cyclododecyl groups. The cycloalkenyl group is exemplified by 1-cyclobutenyl, 1-cyclopentenyl, 1-cyclohexenyl, 1-cycloheptenyl and 1-cyclooctenyl groups. The above-described monovalent aromatic or non-aromatic hydrocarbon groups as R in the general formula (I) can be substituted by substituents for one or more of the hydrogen atoms in a molecule. The substituent is selected from the group consisting of halogen atoms, i.e., atoms of fluorine, chlorine and bromine, hydroxy group, alkoxy groups and acyl groups. Halogenated alkyl groups as a class of the non-aromatic substituted hydrocarbon groups should preferably have 1 to 4 carbon atoms including chloromethyl, trichloromethyl, trifluoromethyl and 2-bromopropyl groups. The group denoted by A in the general formula (I) is a divalent or tervalent organic group which is preferably an aliphatic or aromatic hydrocarbon group. More preferably, the group denoted by A is an o-, m- or p-phenylene group. Since the cyano group-containing oxime sulfonate compound of the invention, which can be used as an acid-generating agent in the inventive photoresist composition, has two or three sulfonate ester groups per molecule, two or three molecules of sulfonic acid are generated from a molecule of the sulfonate compound by exposure to actinic rays so that the efficiency of acid generation can be high so much with the same exposure dose. Each of the groups denoted by R in the general formula (I) representing the oxime sulfonate compound is preferably a halogen-substituted or unsubstituted non-aromatic hydrocarbon group because the heat resistance of the patterned photoresist layer is somewhat decreased as a trend when the group R or hence the oxime sulfonate molecule is bulky. In addition, a halogen-substituted or unsubstituted non-aromatic hydrocarbon group has low absorptivity to ultraviolet light so that the transparency of the photoresist layer to the exposure light is little decreased even by increasing the amount of the acid-generating agent in the photoresist composition with an object to increase the photosensitivity of the composition along with advantageous effects on the pattern resolution and cross-sectional profile of the patterned resist layer. When the inventive photoresist composition is patternwise exposed to KrF excimer laser beams having a wavelength of 248 nm, the group denoted by A in the general formula (I) is preferably an alkylene group in view of the high transparency of alkylene groups to the light of this wavelength, while a phenylene group is preferred as the group A when the photoresist composition is for pattern-wise exposure to i-line ultraviolet light having a wavelength of 365 nm. Further, the halogen-substituted or unsubstituted non-aromatic hydrocarbon group as the group denoted by R is preferably a halogen-substituted or unsubstituted alkyl group having 1 to 4 carbon atoms in consideration of the high diffusibility of the acid generated from the acid-generating agent in the resist layer in the post-exposure baking treatment after pattern-wise exposure of the resist layer to actinic rays. Examples of the cyano group-containing oxime sulfonate compound of the invention, which can be the acid-generating agent as the component (b) in the inventive photoresist composition, include those expressed by the following structural formulas: Me--SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --Me, Me--SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --Me, Et--SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --Et, Bu--SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --Bu, Bu--SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --Bu, CF.sub.3 --SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --CF.sub.3, CF.sub.3 --SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --CF.sub.3, Ch--SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --Ch, Ph--SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --Ph, Me--pPh--SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --pPn--Me, Me--pPn--SO.sub.2 O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --pPn--Me, Me--O--pPn--SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --pPn--O--Me, Me--SO.sub.2 --O--N═C(CN)--(CH.sub.2).sub.3 --C(CN)═N--O--SO.sub.2 --Me, and Bu--SO.sub.2 --O--N═C(CN)--(CH.sub.2).sub.5 --C(CN)═N--O--SO.sub.2 --Bu as the examples of the compound in which the linking group A in the general formula (I) is a divalent hydrocarbon group such as phenylene and alkylene groups; and ##STR1## as the examples of the compound in which the linking group A in the general formula (I) is a tervalent hydrocarbon group, in which Me, Et, Bu, Ch and Ph are methyl, ethyl, butyl, cyclohexyl and phenyl groups, respectively, and mPn and pPn are m-phenylene and p-phenylene groups, respectively. The above-named oxime sulfonate compounds can be used either singly or as a combination of two kinds or more according to need as the acid-generating agent, i.e., component (b), in the chemical-sensitization photoresist composition of the invention. The amount of the cyano group-containing oxime sulfonate compound as the acid-generating agent, i.e., component (b), in the inventive chemical-sensitization photoresist composition is in the range from 0.1 to 30 parts by weight or, preferably, from 1 to 20 parts by weight per 100 parts by weight of the component (a1), when the photoresist composition is of the positive-working type, or the total amount of the components (a2) and (c), when the photoresist composition is of the negative-working type, in respect of obtaining good balance of film-forming behavior of the composition, image-forming behavior and developability. When the amount of the component (b) is too small, complete patterning can hardly be obtained while, when the amount thereof is too large, a decrease is caused in the uniformity of the resist layer formed from the photoresist composition on the substrate surface along with a decrease in the developability of the resist layer after pattern-wise exposure to actinic rays. The chemical-sensitization photoresist composition of the invention is used preferably in the form of a uniform solution prepared by dissolving the above-described essential components in an organic solvent. Examples of suitable organic solvents include ketone compounds such as acetone, methyl ethyl ketone, cyclohexanone, methyl isoamyl ketone and 2-heptanone; monoethers of polyhydric alcohols such as monomethyl, monoethyl, monopropyl, monobutyl and monophenyl ethers of ethylene glycol, diethylene glycol, propylene glycol or dipropylene glycol and monoacetates thereof; cyclic ethers such as dioxane; ester compounds such as methyl lactate, ethyl lactate, methyl acetate, ethyl acetate, butyl acetate, methyl pyruvate, ethyl pyruvate, methyl methoxypropionate and ethyl ethoxypropionate; and amide compounds such as N,N-dimethyl formamide, N,N-dimethyl acetamide and N-methyl-2-pyrrolidone. These organic solvents can be used either singly or as a mixture of two kinds or more according to need. Besides the above-described essential components, it is optional that the photoresist composition of the present invention is admixed with various kinds of known additives used in conventional photoresist compositions and having compatibility with the essential ingredients including auxiliary resins to modify or improve the properties of the resist layer, plasticizers, stabilizers, coloring agents, surface-active agents, carboxylic acid compounds, amine compounds and the like. The procedure for the photolithographic patterning of a resist layer using the photoresist composition of the invention can be conventional as in the prior art technology. In the first place, namely, a substrate such as a semiconductor silicon single crystal wafer is coated with the photoresist composition in the form of a solution by using a suitable coating machine such as a spinner followed by drying to form a uniform coating film of the photoresist composition, which is then exposed pattern-wise to actinic rays such as ultraviolet light, deep-ultraviolet light, excimer laser beams and the like through a pattern-bearing photomask or irradiated pattern-wise with electron beams by scanning according to the desired pattern to form a latent image of the pattern followed by a post-exposure baking treatment. The latent image of the pattern formed in the resist layer is then developed by dipping the substrate in an aqueous alkaline developer solution such as an aqueous solution of tetramethylammonium hydroxide in a concentration of 1 to 10% by weight followed by rinse with water and drying to give a resist layer patterned with good fidelity to the photomask pattern. In the following, the present invention directed to the novel cyano group-containing oxime sulfonate compounds and chemical-sensitization photoresist compositions is illustrated in more detail by way of Examples and Comparative Examples, in which the term of "parts" always refers to "parts by weight". EXAMPLE 1 A cyano group-containing oxime sulfonate compound expressed by the formula CH.sub.3 --SO.sub.2 --O--N═C(CN)--pPn--C(CN)═N--O--SO.sub.2 --CH.sub.3, in which pPn is a p-phenylene group, was synthetically prepared in the following manner. Thus, 20.0 g (0.093 mole) of bis(α-hydroxyimino)-p-phenylene diacetonitrile and 22.6 g (0.233 mole) of triethylamine dissolved in 200 ml of tetrahydrofuran were introduced into a reaction vessel to form a uniform solution which was chilled to and kept at -5° C. and to which 26.7 g (0.233 mole) of mesyl chloride were added dropwise under agitation over a period of 2 hours followed by further continued agitation at -5 ° C. for 2 hours and then at about 25° C. for 20 hours to complete the reaction. The reaction mixture was subjected to distillation at 30° C. under reduced pressure for the removal of tetrahydrofuran to obtain a crude product. A 22 g portion thereof was subjected to purification by repeating recrystallization from acetonitrile to obtain 12.5 g of a white crystalline compound having a melting point at 263° C. as the product which could be identified to be the above-mentioned target compound as being supported by the analytical results shown below. The above-mentioned yield of the product corresponds to 36.3% of the theoretical value. The infrared absorption spectrum of the product compound had absorption bands having peaks at wave numbers of 769 cm -1 , 840 cm -1 , 1189 cm -1 , 1382 cm -1 and 2240 cm -1 . The proton nuclear magnetic resonance ( 1 H-NMR) spectrum of the compound in dimethyl sulfoxide-d 6 had absorptions at δ values of 3.68 ppm and 8.15 ppm. The ultraviolet absorption spectrum of the compound in tetrahydrofuran as the solvent had absorption bands having peaks at wavelengths λ max of 220 nm and 301 nm with molar absorption coefficients of 7900 and 12200, respectively. EXAMPLE 2 A cyano group-containing oxime sulfonate compound expressed by the formula CH.sub.3 --SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --CH.sub.3, in which mPn is a m-phenylene group, was synthetically prepared in substantially the same manner as in Example 1 excepting for the replacement of the bis(α-hydroxyimino)-p-phenylene diacetonitrile with the same amount of bis(α-hydroxyimino)-m-phenylene diacetonitrile. A 30 g portion of the crude reaction product was subjected to purification by repeating recrystallization from acetonitrile to obtain 25.8 g of a white crystalline compound having a melting point at 196° C. as the product which could be identified to be the above-mentioned target compound as being supported by the analytical results shown below. The above-mentioned yield of the product corresponds to 72.0% of the theoretical value. The infrared absorption spectrum of the product compound had absorption bands having peaks at wave numbers of 782 cm -1 , 844 cm -1 , 1191 cm -1 , 1382 cm -1 and 2238 cm -1 . The proton nuclear magnetic resonance ( 1 H-NMR) spectrum of the compound in dimethyl sulfoxide-d 6 had absorptions at δ values of 3.65 ppm, 7.89 ppm, 8.27 ppm and 8.29 ppm. The ultraviolet absorption spectrum of the compound in tetrahydrofuran as the solvent had absorption bands having peaks at wavelengths λ max of 211 nm and 269 nm with molar absorption coefficients of 6500 and 12100, respectively. EXAMPLE 3 A cyano group-containing oxime sulfonate compound expressed by the formula C.sub.4 H.sub.9 --SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --C.sub.4 H.sub.9, in which mPn is a m-phenylene group, was synthetically prepared in substantially the same manner as in Example 1 excepting for the replacement of the bis(α-hydroxyimino)-p-phenylene diacetonitrile with the same amount of bis(α-hydroxyimino)-m-phenylene diacetonitrile and replacement of 26.7 g of mesyl chloride with 36.3 g (0.233 mole) of 1-butanesulfonyl chloride. A 32 g portion of the crude reaction product was subjected to purification by repeating recrystallization from acetonitrile to obtain 20.5 g of a white crystalline compound having a melting point at 98° C. as the product which could be identified to be the above-mentioned target compound as being supported by the analytical results shown below. The above-mentioned yield of the product corresponds to 48.5% of the theoretical value. The infrared absorption spectrum of the product compound had absorption bands having peaks at wave numbers of 783 cm -1 , 844 cm -1 , 1191 cm -1 , 1382 cm -1 and 2239 cm -1 . The proton nuclear magnetic resonance ( 1 H-NMR) spectrum of the compound in acetone-d 6 had absorptions at δ values of 0.98 ppm, 1.52 ppm, 1.92 ppm, 3.70 ppm, 7.91 ppm, 8.27 ppm and 8.40 ppm. The ultraviolet absorption spectrum of the compound in tetrahydrofuran as the solvent had absorption bands having peaks at wavelengths λ max of 211 nm and 268 nm with molar absorption coefficients of 7100 and 13500, respectively. EXAMPLE 4 A cyano group-containing oxime sulfonate compound expressed by the formula CH.sub.3 --pPn--SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --pPn--CH.sub.3, in which mPn is a m-phenylene group and pPn is a p-phenylene group, was synthetically prepared in the following manner. Thus, 10.0 g (0.0465 mole) of bis(α-hydroxyimino)-m-phenylene diacetonitrile and 11.3 g (0.116 mole) of triethylamine dissolved in 200 ml of tetrahydrofuran were introduced into a reaction vessel to form a uniform solution which was chilled to and kept at -5° C. and to which 22.1 g (0.116 mole) of p-toluenesulfonyl chloride were added dropwise under agitation over a period of 2 hours followed by further continued agitation at -5° C. for 2 hours and then at about 25° C. for 20 hours to complete the reaction. The reaction mixture was subjected to distillation at 30° C. under reduced pressure for the removal of tetrahydrofuran to obtain a crude product. A 12 g portion thereof was subjected to purification by repeating recrystallization from acetonitrile to obtain 10.0 g of a white crystalline compound having a melting point at 205° C. as the product which could be identified to be the above-mentioned target compound as being supported by the analytical results shown below. The above-mentioned yield of the product corresponds to 41.3% of the theoretical value. The infrared absorption spectrum of the product compound had absorption bands having peaks at wave numbers of 773 cm -1 , 836 cm -1 , 1197 cm -1 , 1394 cm -1 and 2237 cm -1 . The proton nuclear magnetic resonance ( 1 H-NMR) spectrum of the compound in dimethyl sulfoxide-d 6 had absorptions at δ values of 2.42 ppm, 7.52 ppm, 7.77 ppm and 7.98 ppm. The ultraviolet absorption spectrum of the compound in tetrahydrofuran as the solvent had absorption bands having peaks at wavelengths λ max of 230 nm and 270 nm with molar absorption coefficients of 24000 and 17300, respectively. EXAMPLE 5 A cyano group-containing oxime sulfonate compound expressed by the formula CF.sub.3 --SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --CF.sub.3, in which mPn is a m-phenylene group, was synthetically prepared in substantially the same manner as in Example 2 excepting for the replacement of 26.7 g of the mesyl chloride with 64.7 g (0.233 mole) of trifluoromethanesulfonic acid anhydride. EXAMPLE 6 A cyano group-containing oxime sulfonate compound expressed by the formula CH.sub.3 O--pPn--SO.sub.2 --O--N═C(CN)--mPn--C(CN)═N--O--SO.sub.2 --pPn--OCH.sub.3, in which mPn is a m-phenylene group and pPn is a p-phenylene group, was synthetically prepared in substantially the same manner as in Example 4 excepting for the replacement of 22.1 g of the p-toluenesulfonyl chloride with 24.0 g (0.116 mole) of 4-methoxybenzenesulfonyl chloride. EXAMPLE 7 A negative-working photoresist composition was prepared by dissolving, in a mixture of 384 parts of propyleneglycol monomethyl ether acetate and 96 parts of N-methyl-2-pyrrolidone, 100 parts of a copolymeric resin of hydroxystyrene and styrene having a weight-average molecular weight of 2500 and 15 parts of a melamine resin (Mw-30, a product by Sanwa Chemical Co.) and further admixing the solution with 3 parts of the oxime sulfonate compound prepared in Example 2 as an acid-generating agent. The thus-prepared photoresist solution was applied onto the surface of a silicon wafer on a spinner followed by drying on a hotplate at 90° C. for 90 seconds to give a photoresist layer having a thickness of 1.0 μm. The resist layer was exposed pattern-wise to i-line ultraviolet light of 365 nm wavelength through a Levenson phase-shift mask on a minifying projection exposure machine (Model NSR-2005i10D, manufactured by Nikon Co.) and subjected to a post-exposure baking treatment at 100° C. for 90 seconds followed by a development treatment in a 2.38% by weight aqueous solution of tetramethylammonium hydroxide at 23° C. for 65 seconds, rinse with water for 30 seconds and drying to give a line-and-space pattern of the resist layer. The cross-sectional profile of a line-and-space pattern of the resist layer having a line width of 0.30 μm was excellently orthogonal standing upright on the substrate surface as examined on a scanning electron microscopic photograph. The exposure dose latitude as expressed by Eop/Eg was 1.70, in which Eop is the exposure dose required for the reproduction of a line-and-space pattern of 0.30 μm line width with a line width:space width of 1:1, and Eg is the exposure dose for the incipient pattern formation in the exposed area of a line-and-space pattern of 0.30 μm line width. COMPARATIVE EXAMPLE 1 The experimental procedure for the preparation and testing of a negative-working photoresist composition was substantially the same as in Example 7 described above excepting for the replacement of the oxime sulfonate compound prepared in Example 2 with the same amount of α-(p-toluenesulfonyloxyimino)-4-methoxyphenyl acetonitrile. The results of the evaluation tests were that the cross-sectional profile of a line-and-space patterned resist layer having a line width of 0.30 μm was not orthogonal but had a width narrowed toward the top of the cross-section and the exposure dose latitude Eop/Eg was 1.60. EXAMPLE 8 A negative-working photoresist composition was prepared by dissolving, in 270 parts of propyleneglycol monomethyl ether acetate, 100 parts of a cresol novolac resin as a condensation product of m-cresol and formaldehyde having a weight-average molecular weight of 10000 and 10 parts of a melamine resin (Mw-30, a product by Sanwa Chemical Co.) and further admixing the solution with 1.5 parts of the oxime sulfonate compound prepared in Example 2 as an acid-generating agent. The thus-prepared photoresist solution was applied onto the surface of a silicon wafer on a spinner followed by drying on a hotplate at 90° C. for 90 seconds to give a photoresist layer having a thickness of 2.0 μm. The resist layer was exposed pattern-wise to i-line ultraviolet light of 365 nm wavelength on a minifying projection exposure machine (Model NSR-2005i10D, manufactured by Nikon Co.) and subjected to a post-exposure baking treatment at 100° C. for 90 seconds followed by a development treatment in a 2.38% by weight aqueous solution of tetramethylammonium hydroxide at 23° C. for 65 seconds, rinse with water for 30 seconds and drying to give a line-and-space pattern of the resist layer. As a measure of the photosensitivity of the photoresist composition, the minimum exposure dose was measured for the formation of a line-and-space pattern of 0.80 μm line width in a line:space width ratio of 1:1 to find an exposure dose of 75 mJ/cm 2 . A scanning electron microscopic examination was undertaken for the cross-sectional profile of a line-patterned resist layer having a line width of 0.80 μm by taking a microscopic photograph to find that the cross-sectional profile was excellently orthogonal standing upright on the substrate surface. The ratio of the exposure dose with which a line-and-space pattern of 1 μm line width could be reproduced to have a line:space width ratio of 1:1 to the above-mentioned exposure dose as a measure of the photosensitivity was 1.15 which could be a measure for the dimensional fidelity of pattern reproduction. Further, the heat stability of the patterned resist layer was examined by heating the resist layer on a hotplate to determine the lowest temperature for incipient flowing of a line-and-space pattern of 0.8 μm line width to obtain a temperature of 200° C. COMPARATIVE EXAMPLE 2 The experimental procedure for the preparation of a photoresist composition was substantially the same as in Example 8 described above excepting for the replacement of 1.5 parts of the oxime sulfonate compound prepared in Example 2 with 3 parts of α-(p-toluenesulfonyloxyimino)phenyl acetonitrile. As a result of the evaluation tests of the composition undertaken in the same manner as in the preceding examples, the photosensitivity thereof was found to be 300 mJ/cm 2 . The cross-sectional profile of a line-and-space patterned resist layer having a line width of 0.80 μm was not orthogonal but had a width narrowed toward the top of the cross-section. The dimensional fidelity of the patterned resist layer was 1.35 and the temperature for heat resistance was 140° C. EXAMPLE 9 The experimental procedure for the preparation of a photoresist composition was substantially the same as in Example 8 described above excepting for the replacement of the oxime sulfonate compound prepared in Example 2 with the same amount of another oxime sulfonate compound prepared in Example 3. As a result of the evaluation tests of the composition undertaken in the same manner as in the preceding examples, the photosensitivity thereof was found to be 65 mJ/cm 2 . The cross-sectional profile of a line-and-space patterned resist layer having a line width of 0.80 μm was orthogonal standing upright on the substrate surface. The dimensional fidelity of the patterned resist layer was 1.18 and the temperature for heat resistance was 200° C. EXAMPLE 10 A positive-working photoresist composition was prepared by dissolving, in 400 parts of propyleneglycol monomethyl ether acetate, 30 parts of a first polyhydroxystyrene substituted by tert-butoxycarbonyloxy groups for 39% of the hydroxy groups and having a weight-average molecular weight of 8000 and a molecular weight distribution Mw:Mn of 1.5, 70 parts of a second polyhydroxystyrene substituted by ethoxyethoxy groups for 39% of the hydroxy groups and having a weight-average molecular weight of 8000 and a molecular weight distribution Mw:Mn of 1.5, 2 parts of the oxime sulfonate compound prepared in Example 2 as an acid-generating agent, 0.3 part of triethylamine, 0.2 part of salicylic acid and 5 parts of N,N-dimethylacetamide followed by filtration of the solution through a membrane filter of 0.2 μm pore diameter. This photoresist solution was applied to the surface of a silicon wafer on a spinner followed by drying on a hotplate at 80° C. for 90 seconds to form a dried photoresist layer having a thickness of 0.7 μm, which was exposed pattern-wise on a minifying projection exposure machine (Model NSR-2005EX8A, manufactured by Nikon Co.) in doses stepwise increased with increments of each 1 mJ/cm 2 by varying the exposure time followed by a post-exposure baking treatment at 110° C. for 90 seconds and developed with a 2.38% by weight aqueous solution of tetramethylammonium hydroxide at 23° C. for 65 seconds followed by rinse with water for 30 seconds and drying. Recording was made there for the minimum exposure dose in mJ/cm 2 , which was 4 mJ/cm 2 in this case, as a measure of the sensitivity by which the resist layer in the exposed areas was completely dissolved away in the development treatment. A scanning electron microscopic photograph was taken of the cross-sectional profile of the patterned resist line of 0.25 μm width to find that the cross-sectional profile was excellently orthogonal standing upright on the substrate surface. Further, the heat stability of the patterned resist layer was tested by heating the resist layer on a hot plate to determine the lowest temperature for incipient flowing of a line-and-space pattern of 100 μm line width but no flow of the line-patterned resist layer could be detected at a temperature of 120° C.
Disclosed is a novel positive-working or negative-working chemical-sensitization photoresist composition useful in the photolithographic patterning works for the manufacture of electronic devices. The photoresist composition is characterized by a unique acid-generating agent capable of releasing an acid by the pattern-wise exposure of the resist layer to actinic rays so as to increase or decrease the solubility of the resist layer in an aqueous alkaline developer solution. The acid-generating agent proposed is a novel cyano group-containing oxime sulfonate di- or triester compound represented by the general formula A[C(CN)═N--O--SO.sub.2 --R].sub.n, in which each R is, independently from the others, an unsubstituted or substituted monovalent hydrocarbon group such as alkyl groups, A is a divalent or tervalent organic group or, preferably, phenylene group and the subscript n is 2, when A is a divalent group, or 3, when A is a tervalent group or, preferably 2. Since more than one of sulfonic acid molecules are released from one molecule of the sulfonate compound by the exposure to actinic rays, the chemical-sensitization photoresist composition exhibits high photosensitivity.
2
FIELD OF THE INVENTION The present invention relates to a plunger lift apparatus for the lifting of formation liquids in a hydrocarbon well. More specifically, the plunger comprises an internal nozzle apparatus that operates to propel one or more jets of gas through an internal aperture and into a liquid load, transferring gas into the liquid load and causing an aeration of the liquid load during lift. BACKGROUND OF THE INVENTION A plunger lift is an apparatus that is used to increase the productivity of oil and gas wells. Nearly all wells produce liquids. In the early stages of a well's life, liquid loading is usually not a problem. When rates are high, the well liquids are carried out of the well tubing by the high velocity gas. As a well declines, a critical velocity is reached below which the heavier liquids do not make it to the surface and start to fall back to the bottom, exerting back pressure on the formation and loading up the well. A plunger system is a method of unloading gas in high ratio oil wells without interrupting production. In operation, the plunger travels to the bottom of the well where the loading fluid is picked up by the plunger and is brought to the surface removing all liquids in the tubing. The plunger also helps keep the tubing free of paraffin, salt or scale build-up. A plunger lift system works by cycling a well open and closed. During the open time, a plunger interfaces between a liquid slug and gas. The gas below the plunger will push the plunger and liquid to the surface. This removal of the liquid from the tubing bore allows an additional volume of gas to flow from a producing well. A plunger lift requires sufficient gas presence within the well to be functional in driving the system. Oil wells making no gas are thus not plunger lift candidates. A typical installation plunger lift system 100 can be seen in FIG. 1 . Lubricator assembly 10 is one of the most important components of plunger system 100 . Lubricator assembly 10 includes cap 1 , integral top bumper spring 2 , striking pad 3 , and extracting rod 4 . Extracting rod 4 can be employed depending on the plunger type. Within lubricator assembly 10 is plunger auto catching device 5 and plunger sensing device 6 . Sensing device 6 sends a signal to surface controller 15 upon plunger 200 arrival at the well top. Plunger 200 can be the plunger of the present invention or other prior art plungers. Sensing the plunger is used as a programming input to achieve the desired well production, flow times and wellhead operating pressures. Master valve 7 should be sized correctly for the tubing 9 and plunger 200 . An incorrectly sized master valve 7 will not allow plunger 200 to pass through. Master valve 7 should incorporate a full bore opening equal to the tubing 9 size. An oversized valve will allow gas to bypass the plunger causing it to stall in the valve. If the plunger is to be used in a well with relatively high formation pressures, care must be taken to balance tubing 9 size with the casing 8 size. The bottom of a well is typically equipped with a seating nipple/tubing stop 12 . Spring standing valve/bottom hole bumper assembly 11 is located near the tubing bottom. The bumper spring is located above the standing valve and can be manufactured as an integral part of the standing valve or as a separate component of the plunger system. The bumper spring typically protects the tubing from plunger impact in the absence of fluid. Fluid accumulating on top of plunger 200 may be carried to the well top by plunger 200 . Surface control equipment usually consists of motor valve(s) 14 , sensors 6 , pressure recorders 16 , etc., and an electronic controller 15 which opens and closes the well at the surface. Well flow ‘F’ proceeds downstream when surface controller 15 opens well head flow valves. Controllers operate on time and/or pressure to open or close the surface valves based on operator-determined requirements for production. Additional features include: battery life extension through solar panel recharging, computer memory program retention in the event of battery failure and built-in lightning protection. For complex operating conditions, controllers can be purchased that have multiple valve capability to fully automate the production process. FIGS. 2 , 2 A, 2 B and 2 C are side views of various plunger mandrel embodiments. Although an internal mandrel orifice 44 may or may not be present in prior art plungers, such an orifice can define a passageway for the internal nozzle of the present device. Each mandrel shown comprises a male end sleeve 41 . Threaded male area 42 can be used to attach various top and bottom ends as described below in FIGS. 3 , 3 A, 3 B and 3 C. A. As shown in FIG. 2B , plunger mandrel 20 is shown with solid ring 22 sidewall geometry. Solid sidewall rings 22 can be made of various materials such as steel, poly materials, Teflon®, stainless steel, etc. Inner cut grooves 30 allow sidewall debris to accumulate when a plunger is rising or falling. B. As shown in FIG. 2C , plunger mandrel 80 is shown with shifting ring 81 sidewall geometry. Shifting rings 81 allow for continuous contact against the tubing to produce an effective seal with wiping action to ensure that most scale, salt or paraffin is removed from the tubing wall. Shifting rings 81 are individually separated at each upper surface and lower surface by air gap 82 . C. As shown in FIG. 2 , plunger mandrel 60 has spring-loaded interlocking pads 61 in one or more sections. Interlocking pads 61 expand and contract to compensate for any irregularities in the tubing, thus creating a tight friction seal. D. As shown in FIG. 2A , plunger mandrel 70 incorporates a spiral-wound, flexible nylon brush 71 surface to create a seal and allow the plunger to travel despite the presence of sand, coal fines, tubing irregularities, etc. E. Flexible plungers (not shown) are flexible for coiled tubing and directional holes, and can be used in straight standard tubing as well. FIGS. 3 , 3 A, 3 B and 3 C are side views of fully assembled plungers each comprising a fishing neck ‘A’. Each plunger comprises a bottom striker 46 suited for hitting the well bottom. Recent practices toward slim-hole wells that utilize coiled tubing also lend themselves to plunger systems. With the small tubing diameters, a relatively small amount of liquid may cause a well to load-up, or a relatively small amount of paraffin may plug the tubing. Plungers use the volume of gas stored in the casing and the formation during the shut-in time to push the liquid load and plunger to the surface when the motor valve opens the well to the sales line or to the atmosphere. To operate a plunger installation, only the pressure and gas volume in the tubing/casing annulus is usually considered as the source of energy for bringing the liquid load and plunger to the surface. The major forces acting on the cross-sectional area of the bottom of the plunger are: The pressure of the gas in the casing pushes up on the liquid load and the plunger. The sales line operating pressure and atmospheric pressure push down on the plunger. The weight of the liquid and the plunger weight push down on the plunger. Once the plunger begins moving to the surface, friction between the tubing and the liquid load acts to oppose the plunger. In addition, friction between the gas and tubing acts to slow the expansion of the gas. In some cases, a large liquid loading can cause the plunger lift to operate at a slowed rate. A well's productivity can be impacted by the lift rate. Thus a heavy liquid load can be a major factor on a well's productivity. SUMMARY OF THE INVENTION The present apparatus provides a plunger lift apparatus that can more effectively lift a heavy liquid. In short, a heavy liquid load can be brought to the surface at a higher rise velocity. One or more internal orifices allow for a transfer of gas from the well bottom into the liquid load during plunger lift. This jetting of the gas causes an aeration to occur so the plunger may carry a heavy liquid load to the well top in an improved manner. In addition, a liquid load can rise at a higher velocity. The apparatus can increase the production of liquid allowing for a faster rise velocity with a fixed liquid load. One aspect of the present invention is to provide a plunger apparatus that can have an extended capacity in carrying a liquid load to the well top. Another aspect of the present invention is to increase lift velocity of the plunger and liquid load when rising to the well top. Another aspect of the present invention is to provide a means for transferring momentum from gas at the well bottom through a gas jet and onto a liquid load to assist with overall plunger lift load. Another aspect of the present invention is to provide a plunger that can be used with any existing plunger sidewall geometry. Other aspects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views. The present invention comprises a plunger lift apparatus having a top section with an inner longitudinal orifice and one or more nozzle exit apertures (orifices) at or near its upper surface. The top section can comprise a standard American Petroleum Institute (API) fishing neck, if desired, but other designs are possible. A mandrel mid section allowing for the various sidewall geometries comprises an internal orifice throughout its length. A lower section also comprises an internal longitudinal orifice. The sections can be assembled to form the liquid aeration plunger of the present invention. Gas passes through an internal plunger conduit (orifice), up through an internal nozzle, and out through one or more apertures thereby transferring momentum from a gas to a liquid load providing a lift assist and causing gaseous aeration of the liquid load. When the surface valves open to start the lift process, down hole pressure will result in gas being forced through the plunger nozzles, exiting one or more apertures into the liquid load transferring momentum from the jetting gas onto the liquid load. The gas transfer causes aeration and results in a liquid lift assist. The plunger may carry a heavier liquid load to the well top because the aeration effectively lightens the load. The present apparatus can carry a fixed liquid load at an improved velocity as compared to a non-aerated liquid load. Applying a soapy mixture down to the well bottom between the well casing and tubing can assist the aeration process by allowing a higher surface tension in the gaseous bubbles formed within the liquid load. An additional embodiment incorporates a nozzle type aerator in a bypass plunger design, employing the same basic concept of momentum transfer and gaseous aeration of the liquid load. The present apparatus allows for improved productivity in wells that have large levels of loaded liquid. The disclosed plunger allows for a more efficient lift of high liquid loads both increasing the lift capacity and also the lift velocity by aerating the liquid load during plunger lift. The liquid aeration plunger is easy to manufacture, and easily incorporates into the design into existing plunger geometries. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 (prior art) is an overview depiction of a typical plunger lift system installation. FIGS. 2 , 2 A, 2 B and 2 C (prior art) are side views of plunger mandrels with various plunger sidewall geometries. FIGS. 3 , 3 A, 3 B and 3 C (prior art) are side views of fully assembled plungers each shown with a fishing neck top and utilizing various plunger sidewall geometries. FIG. 4 is a cross-sectional view of an upper section embodiment of a liquid aeration plunger showing an internal orifice, nozzles, and nozzle exit apertures. FIG. 5 is an isometric cut away view of a liquid aeration plunger embodiment. FIG. 6 is an isometric cut away view of a liquid aeration plunger embodiment during a plunger lift. FIGS. 7 , 7 A, 7 B and 7 C (prior art) show side views of variable orifice bypass valves and plunger mandrels with various sidewall geometries. FIG. 8A (prior art) is a side cross-sectional view of a variable orifice bypass valve assembly with the actuator rod shown in the open (or bypass) position. FIG. 8B (prior art) is a side cross-sectional view of a variable orifice bypass valve assembly and similar to FIG. 8A but with the actuator rod shown in its closed (no bypass) position. FIG. 9 is a top view of a grooved actuator rod. FIGS. 9A , 9 B show cross sectional views of possible modifications of an actuator rod for a bypass valve assembly to allow for gas entry in a closed position. FIG. 9C is a cross sectional view of FIG. 9 along line 9 C- 9 C. FIGS. 10 , 10 A, 10 B are side cross-sectional views of the embodiments shown in FIGS. 9C , 9 A and 9 B respectively. Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings, the present invention is a liquid aeration plunger 2000 apparatus ( FIG. 5 ) having an upper section 200 (FIGS. 4 , 5 ) with an inner longitudinal orifice and one or more nozzle exit apertures at or near its upper end. The top section can comprise a standard American Petroleum Institute (API) fishing neck, if desired, but other designs are possible. The plunger has a mandrel mid section that can accommodate various sidewall geometries, an internal orifice throughout its length and a lower section 46 A ( FIG. 5 ) with an internal longitudinal orifice. All the sections can be connected together to allow the gaseous aeration of the liquid load by the plunger of the present invention. When the surface valves open to start the lift process, gas is forced through the plunger nozzles. As the gas exits from the apertures into the liquid load, transferring momentum from the gas to the liquid, a turbulent and gaseous aeration of the liquid occurs. This action results in a more efficient lift of the liquid to the well top. FIG. 4 is a cross-sectional view of upper section 200 of the liquid aeration plunger shown in FIG. 5 . The upper external end is a prior art fishing neck ‘A’ design. Upper section 200 is shown with four nozzle exit apertures 52 dispersed evenly around its upper surface, with each exiting at about 45° to the liquid load boundary. Upper section 200 can easily connect to any mandrel such as that shown in FIGS. 2 , 2 A, 2 B and 2 C. Internal female sleeve orifice 58 mates with the male end sleeve 41 and threaded internal female sleeve orifice 56 mates with threaded male area 42 . Upper section internal through-orifice 54 can communicate with each nozzle exit orifice 53 . It should be noted that the nozzle quantity, location, size and designs are offered by way of example and not limitation. For example, four nozzle orifices 53 and four aperture exits 52 are shown, each at about a 45° cut angle into upper section orifice 54 . However, the present invention is not limited to the design shown. Other nozzle designs could easily be incorporated to encompass one or more exit nozzle apertures, various size nozzle holes, various angles, etc. The upper end has at least one exit orifice that has a total cross sectional area in the range of about 0.25% to 10% of the maximum plunger cross sectional area. Typically, the smallest range of the cross sectional area of either the lower end apertures or the upper end apertures or the internal longitudinal orifice is about 3.22 mm 2 (about 0.005 inch 2 ) to about 32.3 mm 2 (about 0.05 inch 2 ). In FIG. 4 , the four nozzle orifices are each typically about 2.36 mm (about 0.093 inch) in diameter, combining to about 17.4 mm 2 (about 0.027 inch 2 ) of area as compared to the outside diameter of a typical plunger of about 47 mm (about 1.85 inch) or about 1735 mm 2 (about 2.69 inch 2 ). FIG. 5 is an isometric cut side view of liquid aeration plunger 2000 . In this embodiment, upper section 200 , solid wall plunger mandrel 20 , and lower section 46 A, are shown having interconnected internal orifices. Lower section 46 A is modified from present art by providing lower section internal orifice 44 A. Lower section 46 A can be attached to a mandrel by mating male end sleeves 41 and threaded male areas 42 , previously shown in FIGS. 2 , 2 A, 2 B and 2 C. Liquid aeration plunger 2000 functions to allow gas to pass into lower section 46 A at lower entry aperture 48 , up through lower section internal orifice 44 A, through internal mandrel orifice 44 , then up through upper section internal through-orifice 54 , through nozzle exit orifices 53 and finally exiting out of apertures 52 . It should also be noted that the size of nozzle exit orifices 53 and apertures 52 control the amount of gas jetting. The depicted embodiment design is shown by way of example and not limitation. It should be noted that although the mandrel shown is solid wall plunger mandrel 20 , any other sidewall geometry can be utilized including all aforementioned sidewall geometries. Lower section internal orifice 44 A, internal mandrel orifice 44 , and upper section internal through-orifice 54 can be manufactured in various internal dimensions. FIG. 6 shows liquid aeration plunger 2000 during a plunger lift. When the surface valves open to start the lift process, gas G enters the plunger lower entry aperture 48 , passes up through all internal orifices ( 44 A, 44 , 54 , 53 ), exits apertures 52 in directions E, and jets into the liquid load L to form bubbles B in a turbulent fashion. This action results in a transfer of momentum from the jetting gas into the liquid load. The gaseous jetting, turbulence and aeration of the liquid is a result of the momentum transfer. The plunger may carry a heavier than average liquid load to the well top, thereby increasing the load capacity and/or allowing for a faster rise velocity of a given liquid load. The result is an increase in well productivity for wells with high liquid loads. Injecting a soapy mixture S down to the well bottom between the aforementioned well casing 8 and tubing 9 can assist the aeration process by allowing a higher surface tension in the gaseous bubbles B formed within the liquid load L. Liquid aeration plunger 2000 can easily be manufactured with any existing plunger sidewall geometry. Another embodiment of the present invention incorporates a nozzle type aerator in a bypass plunger design, employing the same basic concept of momentum transfer and gaseous aeration of the liquid load. Bypass plungers typically have an actuator that is in a ‘open’ position during plunger descent to the well bottom and is in a ‘closed’ position during a plunger rise to the well top. Modifications to the actuator rod, to the bypass valve, or mandrel housing at the closed interface can be made to accommodate an orifice or an aperture for gas jetting. In an embodiment modifying a typical bypass valve, one or more small apertures or orifices within the actuator rod provide for gas jetting into the liquid load during the ‘closed’ position of the actuator rod. Thus when in a ‘closed’ position, the bypass plunger will function via the transfer of momentum and gas jetting causing aeration of the liquid load. FIGS. 7 , 7 A, 7 B and 7 C show side views of variable orifice bypass valves (VOBV) 300 . Pad plunger mandrel section 60 A, brush plunger mandrel section 70 A, solid ring plunger mandrel section 20 A, and shifting ring plunger mandrel section 80 A can each be mounted to a VOBV 300 by mating female threaded end 64 and male threaded end 66 . Each plunger 61 , 71 , 21 and 81 is shown in an unassembled state. A standard American Petroleum Institute (API) internal fishing neck can also be used. Each mandrel section also has hollowed out core 67 . Each depicted bottom section is a VOBV 300 shown in its full open (or full bypass) set position. The bypass function allows fluid to flow through during the return trip to the bumper spring with the bypass closing when the plunger reaches the well bottom. The bypass feature optimizes plunger travel time in high liquid wells. The present invention is not limited by the specific design of bypass valve and VOBV is shown only as an example. FIG. 8A is a side cross-sectional view of a prior art VOBV assembly 300 with actuator rod 25 shown in the open (or bypass) position. VOBV assembly 300 threaded interface 64 joins to a mandrel section via mandrel threads 66 (See FIGS. 7 , 7 A, 7 B and 7 C). When VOBV assembly 300 arrives at the well top, the aforementioned striker rod within the lubricator hits actuator rod 25 at rod top end 37 moving actuator rod 25 in direction P to its open position. In its open position, the top end of actuator rod 25 rests against variable control cylinder 26 internal surface. Brake clutch 21 will hold actuator rod 25 in its open position allowing well loading (gas/fluids, etc.) to enter the open orifice and move up through the hollowed out section of bypass plunger during plunger descent. This feature optimizes its descent to the well bottom as a function of the bypass setting. Access hole 29 is for making adjustments to the bypass setting via variable orifice opening 31 . In other words, the amount of gas allowed to enter the bypass valve can be adjusted. FIG. 8B is a side cross-sectional view of a prior art VOBV assembly 300 and similar to FIG. 8A but with actuator rod 25 depicted in its closed (no bypass) position. When bottom bumper spring striker end 34 hits the well bottom, the actuator rod 25 moves in direction C to a closed position. In the closed position, rod top end 37 with its slant surface 36 closes against threaded top section end 66 and is held in the closed position by brake clutch 21 thus allowing VOBV 300 to be set in a closed bypass condition to enable itself to rise back to the well top. FIGS. 9A , 9 B show possible modifications of actuator rod 25 which are described in more detail below. When actuator rod 25 is in a closed position, there is a seal along slant surface 36 , which prevents gas flow through the VOBV. The modifications of the embodiment of the present invention will allow for small gas exit aperture(s) when modified actuator rods are in a closed position ( FIG. 8B ). Allowing a portion of gas to exit when in a closed position will cause the aforementioned momentum transfer from the gas into the liquid load within central hollowed out core 67 (see FIGS. 10 , 10 A, 10 B) and will result in a liquid lift assist in a bypass plunger. The modifications are shown by way of example and not limitation of the present invention. FIGS. 9 , 9 C are views of grooved actuator rod 25 A comprising four grooves 94 cut partially into actuator rod top surface 37 , into slant surface 36 and down top side surface 39 . The number and the type of grooves are shown by way of example and not limitation. For example, grooves also could be cut into the mating sidewall of VOBV/mandrel (not shown). In the embodiment shown, section A-A defines a cross section of grooved actuator rod 25 A. Gas would pass into the liquid residing within each mandrel section hollowed out core 67 via grooves 94 . Also shown in dotted line format is an alternate design comprising top slant holes 96 which could be drilled from top surface 37 to just below side surface 39 . Slant holes 96 could replace the aforementioned grooves 94 . Equivalent designs could include a metal burr acting to keep one rod slightly open in the closed position. FIG. 9A is a side cross-sectional view of split orifice actuator rod 25 B comprising central orifice 74 , and four connected orifices 76 positioned about 45° from each other. Gas enters at gas entry aperture 86 located at actuator rod bottom surface 34 . The gas moves up through central orifice 74 , then through nozzle orifices 76 , and exits into the liquid load from apertures 78 located along actuator rod top surface 37 . FIG. 9B is a side cross-sectional view of center orifice actuator rod 25 C comprising central through orifice 84 . Gas enters aperture 86 along actuator rod bottom surface 34 and gas exits aperture 88 at actuator rod top surface 37 . FIGS. 10 , 10 A, 10 B are side cross-sectional views of the embodiments shown in FIGS. 9C , 9 A and 9 B, respectively. Each design is shown by way of example and not limitation. In each case a limited amount of gas is allowed to exit the seal area of the VOBV when the actuator is in a closed position and when the down hole pressure allows gas to be jetted through the valve. FIG. 10 shows VOVB assembly 300 A in a closed position. When down hole pressure is released, gas enters variable orifice opening 31 and/or access hole 29 (see FIG. 8 A) and jets through grooves 94 , transferring gas in direction GE to liquid load L. Also shown are the top slant holes 96 which could be drilled from top surface 37 to below the side surface. Slant holes 96 could replace grooves 94 . FIG. 10A is a side cross-sectional view showing split orifice actuator rod 25 B in a closed position within VOBV assembly 300 B. Split orifice actuator rod 25 B is modified to comprise central orifice 74 and four connected orifices 76 positioned about 45° from each other. Gas G enters at gas entry aperture 86 located at actuator rod bottom surface 34 . The gas moves up through central orifice 74 , through nozzle orifices 76 , and exits in direction GE into the liquid load L from apertures 78 located along actuator rod top surface 37 . FIG. 10B is a side cross-sectional view showing center orifice actuator rod 25 B in a closed position within VOBV assembly 300 C. Center orifice actuator rod 25 B comprises central through orifice 84 . Gas G enters aperture 86 along actuator rod bottom surface 34 and exits out gas exit aperture 88 in direction GE and into the liquid load L. An actuator rod or side escape of the actuator rod or seal area has at least one exit orifice with a total cross sectional area in the range of about 0.25% to about 10% of the maximum plunger cross sectional area. Typically, the smallest range of the cross sectional area of the apertures (or escape area), which exit gas into hollowed out core 67 , is about 3.22 mm 2 (about 0.005 inch 2 ) to about 32.3 mm 2 (about 0.05 inch 2 ). As an example, and not a limitation, in FIG. 10A the four nozzle orifices are each typically about 2.36 mm (about 0.093 inch) in diameter, combining to about 17.4 mm 2 (about 0.027 inch 2 ) of area as compared to the outside diameter of a typical plunger of about 47 mm (about 1.85 inch) or about 1735 mm 2 (about 2.69 inch 2 ). Examples shown above in FIGS. 9 , 9 A, 9 B, 10 , 10 A and 10 B are shown by way of example and not limitation for variable type bypass valve embodiments. Modifications to fixed bypass valves, although not specifically shown, can also provide for the gas jetting in a similar manner as described above. The liquid turbulence and aeration caused by the energy transfer allows for improved efficiency and productivity in wells that have high levels of liquid. The gas jetting allows for a more efficient lift of large liquid loads by increasing the plunger lift capacity of a liquid load and/or increasing the lift velocity of a given load. The liquid aeration plunger is easy to manufacture, and can easily be incorporated into the design of existing plunger geometries. As previously described, applying a soapy mixture down to the well bottom between the well casing and tubing can assist the aeration process by allowing a higher surface tension in the gaseous bubbles formed within the liquid load. It should be noted that although the hardware aspects of the of the present invention have been described with reference to the depicted embodiment above, other alternate embodiments of the present invention could be easily employed by one skilled in the art to accomplish the gas momentum aspect of the present invention. For example, it will be understood that additions, deletions, and changes may be made to the orifices, apertures, or other interfaces of the plunger with respect to design other than those described herein. Although the present invention has been described with reference to the depicted embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
A plunger apparatus operates to propel one or more jets of gas through one or more internal orifices and/or nozzles out through an aperture and into a liquid load whereby a transfer of the gas into the liquid load causes turbulent aeration to the liquid load during a plunger rise. This action can boost the carrying capacity of a plunger lift system resulting in improved well production.
4
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/576,908, filed Dec. 16, 2011. The disclosure of the foregoing United States patent application is specifically incorporated by reference herein in its entirety for all purposes. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates, in general, to methods and systems of communication networks, especially methods for efficiently transmitting medium access control (MAC) header data by devices of the network. More particularly, the invention relates to (but is not limited to) wireless communication networks operating in the Sub-1 GHz band, especially networks using the emerging IEEE standard 802.11 ah. [0004] 2. Relevant Background. [0005] Many types of communication networks, both wired and wireless, transmit and receive packets of data by organizing transmitted signals into frames for coordination, synchronization and relaying of the transmissions. Ethernet is an example of a wired protocol for such signaling; examples of wireless networks include systems using the 802.11 protocols. One advantage to frames is to allow multiple devices to access to the same physical medium. But a disadvantage is that extra information, such as intended recipient, frame type, etc., must also be transmitted with the desired end user data in order to accomplish the coordination, synchronization and relaying. In many cases, such as with Ethernet and current 802.11 systems, this overhead information imposes a relatively light burden because data carrying frames often carry quite a bit of data, and the system uses a high proportion of such data carrying frames. [0006] But in some systems which transmit relatively small amounts of data, on a less frequent basis, on channels (wired or wireless) with limited bandwidth, the overhead information can impose a large burden. An example of such a system is a wireless sensor network, with a large number of sensors. An IEEE 802.11 BSS or Wi-Fi system typically has a central device to communicate with perhaps tens of nearby users, each needing large data volumes (e.g., for viewing video, web pages, etc.) over time periods of seconds or less. In contrast, a sensor network could have hundreds, perhaps thousands, of widely dispersed sensors, each needing to send or receive small amounts of data to a central device, within time periods of minutes or even days. The amount overhead information needed to be sent with each frame, just for correct addressing of so many users, could seriously degrade the sensor network's capabilities. [0007] To address this problem, as well as for efficient use of the radio spectrum, the Institute of Electrical and Electronic Engineers (IEEE) created Task Group ah (TGah) to develop standards so that wireless networks can transmit in a frequency band of 902 MHz to 928 MHz, called the Sub-1 GHz band. An advantage of this band is that greater range can be achieved. Also, there is typically less interference from intervening objects. [0008] A third advantage of the Sub-1 GHz band is that no legacy systems with different protocols need to be accommodated. So communication systems and devices for this band can be designed to optimize overhead efficiency, rather than to optimize interoperability. In particular, the overhead information included in a transmitted frame can be reduced. In frame-based communication systems, the actual data packet to be transmitted to the receiving station and end user, called the payload, is included with other needed information, called header data. The header data allows the radio receiver to find the start of the frame, to determine the addressee of the payload, to check for errors, and to perform other system operations. Current standard communication protocols specify how the frames are to be structured into fields, which are often further structured with subfields. Also, for effective coordination of the system, some frames are designed only to send information for control and coordination of the transmissions, such as scheduling of transmission times by the various system devices. For example, in the 802.11 standards, there are three types of frames: control, data and management. The detailed terminology of frames and frame-based communications are specified in the standard IEEE 802.11-2012. The standard is cited as a reference for terminology and background information about frame transmission, and does not imply that the communication networks of this disclosure necessarily use the physical wireless transmission methods described therein. [0009] FIG. 1 shows standard arrangements of data and management frames known from the IEEE 802.11a/b/g/n standards. In a data frame, the header consists of up to ten fields with a total size of 36+4 octets (or bytes). The Frame Control field conveys information on signaling and the type of frame being sent. Typically three MAC address fields, and sometimes four, are needed to distinguish the source device of the data, the data's destination device, and possible intermediate transmitter and receiver devices. The QoS, HT Control, Duration/ID fields convey information for coordinating channel access among the devices in the network. Finally, a Frame Check Sequence field typically includes the bits of a Cyclic Redundancy Check code used to ensure the frame header fields have been received correctly. The header of a management frame comprises many of the same fields, and three MAC address fields. The current inventions implement methods and systems for reducing this inefficiency. [0010] 3. Glossary and Acronyms [0011] As a convenient reference in describing the invention herein, the following glossary of terms is provided. Because of the introductory and summary nature of this glossary, these terms must also be interpreted more precisely by the context of the detailed description in which they are discussed. ACK Acknowledgement AID Association Identifier AP Access Point CH Compressed Header CH_MAC Compressed Header Medium Access Control CRC Cyclic Redundancy Check DA/SA/RA Destination Address/Source Address/Receiver Address DS Distribution System EOSP End of Service Period FCS Frame Check Sequence FHC Frame Header Compression HT High Throughput HTC High Throughput Control LTF Long Training Field MAC Medium Access Control MMPDU MAC Management Protocol Data Unit MPDU MAC Protocol Data Unit MSDU MAC Service Data Unit PLCP Physical Layer Convergence Procedure PPDU PLCP Protocol Data Unit RA Receiver Address RD Reverse Direction RDG Reverse Direction Grant SIG Signal STA Station STF Short Training Field TA Transmitter Address TDLS Tunneled Direct-Link Setup TIM Traffic Identification Map VHTC Very High Throughput Control SUMMARY OF THE INVENTION [0012] The exemplary embodiments disclosed herein are methods for use in, and systems of, communication networks, and specify forms of header information and fields of management and data frames, and which specify how and when communication networks can use these forms of headers. In certain embodiments, the header fields are reduced in size from the analogous fields specified in the 802.11a/b/e/g/n standards, and some of those standard fields are removed. [0013] In a first family of embodiments, methods and systems are presented for using frame-based communications within a network in which an access point (AP) device communicates directly with other station (STA) devices, in a point-to-multipoint topology. The AP and the STAs form a basic service set (BSS). Data frames which carry end user data have compressed header fields, totaling at most 16 octets. Two fields of a data frame are used for addressing and routing: a 2-octet association identifier/compressed header field (AID/CH), and a BSS identifier (BSSID) field of 6 octets. In a preferred embodiment, the AID/CH field comprises an AID subfield which identifies the STA corresponding to the frame, and a CH Identifier subfield which represents additional compressed information, e.g. the Address 3 (DA or RA) of the frame. The matching between CH Identifier and the additional compressed information is established between a station and the AP through frame header compression negotiation. [0014] In further embodiments, a data frame comprises a Frame Control field, a Sequence Control field, and a Quality of Service (QoS). In a preferred embodiment the lengths of these fields are respectively 2 octets, 1 octet, and 1 octet. In another embodiment, a data frame comprises a Frame Check Sequence (FCS) field, which can be used to provide error correction capabilities. In one embodiment the FCS has 4 octets, and in another embodiment it has 2 octets. In the latter case the FCS can comprise a two octet cyclic redundancy check code, such as a CRC-16-CCITT. [0015] In order to compress more information in a frame header, a second family of embodiments discloses methods and systems in which the AP and the STAs can transmit signals to negotiate whether compressed headers can be used for transmission of a data frame. A CH Identifier (e.g. 3-bit length) can be used to indicate source or destination MAC address. In one embodiment, a CH Identification Request frame is transmitted from a STA (or from the AP) that would like to send a subsequent data frame using compressed header fields to the AP (respectively, to a STA). The CH Identification Request frame preferentially comprises a Category field, an Action Value field, a Dialog Token field, and at least one pair of fields, the pair of fields comprising a CH Identifier field of 1 octet and a DA/SA MAC address field of 12 octets. A further embodiment also comprises a CH Identification Response frame, of size at most 5 octets. [0016] In a third family of embodiments, methods and systems are presented for using frame-based communications within a network in which an AP device communicates directly with other STAs, in a point-to-multipoint topology. In this family of embodiments, management frames, which transmit management information for network services, have compressed header fields, totaling at most 16 octets. Two fields of a management frame are used for addressing and routing: a 2-octet association identifier/compressed header field (AID/CH), and a Basic Service Set Identifier (BSSID) field of 6 octets. In a preferred embodiment, the AID field identifies the STA corresponding to the frame. [0017] In further embodiments, the header fields of a management frame comprise a Frame Control field, a Sequence Control field and a FCS field. In a preferred embodiment, the Frame Control field uses 2 octets, and the Sequence Control field uses 1 octet. In two further embodiments the FCS uses either 2 or 4 octets, and can be used to convey error detection and correction information, often using cyclic redundancy check coding. [0018] In two further families of embodiments, the Frame Control field of a data frame or a management frame is used for conveying information regarding whether compressed headers are being used. In the first of these families, either a new Protocol Version bit set (in the Protocol Version field) is used, or else a new Type and SubType value combination in the Type and SubType subfields is used. In the second of these families, a From DS field (indicating whether the frame is to/from a Distribution System) is created within the Frame Control field to convey the order of the BSSID and AID fields within the compressed header fields. BRIEF DESCRIPTION OF THE DRAWINGS [0019] The figures described below illustrate exemplary embodiments of the invention, and do not limit the scope of the claims. [0020] FIG. 1 shows a standard organization of the MAC header fields of data and management frames, as known in the art. [0021] FIG. 2 shows a standard organization of subfields in a Frame Control Field. [0022] FIG. 3 shows a standard organization of the fields in a Physical Layer Convergence Procedure Protocol Data Unit, including the SIG field. [0023] FIG. 4 shows the organization of the fields and subfields in compressed header data frames, according to embodiments of the invention. [0024] FIG. 5 shows an organization of the fields and subfields of a CH Identification Request frame, and the fields of a CH Identification Response frame, according to embodiments of the invention. [0025] FIG. 6 shows a signaling process by which a transmitter (either a STA or an AP) negotiates use of compressed MAC header formats for data frames with a receiver (respectively, either an AP or a STA), according to embodiments of the invention. [0026] FIG. 7 shows compressed header MAC fields for management frames, according to embodiments of the invention. [0027] FIG. 8 shows two embodiments of the Frame Control field of the compressed header management frame, according to embodiments of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0028] In the description and claims that follow, the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. [0029] Many types of communication networks have an architecture in which devices in the network communicate through one device, called an access point (AP). The AP is often connected to another network, such as the interne. The other devices in the network, called stations (STAB), route most or all of their transmissions through the AP. As discussed above, for transmissions to be coordinated and sent to the correct device, the information to be transmitted is often broken into packets and the packets of digital data are sequentially encapsulated with other data for addressing and synchronization. The combination is called a frame. [0030] Examples of such frame-based communications networks are specified in the standards 802.11. These standards specify three types of frames: data, management and control frames. FIG. 1 shows the structure of how information is encapsulated into the first two types of frames, according to these standards. The Frame Body contains a packet of the information that a STA or AP wishes to transmit. The other components of the frames, called fields or elements, are of specified length (in octets, also called bytes), and contain the necessary extra information needed for routing the information and coordinating transmissions within and out of the network. This extra information is called medium access control (MAC) header information, and the extra fields are called frame header fields. The entire frame is termed the MAC Protocol Data Unit (MPDU). As shown in FIG. 3 , the entire MPDU is itself enclosed in a Physical Layer Convergence Procedure Protocol Data Unit (PPDU), which is used for physical synchronization of the transmitter and receiver. In some cases, multiple MPDSUs are transmitted in the data field of FIG. 3 ; these are Aggregated MPDUs (A-MPDU). FIG. 2 shows a standard arrangement of the subfields of the Frame Control field. The standards are cited as a reference for terminology and background information about frame transmission, and do not imply that the communication networks of this disclosure necessarily use the physical wireless transmission methods described therein. [0031] There are situations where it is desirable to use the general structure of such a frame-based communication network, but where it would be inefficient to include all the detailed information included in all the fields of FIG. 1 . An example of such a situation is in a wireless sensor network, particularly for one using the Sub-1 GHz band. In the United States, this band is 902 MHz to 928 MHz. For such a network, efficiency of transmission is of primary importance for a variety of reasons: the bandwidth is limited, STAs (e.g., a sensor) typically need to transmit and receive only small amounts of data on an intermittent basis, and there may be upwards of thousands of STAs. Finally, in the case of networks using the Sub-1 GHz band, backwards compatibility with 802.11a/b/g/n is not needed. [0032] The exemplary embodiments detailed herein improve transmission efficiency in a frame-based communication network by allowing the use of a compressed set of frame header fields. Other embodiments specify signaling processes by which STAs and the AP can negotiate whether to use such a compressed frame header format. [0033] Address fields of a data frame in the 802.11 standards are the Receiver Address (RA), Transmitter Address (TA), Source Address (SA), and the Destination Address (DA). The Address fields of a management frame in the 802.11 standards are Address 1 (RA), Address 2 (TA), and Address 3. All are 6-octet MAC addresses. The AID can be used to identify the STA. The RA and TA of a frame are always used to identify the receiver and the transmitter in the BSS. The SA and DA are used to identify the source or the destination of the frame which may be outside the BSS. Once a STA is associated with an AP, the AP will allocate an Association Identifier (AID) to the STA. The AID can be used to replace the MAC address in MAC header fields. [0034] In a sensor network, only limited amounts of data will need to be transmitted between the AP and the STAs, and the AP will coordinate communication with any distribution system (DS). Using all four address fields of a data frame would not be necessary in a data frame within a sensor network, especially from a STA to the AP. STAs, and APs, only need to send enough information in the header fields so the intended receiver knows the frame is intended for it. Some fields/subfields in standard MAC headers also might not be required for some cases, e.g. TXOP Limit/QueueSize subfields, Address 3 in a management frame. Further, some fields/subfields can be compressed. The transmitter or the receiver of a frame can be identified by the AID of the transmitter or the receiver. By removing some fields/subfields in a frame header and compressing some fields/subfields, the MAC overhead can be decreased. One such embodiment is to transmit only one AID to replace the TA and RA, and one MAC address in the header fields. [0035] FIG. 4 shows a particular embodiment of a compressed set of MAC frame header fields, to be used with data frames, according to the present invention. The transmitter and the receiver of the data frame are not identified by two MAC Addresses. Instead, a MAC address Basic Service Set Identifier (BSSID) field, comprising the AP's MAC address, of 6 octets, and one AID field, of 2 octets, is used to identify the transmitter and the receiver. The BSSID field is used to identify whether the frame is in the same BSS. The BSSID is also used to avoid wrong reception of the frames. For example, when a STA in another BSS with the same AID as the AID in the compressed data frame receives the compressed data frame, the STA will discard the frame. The reason is that the BSSID in the frame is not the same as the BSSID of the AP that the STA is associated with. [0036] A data frame includes a Frame Control field, as is known in the art, and shown in FIG. 2 . Two subfields can be used with the compressed header format just described. In one embodiment, if the From DS bit is 1 and the To DS bit is 0, the BSSID is the transmitter identifier and AID is the receiver identifier. When “From DS” bit is 0 and the “To DS” bit is 1, the BSSID is the receiver identifier and the AID is the transmitter identifier. But when the “From DS” bit in Frame Control field is 1 and the “To DS” bit in Frame Control field is also 1, the compressed header is not used. In this embodiment, tunneled direct link setup (TDLS) is not to be used. [0037] In another embodiment, a final Frame Check Sequence (FCS) field is included among the compressed data frame headers to implement correction of possible transmission errors of the bits in the frame. A preferred embodiment is to use a cyclic redundancy check (CRC) error correcting code. Using a 4-octet CRC is known in the art, and can be used in the present embodiments. But since in the embodiment shown in FIG. 4 the size of the header fields is reduced, the FCS can use a shorter, 2-octet, CRC code, such as the 16-CRC-16-CCITT. [0038] To signal whether the data frame is normal or compressed, a number of options are possible. In a first embodiment, a new protocol version in the Protocol Version subfield can be used. Presently, 00 is the protocol version used by the non-compressed frame. A non-compressed data frame will never include the new protocol version in the frame's Protocol Version subfield. Once a data frame includes the new protocol version in Protocol Version subfield, the frame is a compressed frame. In a second embodiment, one bit in the signal (SIG) field of the Physical (PHY) Layer Convergence Procedure (PLCP) frame, shown in FIG. 3 , can be used. A non-compressed data frame will set the selected bit in the signal (SIG) field of the PLCP to 0. Once a data frame sets the selected bit in the SIG field of the PLCP to 1, the frame is a compressed frame. In a third embodiment, a new MPDU Type/SubType value combination in the Type and SubType subfields can be used. A non-compressed data frame will never include the new MPDU Type/SubType value combination in the frame's Type and SubType subfields. [0039] In networks with at most 6000 STAs in a BSS, such as in a network of 802.11ah, 13 bits suffice to indicate the AID. Then in the field there are still 3 bits left in a 2-byte field. The three remaining bits can be used to identify the source or the destination of the frame that was originally identified by 6-byte SA and 6-byte DA. This can further decrease the frame header length. The field can be named as AID/CH identifier field, and includes 13-bit AID and 3-bit CH identifier. A particular embodiment is shown in FIG. 4 . In this embodiment, in the case that From DS subfield in the Frame Control field is 0, and the To DS subfield is 1, then bits 13 to 15 (inclusively) are the DA identifier. In the case that the From DS subfield is 1, and the To DS subfield is 0, then bits 13 to 15 (inclusively) are the SA identifier. As described below, CH Identification Request/Response action frames are used to match the CH Identifier to the DA/SA MAC address. The 3-bit SA/DA identifier is normally enough since for a given RA/TA pair (one STA and its associated AP), the possible SAs or DAs are the STA, edge router/bridge, AAA server, policy server, or signup server. [0040] To manage DA/SA Identification, a non-AP STA sends a CH Identification Request action frame to the AP to indicate the mapping between CH Identifiers and DA/SA MAC Addresses. An embodiment of such frame is shown in FIG. 5 . At most eight pairs of CH Identifiers and DA/SA MAC Addresses can be included. After receiving a CH Identification Request frame, the AP sends a CH Identification Response frame to acknowledge the mapping between a CH Identifier and a DA/SA MAC Address. An embodiment of such a CH Identification Response frame is also shown in FIG. 5 . [0041] FIG. 6 illustrates the signaling of the CH Identification Request and the CH Identification Response messages. [0042] The Duration/ID field in standard 802.11 frames carries the remaining duration of the transmit opportunity (TXOP). A STA that receives the frame will not try to contend the wireless medium (count down the backoff timer or transmit the frames when the backoff timer becomes to 0) during the remaining TXOP. This can avoid collisions even if the STA can't detect the following acknowledge frame. 802.11 ah adds a 2-bit ACK Indication in the SIG field. With the ACK Indication help, a neighbor STA that receives the frame but can't detect the acknowledgement will not try to contend for the wireless medium access during the transmission of the acknowledgement. Because a 2-bit ACK Indication is added to the SIG field PHY layer fields, the Duration/ID field can be eliminated. A 2-octet QoS Control field in non-compressed frames includes various subfields: 3-bit TID, End of Service Period (EOSP), 2-bit ACK Policy, 1-bit A-MSDU Present, and 8-bit TXOP Limit/Queue Size. The EOSP, 1-bit A-MSDU Present, and 8-bit TXOP Limit/Queue Size subfields can be removed from compressed frames since they are not important to the compressed frame. In a further embodiment, the QoS Control field is reduced to 1 octet, and in a preferred embodiment, 4 bits of it are used to indicate the Traffic Identification Map (TID) of the frame, 2 bits are used to indicate the acknowledgement policy (ACK), and the other bits are reserved. A 2-octet Sequence Control field in non-compressed frames can help the receiver detect a duplicate frame. Given that a sensor STA has lower data rate, a one-octet Sequence Control field is long enough to detect a duplicate frame. So in another embodiment, a single octet Sequence Control field is used. [0043] Other families of embodiments use the Compressed Management Frame Header fields shown in FIG. 7 . By using a reduced set of frames for the header fields, greater transmission efficiency can be achieved. The Address3, Duration, and HT Control field are removed from standard management frame header fields shown in FIG. 1 to make the compressed MAC header of FIG. 7 . The HT control field can be removed to make the compressed management MAC header. This means that the compressed frame will not do the functionality related with HT Control fields. As stated above, 802.11ah adds a 2-bit ACK Indication in the SIG field PHY layer fields. With the ACK Indication help, a neighbor STA that receives the frame but can't detect the acknowledgement will not try to contend the wireless medium during the transmission of the acknowledgement. So the Duration/ID field can be eliminated since a 2-bit ACK Indication is added to the SIG field PHY layer fields. Only one Address field, of size 6 octets, and one AID field, of size 2 octets, are used to identify the transmitter and the receiver. In some known methods, a STA uses Address3 to decide whether a group management frame should be accepted. Given that the TA is the same as Address3 in group management frames, it is safe to remove Address3 to make the compressed management frames. The remaining fields of the Compressed Management Frame Header fields comprise a Frame Control (2 octets), a Sequence Control field (2 octets) and a Frame Check Sequence field (either 2 or 4 octets). [0044] In one embodiment, the AID field is used to identify the destination of the management frame. This embodiment is used when the From DS subfield in the Frame Control field is 1. [0045] In another embodiment, the AID field is used to identify the source of the management frame. This embodiment is used when the From DS subfield in the Frame Control field is 0. [0046] Different embodiments involve variations in the information carried in the Frame Control field. [0047] In one family of embodiments, the Frame Control field comprises a Type and a SubType Field. [0048] To signal whether the management frame is normal or compressed, a number of options are possible. In one embodiment, a new protocol version in the Protocol Version subfield can be used. A non-compressed management frame will never include the new protocol version in the frame's Protocol Version subfield. Once a management frame includes the new protocol version in Protocol Version subfield, the frame is a compressed frame. In another embodiment, one bit in the signal (SIG) field of the Physical (PHY) Layer Convergence Procedure (PLCP) frame can be used. A non-compressed management frame will set the selected bit in the signal (SIG) field of the Physical (PHY) Layer Convergence Procedure (PLCP) to 0. Once a management frame sets the selected bit in the signal (SIG) field of the Physical (PHY) Layer Convergence Procedure (PLCP) to 1, the frame is a compressed frame. In a third embodiment, a new MPDU Type/SubType value combination in the Type and SubType subfields can be used. A non-compressed management frame will never include the new MPDU Type/SubType value combination in the frame's Type and SubType subfields. [0049] In some embodiments a final Frame Check Sequence field of 2 or 4 octets is included to implement correction of possible transmission errors of the bits in the compressed header fields. A preferred embodiment is to use a cyclic redundancy check (CRC) error correcting code: CRC-16-CCITT, though other 2 octet codes can be used. [0050] Yet other embodiments reduce the size of, or remove altogether, at least one of the standard 802.11 MAC header fields to form the header fields for data or management frames. As would be apparent based on the explanations and embodiments disclosed above, in a network, such as a sensor network, with an AP and a plurality of STAs directly communicating, the modified and remaining forms of the MAC header fields used to transmit the data or management frame only need to be able to identify the receiver (AP or STA) and the transmitter (respectively the STA or the AP), and whether the frame is being transmitted using the modified header fields. [0051] Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of exemplary embodiments, and that numerous changes in the combination and arrangement of elements will be apparent to those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed.
Methods and systems are disclosed specifying the arrangement and content of the fields in data and management frames, which allow for greater payload efficiency in frame-based communication networks. The content of the fields is changed from the standard 802.11 arrangement to meet of the needs of networks such as Sub-1GHz networks, including those of the 802.11 ah standard, and sensor networks with a large number of stations transmitting at low data rates. In some embodiments, MAC header fields are reduced from standard 802.11 header fields by using only two fields for addressing and eliminating standard fields that are not used in sensor networks.
7
FIELD OF THE INVENTION [0001] This invention relates to improvements in permitting brighter colorations within thermoplastic fibers and/or yarns while simultaneously providing more efficient production methods of manufacturing of such colored fibers as well. Generally, such fibers and/or yarns have been colored with pigments, which exhibit dulled results, or dyes, which exhibit high degrees of extraction and low levels of lightfastness. Such dull appearances, high extraction levels, and less than stellar lightfastness properties negatively impact the provision of such desirable colored thermoplastic (such as, without limitation, polypropylene) fibers and/or yarns which, in turn, prevents the widespread utilization of such fibers and yarns in various end-use applications. Thus, it has surprisingly been determined that brighter colorations, excellent extraction, and more-than-acceptable lightfastness characteristics can be provided through manufacture with certain polymeric colorants that include poly(oxyalkylene) groups thereon. Fabric articles comprising such novel thermoplastic fibers and/or yarns are also encompassed within this invention. DISCUSSION OF THE PRIOR ART [0002] All U.S. patents cited below are herein entirely incorporated by reference. [0003] Thermoplastic fibers have been utilized many years for myriad different fabric and textile applications. In particular, polyolefin, polyester, and polyamide fibers have been prominent as replacements for naturally occurring fibers (such as cotton and wool, for instance) due to lower costs, more reliability in supply, physical properties, and other like benefits. Colorations have been available for such thermoplastic, synthetic fibers in order to provide aesthetic, identification, and other properties. Such colorations have been mostly provided through pigments that thoroughly color the target fibers and exhibit sufficiently high lightfastness and crocking characteristics that use thereof has not been curtailed. Dyeing within baths is available for already-formed fabrics (such as knit, woven, and/or non-woven textiles), if a solid color is desired, and also for yarns with selected properties through package dyeing procedures. However, accent yarns or other fibers that require individual colorations requires coloring during production. In addition, some polymers such as polypropylene, polyethylene, etc., have not been heretofore able to accept dyes of any kind, and have thus been colored with pigment. Thus, although such pigment colorants are prevalent and generally effective at providing color within such thermoplastic fibers, there are certain drawbacks for which improvements have been unavailable. For example, pigments are notoriously capable of staining fiber manufacturing/extrusion machinery such that control of discolorations within subsequently produced fibers is rather difficult, and the time required to change colors is high. Also, pigments impart a dulling appearance, a lack of brightness, and a low luster, all believed to be due to the solid nature of such coloring agents. In addition, pigment size and dispersion limits the processability of small fibers, which are desirable for their improved touch and feel. Thus, improvements in such areas are desirable for coloring agents to be introduced within thermoplastic fibers. [0004] In particular, it has been found that improvements in coloring individual polyolefin fibers are needed. For instance, there has been a continued desire to utilize low denier polypropylene fibers in various different products, such as apparel (due to highly effective soft hand properties), and the like. Polyolefin fibers exhibit excellent strength characteristics, highly desirable hand and feel, and do not easily degrade or erode when exposed to certain “destructive” chemicals. However, even with such impressive and beneficial properties and an abundance of polyolefin (such as polypropylene, polyethylene, and the like), which is relatively inexpensive to manufacture and readily available as a petroleum refinery byproduct, such fibers are not widely utilized in products that require fiber and/or yarn colorations therein. Specifically, although polyesters (such as polyethylene terephthalate, or PET) and polyamides (such as nylons) are generally more expensive to manufacture, such fibers do not exhibit the same unacceptable color disadvantages inherent within polyolefins. This is due in large part to the difficulties inherent in providing sufficiently bright colorations within such target polyolefin fibers and/or yams in general. Thus, it is imperative to provide remedies to such issues to permit utilization of such lower cost polymer materials in greater varieties of end-uses. [0005] Pigments, the most prevalent of polyolefin fiber colorants utilized throughout the fabric industry, as noted above, are, as is well-known, solid particles that require a relatively high amount to provide sufficiently deep colorations within such target materials. Because such pigments exhibit colorations within the discrete areas in which they are actually present, complete pigment presence is required to fully color such target fibers and/or yams. If certain discrete areas of such target materials do not include any or insufficient amounts of pigments, streaks, uneven colorations, and other aesthetically displeasing results will most likely result. Hence, proper color provision via pigment presence within polyolefin fibers and/or yarns requires large amounts of such solid particles to accord the needed level of colorations therein. However, with such a large amount of pigment present within such target fibers and/or yarns comes an inevitable dull appearance as well. Without intending to be limited to any specific scientific theory, it has now been hypothesized by the inventors that such a dull appearance is attributable to the lack of transparency through the target fiber and/or yarn within which such pigments are added. The solid nature of such pigment particles basically appears to fill the entire fiber and/or yarn to the extent that light cannot pass through easily. Thus, the visible color provided by the fiber and/or yarn is limited to that portion of the scattered light that is reflected back to the viewer alone. As such, the color appears dull to the eye thereby compromising the resultant brightness effect of the fiber, and the ultimate fabric within which such a fiber is incorporated. Thus, there exists the need to provide a distinct improvement on dullness (brightness) in this type of situation in order to permit utilization of more brightly colored polyolefin fibers and/or yarns in order to permit, in turn, more aesthetically pleasing fabric articles from a coloration perspective. Furthermore, and just as important, such pigments are extremely difficult to purge from within manufacturing machinery, particularly within fiber extrusion units, such that once a new color is desired for target fiber materials, extensive purging is required for proper cleaning. Such cleaning is generally quite extensive and complicated since a small amount of residual pigment anywhere within the machinery can discolor any amount of extruded fiber therein. Thus, utilization of either potentially harmful solvents, in-depth and invasive cleaning procedures throughout the entire unit, and/or wasteful flushing processes that also potentially result in pigment effluent production within wastewater, and the norm rather than the exception for pigment-colored polypropylene methods. [0006] Dyes have also been utilized to color not only polyolefin fibers and/or yams, but also materials such as nylon, polyesters, cotton, and other fiber types. As noted above, in general, polyolefins are an economically superior fiber as compared with other synthetic types (polyesters, nylons, for example); however, its widespread use has been limited due to such issues as this coloration problem. Thus, although dyes have provided bright colorations in these other types of fibers, extraction and lightfastness issues have, again, severely limited utilization of such coloring agents within polyolefins. In essence, such soluble coloring agents do not react readily within polyolefin without exhibiting migration and extraction over time. Polyesters and nylons, as examples, include reactive groups that permit reaction therein with dyes (sulfonated types, for example) and which in turn do not exhibit appreciable extraction as a result. Within polyolefins, to the contrary, extraction levels are quite high for such dyes and thus unevenness in color, streaking, if not complete loss in color, are typical results. This problem is further amplified when fabrics made therefrom such dyed polyolefins are subjected to laundering treatments. Lightfastness (the ability of the target fibers and/or yams to retain their desired color levels, if not colors at all) are generally unacceptable as well when dyes are utilized without having excessive amounts of protecting agents (UV absorbers, for example) added in addition. Furthermore, the same machinery staining issues and potential wastewater problems are present with dyes as well, albeit to a lesser degree because of the liquid nature of such coloring agents. In any event, a certain degree of difficulty still exists within liquid dye processing within polyolefin fiber and/or yarn manufacturing (extruding, for example) due to such staining characteristics. Thus, as for pigments above, efficiency is compromised during fiber manufacture such that any cost benefits of utilizing polyolefin as compared with other synthetic fiber and/or yam types are reduced to a level that is unacceptable for displacement within the fabric industry. [0007] In addition, with pigment coloring of fibers, the pigments are normally matched to a standard shade in a high concentration masterbatch that is then diluted with uncolored polymer during the fiber manufacture. As such, if there is a problem or mismatch between the color masterbatch, there is only limited adjustment available at the fiber manufacturing stage. This often necessitates re-manufacture of the masterbatch, adding expense and delaying the manufacturing process. [0008] All in all, it is evident that polyolefin has suffered from coloring limitations in the past such that displacement of more expensive fiber types has not been forthcoming and that the standard coloring agents utilized today have neither imparted the necessary brightness, extraction levels, lightfastness properties, and low staining characteristics that appear to be the main obstacles to more widespread use of colored polypropylene fibers within the fabric industry. To date, there simply has not been any coloring agent that has accorded necessary bright colorations, excellent low (if not nonexistent) extraction levels, and superior lightfastness results within the polypropylene fiber and/or yarn industry. DESCRIPTION OF THE INVENTION [0009] It is thus an object of the invention to provide thermoplastic (such as polypropylene, as one non-limiting example) fibers and/or yams that exhibit extremely bright and aesthetically pleasing colorations as compared to pigmented products. A further object of the invention is to provide such colorations that are of very low, if nonexistent, extraction. A further object of the invention is to provide a specific method for the production of brightly colored thermoplastic fibers that permits quick and efficient changeover from one colorant to another. Additionally, another object of this invention is to provide a brightly colored thermoplastic fiber and/or yam that exhibits outstanding lightfastness properties, either alone or in the presence of minimal amounts of UV absorber additives. Another object of the invention is to provide a process for manufacturing fibers using liquid colors in which the shade can be adjusted to match some standard. [0010] Accordingly, this invention encompasses a colored thermoplastic fiber compromising a liquid colorant present therein in a rod-like configuration. Furthermore, this invention encompasses a colored thermoplastic fiber including at least one liquid colorant therein, wherein said at least one liquid colorant therein exhibits a very low extraction and crocking level therefrom. Additionally, this invention encompasses a method of producing a colored thermoplastic fiber including the steps of a) providing a molten thermoplastic formulation, optionally including colored thermoplastic concentrates therein, wherein said concentrates comprise at least one liquid polymeric colorant; and b) extruding said thermoplastic formulation of step “a” within a fiber extrusion line to form a colored thermoplastic fiber, wherein, optionally at least one liquid polymeric colorant is simultaneously injected within said fiber extrusion line during extrusion of said thermoplastic formulation of step “a”; and. Optionally, this process has the additional steps of providing multiple liquid color constituents in step “a” or “b”, matching the resulting fibers to a standard, and adjusting the ratio of the multiple liquid color constituents so provided to adjust the color of the resulting fiber to match the standard. This invention also encompasses the formation of a colored film including such liquid polymeric colorants, and the formation of colored tape fibers therefrom. [0011] As used herein, the term “thermoplastic” is intended to mean a polymeric material that will melt upon exposure to sufficient heat but will retain its solidified state, but not prior shape without use of a mold or like article, upon sufficient cooling. Specifically, as well, such a term is intended solely to encompass polymers meeting such a broad definition that also exhibit either crystalline or semi-crystalline morphology upon cooling after melt-formation through the use of the aforementioned mold or like article. For this invention, however, the thermoplastic is to be utilized to from fibers and/or yarns through any number of techniques, including, without limitation, extrusion (for multifilament and monofilament types), spinning, water- and/or air-quenching, spun-bonded and/or melt-blown non-woven products, staple fibers, bicomponent/splittalbe fibers, tape and/or ribbon fibers (through slit film procedures, as one example), and the like. Particular types of polymers contemplated within such a definition include, without limitation, polyolefins (such as polyethylene, polypropylene, polybutylene, and any combination thereof), polyamides (such as nylon), polyurethanes, polyesters (such as polyethylene terephthalate), polylactic acids, and any copolymers of these broad types, either within the same classification or not. Polypropylene fibers are most preferred, although polyesters are preferred as well. The particular polypropylene fiber and/or yam of this invention may be of any denier, including microdeniers (below about 1.5 denier per fiber) or higher deniers 1.5 denier per fiber or higher), as merely examples. [0012] The target fibers and/or yams may also be textured in any manner commonly followed for polypropylene materials. One example of this is false-twist texturing, in which a twist is imparted to the fiber through the use of spindles, and while the fiber is in the twisted state it is heated and then cooled to impart into the individual filaments a memory of the twisted state. The yam is then untwisted, but retains bulk due to the imparted memory. In another texturing embodiment, known as bulked continuous filament (BCF), the yam is pushed with air jets into a stuffer box where it is crowded in a non-uniform state with other fibers and heated to retain the memory of this non-uniform state. The yam is then cooled, but again retains bulk due to the imparted memory. Of course, other texturing methods, such as air texturing, gear texturing, and the like, may be used. [0013] The term “polypropylene” is intended to encompass any polymeric composition comprising propylene monomers, either alone or in mixture or copolymer with other randomly selected and oriented polyolefins, dienes, or other monomers (such as ethylene, butylene, and the like). Such a term also encompasses any different configuration and arrangement of the constituent monomers (such as syndiotactic, isotactic, and the like). Thus, the term as applied to fibers is intended to encompass actual long strands, tapes, threads, and the like, of drawn polymer. The polypropylene may be of any standard melt flow (by testing); however, standard fiber grade polypropylene resins possess ranges of Melt Flow Indices between about 1 and 1000. [0014] Contrary to standard manufacturing procedures and techniques for plaques, containers, sheets, and the like (such as taught within U.S. Pat. No. 4,016,118 to Hamada et al., for example), fibers clearly differ in structure since they must exhibit a length that far exceeds its cross-sectional area (such, for example, its diameter for round fibers). Fibers are extruded and drawn; articles are blow-molded or injection molded, to name two alternative production methods. Also, the crystalline morphology of polypropylene within fibers is different than that of standard articles, plaques, sheets, and the like. For instance, the dpf of such polypropylene fibers is at most about 5000; whereas the dpf of these other articles is much greater. Polypropylene articles generally exhibit spherulitic crystals while fibers exhibit elongated, extended crystal structures. Thus, there is a great difference in structure between fibers and polypropylene articles such that any predictions made for spherulitic particles (crystals) of colored polypropylene articles do not provide any basis for determining the effectiveness of coloring agents as additives within polypropylene fibers. For instance, plaques made with pigments can exhibit bright, deep shades, and still appear transparent. In fiber form, dullness (low brightness) and opacity are prominent when deep shades of pigmented fibers are produced. Thus, the significant differences in form and structure between sheet-like articles and fibers (and/or yarns) of the same thermoplastic, make it difficult to predict how effective a specific coloring agent may perform within one through knowledge of the other. [0015] The coloring agents particularly useful within this invention are those that are liquid in nature, preferably, though not necessarily, polymeric in nature [i.e., poly(oxyalkylenated)] to the extent that, upon introduction within such target polypropylene fibers, extraction therefrom is severely limited, if not nonexistent. The term “liquid” is intended to mean that such colorants are liquid at room temperature and standard pressure (25° C. at 1 atmosphere). Example colorants that meet these limitations (and thus are defined by the term “liquid polymeric colorants” herein) are those that are available from Milliken & Company under the tradename CLEARTINT®. Alternatively, liquid dyestuffs may also be utilized, although less preferred than polymeric types. [0016] The preferred colorants in this general class are represented by the following formula (I): (I) R{A[(B) n ] m } x wherein R is an organic chromophore; A is a linking moiety in said chromophore selected from the group consisting of N, O, S, SO 2 N, and CO 2 ; B is an alkyleneoxy constituent contains from 2 to 4 carbon atoms; n is an integer of from 2 to about 500; m is 1 when A is O, S, or CO 2 , and m is 2 when A is N or SO 2 N; and x is an integer of from 1 to about 5. [0024] The molecular weight of such colorants are at least 2000 and, due to the high oxyalkylenation present, are highly water soluble and liquid at room temperature. The organic chromophore is, more specifically, one or more of the following types of compounds: azo, diazo, disazo, trisazo, diphenylmethane, triphenylmethane, xanthene, nitro, nitroso, acridine, methine, styryl, indamine, thiazole, oxazine, stilbene, or anthraquinone. In an alternative embodiment, the chromophore may be optically inactive, at least within the visible spectrum, but absorb uv radiation, as one example, thereby imparting ultraviolet protection to the target fibers. Preferably, R is one or more of azo, diazo, triphenylmethane, methine, anthraquinone, or thiazole based compounds. Such a group may produce coloring effects that are evident to the eye; however, optical brightening chromophores are also contemplated in this respect. Group A is present on group R and is utilized to attach the polyoxyalkylene constituent to the organic chromophore. Nitrogen is the preferred linking moiety. The polyoxyalkylene group is generally a combination of ethylene oxide and propylene oxide monomers. Preferably propylene oxide is present in the major amount, and most preferably the entire polyoxyalkylene constituent is propylene oxide. [0025] The preferred number of moles (n) of polyoxyalkylene constituent per polyoxyalkylene chain is from 2 to 50, more preferably from 10 to 30. Also, preferably two such polymeric chains are present on each polymeric colorant compound (x, above, is preferably 2). In actuality, the number of moles (n) per polymeric chain is an average of the total number present since it is very difficult to control the addition of specific numbers of moles of alkyleneoxy groups. The Table below lists the particularly preferred colorants (with the range of alkoxylation present on the colorant listed due to the inexactness of production of specific chain lengths) for utilization in relation to Structure (I), above: COLORANT TABLE Preferred Poly(oxyalkylenated) Colorants Col. # R A B(with moles) m x Color 1 Methine N 6-8 EO; 12-15PO 2 1 Yellow 2 Benzothiazole N 6-8 EO; 10-12 PO 2 1 Red diazo 3 Triphenyl- N 2-4 EO; 12-15 PO 2 2 Cyan methane 4 Amino- N 10-12 EO; 12-15 PO 2 1 Violet thiophene Diazo 5 Phenyl Diazo N 8-10 EO; 10-12 PO 2 2 Orange Such colorants provide the aforementioned, highly desirable, low extraction properties, as well as the significant bright colorations as compared with pigmented fibers. [0027] Without intending on being limited to any specific scientific theory, it appears that such colorants are capable of complete introduction within the target polypropylene fibers to the extent that transparent thin rod-like configurations of the liquid colorants are present within the fibers after extrusion. Such configurations thus permit an even distribution of color throughout the target fiber, and, apparently, with a strong cohesive nature while present therein said fibers, such thin rod-like configurations are not amenable to easy migration from therein either. In other words, although small openings may exist within and/or at the surface of such extruded polypropylene fibers, the rod-like configurations of the colorants therein do not break, but appear to keep there rod-like appearance and the liquid colorant thus does not migrate or escape through such surface openings, even if such fibers come into contact with adhesive surfaces themselves. Such a physical appearance is shown within the drawings discussed below. In essence, empirically the liquid colorants (polymerics, preferably, although possible liquid dyestuffs may function similarly) will appear as long strands of color within extruded fibers if the methods of producing disclosed herein are employed when viewed at proper magnifications (such as from 300 to 1000X; proper viewing may be seen most readily between 500 and 600X). Cross-sectionally, such long strands will appear as small dots within the target fibers. These dots will be the tops of these rod-like structures which can then be noticed from side views as the aforementioned strands. Thus, since these strands are basically pools of liquid color stretched during the fiber extrusion process, these structures will exhibit aspect ratios (length to diameter) of from 10:1 to 500,000:1, preferably from 50:1 to 100,000:1, more preferably from 50:1 to 10,000:1, and most preferably from 100:1 to 1,000:1. Thus, the term rod-like is intended to encompass these high aspect ratio strands of liquid color within target thermoplastic fibers. Since the thermoplastic will be colorless, or at least sufficiently different in color from the added liquid coloring agent, it is relatively easy to view such rod-like structures through side views coupled with cross-sectional views. Again, the continuous strands of color or easily viewed from the side; the “dots” of tops of different strands are easily viewed in cross-section. [0028] This rod-like configuration also provides effective and even colorations throughout such target fibers because of the ability of light to pass through such fibers and transparent film-like structures simultaneously. Thus, light is transmitted through such fibers as well as absorbed by the colorants therein due to the transparent appearance of the resultant fiber. The resultant appearance is, unexpectedly, very bright in nature, much more so, for example, than the empirical appearance of the above-discussed pigmented fibers that require a large amount of solid particles therein to provide even colorations throughout, but which, as a result, also exhibit very dull appearances as well. The colored transparent nature available with these inventive liquid colorants produces the bright colorations, much like a colored filter placed over a light imparts a bright, colored effect when the light shines therethrough. The fibers themselves are generally solid in nature, and, cross-sectionally, appear as round, triangular, square, and/or rectangular in shape, but may have any cross sectional shape, such as octalobal which is popular in carpet fibers. [0029] Such fibers (or yams comprising such fibers) may also include the presence of certain compounds that quickly and effectively provide rigidity and/or tensile strength to the target polypropylene fiber to a level heretofore unavailable, particularly in terms of permitting high-speed spinning for greater efficiency in fiber and/or yam manufacturing. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a~manner, the nucleator compounds provide nucleation sites for polypropylene crystal growth which, in turn, appear to provide thick lamellae within the fibers themselves which, apparently (without intending on being bound to any specific scientific theory) increase the processability of the target fibers to such a degree that the tensions associated with high-speed spinning can easily be withstood. The preferred nucleating compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as sodium benzoate, certain sodium and lithium phosphate salts (such as sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA- 11or NA-21), zinc glycerolate, and others. Sodium benzoate, in general, is not preferred because it is known to outgas corrosive benzoic acid, among other deficiencies. Also, the amount of nucleating agent present within the inventive fiber is at least 10 ppm; preferably this amount is at least 100 ppm; and most preferably is at least 1250 ppm. Any amount of such a nucleating agent should suffice to provide the desired shrinkage rates after heat-setting of the fiber itself; however, excessive amounts (e.g., above about 10,000 ppm and even as low as about 6,000 ppm) should be avoided, primarily due to costs, but also due to potential processing problems with greater amounts of additives present within the target fibers. [0030] Another potentially preferred class of nucleators suitable for incorporation within the inventive colored fibers include saturated metal or organic salts of bicyclic dicarboxylates, preferably saturated metal or organic salts of bicyclic dicarboxylates, preferably, bicyclo[2.2.1 ]heptane-dicarboxylates, or, generally, compounds conforming to Formula (I) wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are individually selected from the group consisting of hydrogen, C 1 -C 9 alkyl, hydroxy, C 1 -C 9 alkoxy, C 1 -C 9 alkyleneoxy, amine, and C 1 -C 9 alkylamine, halogen, phenyl, alkylphenyl, and geminal or vicinal carbocyclic having up to nine carbon atoms, R′ and R″ are the same or different and are individually selected from the group consisting of hydrogen, C 1 -C 30 alkyl, hydroxy, amine, polyamine, polyoxyamine, C 1 -C 30 alkylamine, phenyl, halogen, C 1 -C 30 alkoxy, C 1 -C 30 polyoxyalkyl, C(O)—NR 11 C(O)O—R′″, and C(O)O—R′″, wherein R 11 is selected from the group consisting of C 1 -C 30 alkyl, hydrogen, C 1 -C 30 alkoxy, and C 1 -C 30 polyoxyalkyl, and wherein R′″ is selected from the group consisting of hydrogen, a metal ion (such as, without limitation, Na + , K + , Li + ,Ag + and any other monovalent ions), an organic cation (such as ammonium as one non-limiting example), polyoxy-C 2 -C 18 -alkylene, C 1 -C 30 alkyl, C 1 -C 30 alkylene, C 1 -C 30 alkyleneoxy, a steroid moiety (for example, cholesterol), phenyl, polyphenyl, C 1 -C 30 alkylhalide, and C 1 -C 30 alkylamine; wherein at least one of R′ and R″ is either C(O)—NR 11 C(O)O—R′″ or C(O)O—R′″, wherein if both R′ and R″ are C(O)O—R′″ then R′″ both R′ and R″ may be combined into a single bivalent metal ion (such as Ca 2+ , as one non-limiting example) or a single trivalent metal overbase (such as Al—OH, for one non-limiting example). Preferably, R′ and R″ are the same and R′″ is either Na + or combined together for both R′ and R″ and Ca 2+ . Other possible compounds are discussed in the preferred embodiment section below. [0032] Preferably, as noted above, such a compound conforms to the structure of Formula (II) wherein M 1 and M 2 are the same or different and are independently selected from the group consisting of metal or organic cations or the two metal ions are unified into a single metal ion (bivalent, for instance, such as calcium, for example), and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are individually selected from the group consisting of hydrogen, C 1 -C 9 alkyl, hydroxy, C 1 -C 9 alkoxy, C 1 -C 9 alkyleneoxy, amine, and Cl-C 9 alkylamine, halogen, phenyl, alkylphenyl, and geminal or vicinal carbocyclic having up to 9 carbon atoms. Preferably, the metal cations are selected from the group consisting of calcium, strontium, barium, magnesium, aluminum, silver, sodium, lithium, rubidium, potassium, and the like. Within that scope, group I and group II metal ions are generally preferred. Among the group I and II cations, sodium, potassium, calcium and strontium are preferred, wherein sodium and calcium are most preferred. Furthermore, the M 1 and M 2 groups may also be combined to form a single metal cation (such as calcium, strontium, barium, magnesium, aluminum, including monobasic aluminum, and the like). Although this invention encompasses all stereochemical configurations of such compounds, the cis configuration is preferred wherein cis-endo is the most preferred embodiment. The preferred embodiment polyolefin articles and additive compositions for polyolefin formulations comprising at least one of such compounds, broadly stated as saturated bicyclic carboxylate salts, are also encompassed within this invention. [0034] As they apply to this invention, then, the terms “nucleators”, “nucleator compound(s)”, “nucleating agent”, and “nucleating agents” are intended to generally encompass, singularly or in combination, any additive to polypropylene that produces nucleation sites for polypropylene crystals from transition from its molten state to a solid, cooled structure. Hence, since the polypropylene composition (including nucleator compounds in certain cases) must be molten to eventually extrude the fiber itself, the nucleator compound will provide such nucleation sites upon cooling of the polypropylene from its molten state. The only way in which such compounds provide the necessary nucleation sites is if such sites form prior to polypropylene recrystallization itself. Thus, any compound that exhibits such a beneficial effect and property is included within this definition. Such nucleator compounds more specifically include dibenzylidene sorbitol types, including, without limitation, dibenzylidene sorbitol (DBS), monomethyldibenzylidene sorbitol, such as 1,3:2,4-bis(p-methylbenzylidene) sorbitol (p-MDBS), dimethyl dibenzylidene sorbitol, such as 1,3:2,4-bis(3,4-dimethylbenzylidene) sorbitol (3,4-DMDBS); other compounds of this type include, again, without limitation, sodium benzoate, NA-11, NA-21, bicyclic dicarboxylate salts, and the like. The concentration of such nucleating agents (in total) within the target polypropylene fiber is at least 100 ppm, preferably at least 1250 ppm. Thus, from about 100 to about 5000 ppm, preferably from about 500 ppm to about 4000 ppm, more preferably from about 1000 ppm to about 3500 ppm, still more preferably from about 1500 ppm to about 3000 ppm, even more preferably from about 2000 ppm to about 3000 ppm, and most preferably from about 2500 to about 3000 ppm. [0035] Also, without being limited by any specific scientific theory, it appears that the potential, but not required, nucleators which perform the best are those which exhibit relatively high solubility within the propylene itself Thus, compounds which are readily soluble, such as 1,3:2,4-bis(p-methylbenzylidene) sorbitol provides the lowest shrinkage rate for the desired polypropylene fibers. The DBS derivative compounds are considered the best shrink-reducing nucleators within this invention due to the low crystalline sizes produced by such compounds. Other nucleators, such as NA-11, also impart acceptable characteristics to the target polypropylene fiber in terms of, for example, withstanding high speed spinning tensions; however, apparently due to poor dispersion of NA-11 in polypropylene and the large and varied crystal sizes of NA-11 within the fiber itself, the performance is less consistent than for the highly soluble, low crystal-size polypropylene produced by well-dispersed 3,4-DMDBS or, preferably, p-MDBS. [0036] It has been determined that the nucleator compounds that exhibit good solubility in the target molten polypropylene resins (and thus are liquid in nature during that stage in the fiber-production process) provide more effective fiber properties for withstanding high speed spinning tension levels. Thus, substituted DBS compounds (including DBS, 3,4-DMDBS, and, preferably p-MDBS) appear to provide fewer manufacturing issues as well as lower shrink properties within the finished polypropylene fibers themselves. Although 3,4-DMDBS is preferred for such low denier fibers, any of the above-mentioned nucleators may be utilized within this invention. Mixtures of such nucleators may also be used during processing in order to provide such spinning efficiencies and low-shrink properties as well as possible organoleptic improvements, facilitation of processing, or cost. [0037] In addition to those compounds noted above, sodium benzoate and NA-11 are well known as nucleating agents for standard polypropylene compositions (such as the aforementioned plaques, containers, films, sheets, and the like) and exhibit excellent recrystallization temperatures and very quick injection molding cycle times for those purposes. The dibenzylidene sorbitol types exhibit the same types of properties as well as excellent clarity within such standard polypropylene forms (plaques, sheets, etc.). For the purposes of this invention, it has been found that the dibenzylidene sorbitol types are preferred as nucleator compounds within the target polypropylene fibers. [0038] Furthermore, such fibers may include other coloring agents, such as pigments, titanium dioxide, and the like, as well as fixing agents for lightfastness purposes. To that end, certain ultraviolet absorbers provide excellent protection from ultraviolet radiation and thus aids in reducing, if not preventing, color degradation due to such exposure. Any type of ultraviolet absorber compound or formulation that is dispersible within thermoplastics may be utilized within this invention. However, some non-limiting examples of such components include phenolic antioxidants, such as HOSTANOX® 245, O10, O14, O16, O3, and blends with HOSTANOX® M, all available from Clariant; processing stabilizers, such as HOSTANOXS PAR 24, SANDOSTAB® PEPQ (from Clariant), and blends with SANDOSTAB® QB; sulfur-containing co-stabilizers, such as HOSTANOX® SE 4 or SE 10; metal deactivators, such as HOSTANOX® OSP 1; light stabilizers, such as NYLOSTAB® S-EED (from Clariant, as well); and straightforward ultraviolet absorbers, such as CHIMASSORB®D 2020, 944, 119, and/or 119FL, TINUVIN® 783, 353, 234, 1577, and/or 622 (all available from Ciba Specialty Chemicals). Preferred is TINUVIN® 783 for such a purpose. [0039] In terms of providing effective colorations for brightness, it is further desirable to avoid pigments as nucleating agents; however, if desired, slight amounts of such pigments may be added for nucleation or coloration purposes if such are desired end results. Other additives may also be present, including antistatic agents, brightening compounds, clarifying agents, antioxidants, antimicrobials (preferably silver-based ion-exchange compounds, such as ALPHASAN® antimicrobials available from Milliken & Company), fillers, and the like. Furthermore, any fabrics made from such inventive fibers may be, without limitation, woven, knit, non-woven, in-laid scrim, any combination thereof, and the like. Additionally, such fabrics may include fibers other than the inventive polypropylene fibers, including, without limitation, natural fibers, such as cotton, wool, abaca, hemp, ramie, and the like; synthetic fibers, such as polyesters, polyamides, polyaramids, other polyolefins (including non-low-shrink polypropylene), polylactic acids, and the like; inorganic fibers such as glass, boron-containing fibers, and the like; and any blends thereof. [0040] In addition, this invention can be practiced with any melt extrudable thermoplastic polymer, such as polyester, nylon, poly lactic acid, and the like, with similar results. [0041] Such inventive fibers can be included in a fabric such as a carpet, upholstery fabric, woven fabric, knit fabric, nonwoven, pile fabric, netting, and the like. In addition, these fibers can be combined in such fabric structures as accent yams, especially if the additional non-inventive fibers are dye accepting. In such a case, the inventive yarns provide accent yams with bright appearance. In addition, individual yarns may be incorporated within non-fabric structures, such as, as one non-limiting example, fishing lures, and other end-uses in which brightly colored strong fibers are desirable. [0042] Inventive yams and fibers can be used in any standard textile process, including, without limitation, such methods as yam texturing processes such as stuffer box, bulk continuous filament (BCF), air jet texturing, twisting, false twist testing, and the like. They can also be combined with other yams or used in other processes to make “elegant” or “fancy” yams, such as chenille, slub yams, stria yarns, etc., with all of the incumbent advantages of combining the technologies. In addition, the transparent nature of the color can be used in light weight fabrics to make colored transparent fabrics such as may be desirable to show a pattern on a substrate covered by the inventive fabric. BRIEF DESCRIPTION OF THE DRAWINGS [0043] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate a potentially preferred embodiment of producing the inventive low-shrink polypropylene fibers and together with the description serve to explain the principles of the invention wherein: [0044] FIG. 1 is a schematic of the potentially preferred method of producing colored polypropylene fibers through typical spinning machinery. [0045] FIG. 2 is a schematic of the potentially preferred method of producing colored polypropylene tape fibers. [0046] FIG. 3 is a schematic of the potentially preferred method of producing colored polypropylene fibers through typical high-speed spinning machinery. [0047] FIG. 4 is a side-view color microphotograph of a green-colored inventive polypropylene fiber magnified at 565X colored with a liquid polymeric colorant. [0048] FIG. 5 is a side-view color microphotograph of a comparative green-colored polypropylene yarn magnified at 565X having pigments present throughout. [0049] FIG. 6 is a cross-sectional view of a plurality of green-colored inventive polypropylene fibers magnified at 565X colored with a liquid polymeric colorant. DETAILED DESCRIPTION OF THE DRAWING AND OF THE PREFERRED EMBODIMENT [0050] FIG. 1 depicts the non-limiting preferred procedure followed in producing the inventive low denier polypropylene fibers. The entire fiber production assembly 10 comprises an extruder 11 including a metering pump (not illustrated) for introduction of specific amounts of polymer into the extruder 11 (to control the denier of the ultimate target manufactured fiber and/or yarn) which also comprises four [five] different zones 12 , 14 , 16 , 18 , 20 through which the polymer (not illustrated) passes at different, increasing temperatures. The molten polymer is mixed with the liquid polymeric colorant (here, Example 1 from the Colorant Table, above, preferably) within a mixer zone 22 . Basically, the polymer (not illustrated) is introduced within the fiber production assembly 10 , in particular within the extruder 11 . The temperatures, as noted above, of the individual extruder zones 12 , 14 , 16 , 18 , 20 and the mixing zone 22 are as follows: first extruder zone 12 at 210° C., second extruder zone 14 at 220° C., third extruder zone 16 at 230° C., fourth extruder zone 18 at 235° C., [fifth extruder zone 20 at 240° C.,] and mixing zone 22 at 240° C. The molten polymer (not illustrated) then moves into a spinneret area 24 set at a temperature of 240° C. for strand extrusion. All such temperatures may be modified as needed, and these levels are non-limiting and simply potentially preferred. The fibrous strands 28 then pass through an air-blown treatment shroud [area] 26 set at a temperature of 175° C. and then through a treatment area 29 whereupon a lubricant, such as water or an oil, is applied thereto the strands 28 . The strands 28 are then collected into a bundle 30 via a take-up roll 32 to form a multifilament yarn 33 which then passes to a series of tensioning rolls 34 , 36 prior to drawing. The yarn 33 then passes through a series of two different sets of draw rolls 38 , 40 , 42 , 44 which increase the speed of the collected finished strands 33 as compared with the speed of the initially extruded strands 28 . The finished strands 33 extend in length due to a greater pulling speed in excess of such an initial extrusion speed within the extruder 11 . The strands 33 are then passed through a series of relax rolls 46 , 48 and ultimately to a winder 50 for ultimate collection on a spool (not illustrated). The speed of the winder 50 ultimately dictates the speed and efficiency of the entire apparatus in terms of permitting high speed manufacturing and spinning (drawing) with minimal, if any, breakage of the target fibers during such a procedure. The draw rolls are heated to a very low level as follows: first draw rolls 38 , 40 60-70° C. and the second set of draw rolls 42 , 44 80-90° C., as compared with the remaining areas of high temperature exposure as well as comparative fiber drawing processes. The draw rolls 38 , 40 , 42 , 44 individually and, potentially independently rotate at a speed of from about 1000 meters per minute to as high as about 5000 meters per minute. The second draw rolls 42 , 44 generally rotate at a higher speed than the first in excess of about 800 meters per minute up to 1000 meters per minute over those of the first set. [0051] FIG. 2 depicts the non-limiting preferred procedure followed in producing the inventive low-shrink polypropylene tape fibers. The entire fiber production assembly 110 comprises a mixing manifold 111 for the incorporation of molten polymer and additives (such as the aforementioned nucleator compound) which then move into an extruder 112 . The extruded polymer is then passed through a metering pump 114 to a die assembly 116 , whereupon the film 117 is produced. The film 117 then immediately moves to a quenching bath 118 comprising a liquid, such as water, and the like, set at a temperature from 5 to 95° C. (here, preferably, about room temperature). The drawing speed of the film at this point is dictated by draw rolls and tensionsing rolls 120 , 122 , 124 , 126 , 128 set at a speed of about 100 feet/minute, preferably, although the speed could be anywhere from about 20 feet/minute to about 200 feet/minute, as long as the initial drawing speed is at most about ⅕ th that of the heat-draw speed later in the procedure. The quenched film 119 should not exhibit any appreciable crystal orientation of the polymer therein for further processing. Sanding rolls 130 , 131 , 132 , 133 , 134 , 135 , may be optionally utilized for delustering of the film, if desired. The quenched film 119 then moves into a cutting area 36 with a plurality of fixed knives 138 spaced at any distance apart desired. Preferably, such knives 138 are spaced a distance determined by the equation of the square root of the draw speed multiplied by the final width of the target fibers (thus, with a draw ratio of 5:1 and a final width of about 3 mm, the blade gap measurements should be about 6.7 mm). Upon slitting the quenched film 119 into fibers 140 , such fibers are moved uniformly through a series of nip and tensioning rolls 142 , 143 , 144 , 145 prior to being drawn into a high temperature oven 146 set at a temperature level of between about 280 and 350° C., in this instance about 310° C., at a rate as noted above, at least 5 times that of the initial drawing speed. Such an increased drawing speed is effectuated by a series of heated drawing rolls 141 , 150 (at temperatures of about 360-400° F. each) over which the now crystal-oriented fibers 154 are passed. A last tensioning roll 152 leads to a spool (not illustrated) for winding of the finished tape fibers 154 . [0052] FIG. 3 depicts the non-limiting preferred procedure followed in producing the inventive low denier polypropylene fibers. The entire fiber production assembly 210 comprises an extruder 211 including a metering pump (not illustrated) for introduction of specific amounts of polymer into the extruder 211 (to control the denier of the ultimate target manufactured fiber and/or yarn) which also comprises five different zones 212 , 214 , 216 , 218 , 220 through which the polymer (not illustrated) passes at different, increasing temperatures. The molten polymer is mixed with the nucleator compound (also molten) within a mixer zone 222 . Basically, the polymer (not illustrated) is introduced within the fiber production assembly 210 , in particular within the extruder 211 . The temperatures, as noted above, of the individual extruder zones 212 , 214 , 216 , 218 , 220 and the mixing zone 22 are as follows: first extruder zone 212 at 205° C., second extruder zone 214 at 215° C., third extruder zone 216 at 225° C., fourth extruder zone 218 at 235° C., fifth extruder zone 220 at 240° C., and mixing zone 222 at 245° C. The molten polymer (not illustrated) then moves into a spinneret area 224 set at a temperature of 250° C. for strand extrusion. All such temperatures may be modified as needed, and these levels are non-limiting and simply potentially preferred. The fibrous strands 228 then pass through an air-blown treatment area 226 and then through a treatment area 229 whereupon a lubricant, such as water or an oil, is applied thereto the strands 228 . The strands 228 are then collected into a bundle 230 via a take-up roll 232 to form a multifilament yarn 233 which then passes to a series of tensioning rolls 234 , 236 prior to drawing. The yarn 233 then passes through a series of two different sets of draw rolls 238 , 240 , 242 , 244 which increase the speed of the collected finished strands 233 as compared with the speed of the initially extruded strands 228 . The finished strands 233 extend in length due to a greater pulling speed in excess of such an initial extrusion speed within the extruder 211 . The strands 233 are then passed through a series of relax rolls 246 , 248 and ultimately to a winder 250 for ultimate collection on a spool (not illustrated). The speed of the winder 250 ultimately dictates the speed and efficiency of the entire apparatus in terms of permitting high speed manufacturing and spinning (drawing) with minimal, if any, breakage of the target fibers during such a procedure. The draw rolls are heated to a very low level as follows: first draw rolls 238 , 240 68° C. and the second set of draw rolls 242 , 244 88° C., as compared with the remaining areas of high temperature exposure as well as comparative fiber drawing processes. The draw rolls 238 , 240 , 242 , 244 individually and, potentially independently rotate at a speed of from about 1000 meters per minute to as high as about 5000 meters per minute. The second draw rolls 242 , 244 generally rotate at a higher speed than the first in excess of about 800 meters per minute up to 1000 meters per minute over those of the first set. [0053] In FIG. 4 , the presence of rod-like structures of color is evident throughout the fiber. Such rod-like structures are basically the liquid polymeric colorants stretched in the same manner as the resin fiber is stretched during extrusion. The shear of extrusion forms long high aspect ratio rod-like configurations of liquid colorant within the target fiber. Such a rod-like structure thus imparts colorations to the target fiber while simultaneously allowing transmission of light therethrough. As such, the fiber remains transparent to light, thereby exhibiting an increased brightness and luster. Furthermore, these rod-like structures, although they remain liquid in nature, are not in individual pools of color, but are stretched in such a rod-like manner, such that the liquid component cannot be easily extracted from within the target fiber without damaging the fiber itself. [0054] In FIG. 5 , the presence of pigment particles is evident throughout the fiber. Such pigment particles are solid in nature. The color imparted to the target fiber is thus substantially reliant upon absorption of light by such solid particles. There is little chance of light transmission through the fiber such that the fiber lacks transparency. As a result, brightness and luster are compromised such that the fiber exhibits a dulling effect, particularly in comparison with the fiber of FIG. 4 . [0055] In FIG. 6 , the presence of “dots” of color can be seen within the cross-sectional views of the target fibers (as in FIG. 4 ). Such “dots” are the portions of the rod-like high aspect ratio structures of the liquid colorants that were stretched during extrusion. The plurality of “dots” thus shows the inclusion of numerous different rod-like structures throughout individuals fibers. Coupled with the side view (as in FIG. 4 ), it can be seen how a liquid coloring agent (polymeric type, preferably, though not necessarily) is stretched from a starting pool of liquid into this high aspect ratio strand (rod-like structure). [heading-0056] Inventive Fiber and Yarn Production EXAMPLE #1 Polymeric Colorant Fibers [0057] Yarns were made using a commercially available polypropylene fiber grade resin Amoco 7550 (melt flow of 18), using a standard fiber spinning apparatus as described previously. The five colorants from the COLORANT TABLE, above, were formed into 10% concentrates premixed with fiber grade polypropylene resin and fed into the hopper of the extruder during fiber extrusion. In one preferred embodiment, fiber grade resin polypropylene was fed into the extruder on an Alex James & Associates multifilament fiber extrusion line as noted above in FIG. 1 along with a 10% color concentrate including the required liquid polymeric colorants. Yarn was produced with the extrusion line conditions shown in Table 1 using a 68 hole spinneret, giving a yarn of nominally 150 denier. The godet roll temperatures were 67° C. (for 38 , 40 in FIG. 1 ), 85° C. (for 42 , 44 ), and 125° C. (for 46 , 48 ), respectively, with a nominal winder speed of about 1300 m/min. Pigmented fibers were also made for comparative purposes. [0058] The extruder and cooling conditions were as follows: Procedural Conditions Table #1 Extruder Temperature Zone #1 210° C. Extruder Temperature Zone #2 220° C. Extruder Temperature Zone #3 230° C. Extruder Temperature Zone #4 235° C. Mixer Temperature 240° C. Spinneret Temperature #1 240° C. Spinneret Temperature #2 240° C. Shroud Temperature 175° C. [0059] Winder take-up speeds of 1290 m/min with draw ratios of approximately 3.5 were utilized and deniers between 150 and 200 were produced. A minimum of 3 samples were produced with concentrations of ½ and or 1% color in the Amoco 7550 for each of the colors. Extrusion conditions and physical properties of these samples are detailed in the following tables. Additionally, comparative pigmented samples were produced with three pigments provided by Standridge Color Concentrate 86600 blue 25% GSP, fade red HUV and yellow HG 25% which are identified in the table below as blue, red and yellow pigment, respectively. Procedural Conditions Table #2 Fiber Extrusion Conditions Color Draw Heat Set Sample ID Polymer Color Level Ratio (° C.) 1 Amoco 7550 None 0 3.49 125 2 Amoco 7550 None 0 4.56 125 3 Amoco 7550 None 0 3.44 125 4 Amoco 7550 10% Colorant #3 0.5 4.56 125 5 Amoco 7550 10% Colorant #3 0.5 3.44 125 6 Amoco 7550 10% Colorant #3 0.5 3.53 125 7 Amoco 7550 10% Colorant #5 0.5 3.49 125 8 Amoco 7550 10% Colorant #5 0.5 3.44 125 9 Amoco 7550 10% Colorant #5 0.5 4.56 125 10 Amoco 7550 10% Colorant #2 0.5 3.44 125 11 Amoco 7550 10% Colorant #2 1.0 3.44 125 12 Amoco 7550 10% Colorant #2 1.0 3.44 125 13 Amoco 7550 10% Colorant #2 1.0 3.55 125 14 Amoco 7550 10% Colorant #4 0.5 3.49 125 15 Amoco 7550 10% Colorant #4 0.5 3.94 125 16 Amoco 7550 10% Colorant #4 0.5 4.56 125 17 Amoco 7550 10% Colorant #1 0.5 4.56 125 18 Amoco 7550 10% Colorant #1 0.5 3.44 125 19 Amoco 7550 10% Colorant #1 0.5 3.53 125 20 Amoco 7550 Blue Pigment 0.5 3.44 125 21 Amoco 7550 Red Pigment 0.5 3.44 125 22 Amoco 7550 Yellow Pigment 0.5 3.44 125 [0060] Experimental Table #1 Fiber Properties 3% 130 C. Denier Elongation Tenacity Modulus Shrinkage Sample ID (g/9000 m) (%) (g/den) (g/den) (%) 1 153.8 53.0 4.6 41.6 6.6 2 85.7 32.1 6.5 67.9 9.9 3 159.7 67.9 4.7 44.4 11.1 4 172.7 61.5 5.0 44.0 14.8 5 147.4 74.4 4.6 42.4 8.5 6 150.7 66.1 4.2 38.9 9.6 7 149.5 41.1 4.4 41.2 7.2 8 155.1 54.7 4.1 38.7 8.0 9 169.2 46.6 5.6 51.0 10.4 10 156.2 51.1 5.0 43.9 13.6 11 181.0 50.0 4.6 42.8 9.0 12 153.8 46.6 4.9 45.3 9.5 13 153.6 35.5 4.8 45.4 13.6 14 154.1 47.7 4.3 39.5 11.2 15 151.4 48.0 4.4 41.8 7.0 16 168.8 27.0 5.3 51.4 15.3 17 177.3 44.8 5.2 46.7 11.5 18 149.9 58.1 4.6 43.4 11.7 19 150.7 48.4 4.6 43.0 14.8 20 153.7 84.7 3.8 35.8 N/A 21 150.7 66.8 3.3 35.8 N/A 22 151.6 40.6 4.3 40.8 N/A [0061] The above samples have similar physical properties to those of fibers spun with pigments (solution dyed) in the same polypropylene resin, however the luster of the colors is significantly different. It is also important to note that the polymeric colorants are generally non-nucleating and will, under the same processing conditions have similar physical properties while the pigments (specifically the blue pigment—Sample 20) generally are nucleating which often requires the fiber spinning equipment to be operated under different conditions to obtain similar physical properties—note the higher elongation of sample 20 in comaprison to samples 21 and 22. EXAMPLE 2 Polymeric Colorant Fibers with TiO 2 and Pigments [0062] A series of polypropylene samples was produced under the standard fiber spinning conditions described in Example 1 to test the ability to combine both solid pigments and liquid polymeric colorants in the same fibers. The drawing conditions for these example yarns are detailed in the following table. Procedural Conditions Table #3 Spinning Conditions Roll Speed Roll Temperature (m/min) ° C. Feed Roll 800 Not heated Draw Roll 1 805 55 Draw Roll 2 1450 75 Draw Roll 3(A + B) 2000 120  Relax Roll 1980 Not heated [0063] Using the standard fiber spinning conditions as described above, a series of 10 experiments were performed to produce samples with liquid polymeric colorants labeled by Milliken & Company Product numbers, and TiO 2 which is commonly used in the production of thermoplastic fibers to produce dull (9% TiO 2 ) and semi-dull (3% TiO 2 ) appearance. The fibers were successfully produced at all of the conditions tested and the list of colorants, TiO 2 levels and fiber properties are detailed in the Table below using polymeric liquid colorant mixtures available from Milliken & Company under the tradename CLEARTINT®. TABLE #2 Fiber Properties Polymeric Color Concentrate 5% Secant Polymeric Color Level TiO 2 Level Denier Elongation Tenacity Modulus Sample ID (Color/Number) (%) (%) (g/9000 m) (%) (g/den) (g/den) T1  Blue 9805 20 N/A 166 50.60 4.626 32.49 T2  Blue 9805 20 9 152 57.20 5.345 37.40 T3  Blue 5603 10 N/A 153 53.44 5.872 42.94 T4  Blue 5603 5 3 157.92 47.75 5.053 39.01 T5  Smoke 9809 10 N/A 161 31.56 4.323 37.81 T6  Smoke 9809 10 3 158 39.79 4.824 37.56 T7  Amber 9808 20 N/A 164 51.38 4.898 36.89 T8  Amber 9808 20 3 161 57.77 4.83 34.70 T9  Green 5062 10 N/A 158 51.81 5.225 40.38 T10 Green 5062 5 3 153 54.55 5.42 40.50 [0064] In addition to experiments with TiO 2 a series of experiments were conducted to determine the viability of spinning polypropylene fibers with the liquid polymeric colorants and standard fiber pigments. A series of 8 experiments, listed in the table below, were produced under the standard spinning conditions described above. The pigments, obtained from Standridge Color Concentrate, Social Circle, Ga., are commercially available and are typical of the pigments used within the polypropylene fiber industry. Specifically, the green pigment is identified as SCC 3654, the red pigment is SCC 4591 and the black pigment is SCC 23005. The polymeric colorants in these example experiments are identified as PP Green 5720, PP Red 5718, and PP Smoke 5719 for the green, red and black liquid polymeric colorant respectively (all available under the tradename CLEARTINT® from Milliken & Company). Fiber Additives Table #2 Polymer Colorant Pigment TiO2 Sample Level Level Level ID Color (%) (%) (%) P1 Green 1.8 0 0 P2 Green 1.5 1.5 0 P3 Green 0 1.5 0 P4 Red 0 1.5 9 P5 Red 2 1.5 9 P6 Black 0 1.5 0 P7 Black 2 0 0 P8 Black 2 1.5 0 EXAMPLE 3 Polymeric Colorant Fibers with Nucleators [0065] A series of experiments were conducted using commercially available nucleators in combination with the liquid polymeric colorants (from the COLORANT TABLE, above) to produce continuous filament fibers. Using the same conditions as described in Example 1 above, 13 samples were produced using a commercially available polypropylene nucleator, Millad 3940 (MDBS). Fiber compositions for the 13 experimental samples are found in Fiber Additives Table #3 below and the physical properties of the final fibers are found in Fiber Properties Table #4. Fiber Additives Table #3 Nucleated Fiber Conditions Additive Color Heat Level Level Set Draw Sample ID Polymer Additive (ppm) Color (%) (C.) Ratio A Amoco 7550 M3940 2750 10% Colorant #3 0.5 125 4.0 B Amoco 7550 M3940 2750 10% Colorant #3 0.5 125 5.1 C Amoco 7550 M3940 2750 10% Colorant #3 0.5 125 3.4 D Amoco 7550 M3940 2750 10% Colorant #5 0.5 125 3.4 E Amoco 7550 M3940 2750 10% Colorant #2 0.5 125 4.0 F Amoco 7550 M3940 2750 10% Colorant #2 0.5 125 3.4 G Amoco 7550 M3940 2750 10% Colorant #2 0.5 125 5.1 H Amoco 7550 M3940 2750 10% Colorant #4 0.5 125 5.1 I Amoco 7550 M3940 2750 10% Colorant #4 0.5 125 4.0 J Amoco 7550 M3940 2750 10% Colorant #4 0.5 125 3.4 K Amoco 7550 M3940 2750 10% Colorant #1 0.5 125 5.1 L Amoco 7550 M3940 2750 10% Colorant #1 0.5 125 4.0 M Amoco 7550 M3940 2750 10% Colorant #1 0.5 125 3.4 [0066] Fiber Properties Table #4 Colored and Nucleated Fibers 3% 130 C. Denier Elongation Tenacity Modulus Shrinkage Sample ID (g/9000 m) (%) (g/den) (g/den) (%) A 129 65.996 4.805 46.823 8.524 B 152.5 41.467 5.555 56.61 9.64 C 154.5 93.919 3.939 36.697 6.595 D 151.1 73.769 3.825 39.584 6.973 E 131 30.29 4.474 46.237 8.678 F 155.4 40.265 3.446 36.636 5.995 G 160.4 28.747 5.044 52.14 8.136 H 153.8 23.227 5.208 52.764 8.893 I 134 23.895 3.94 39.574 8.79 J 151.3 50.934 3.06 32.392 7.019 K 163.4 20.941 5.218 54.94 9.255 L 132.1 37.146 4.768 50.275 8.849 M 159.7 72.707 3.309 34.248 6.976 Additionally using other commercially available nucleator compounds a series of yarns were produced using a Basell 35MFI fiber grade resin, Grade PDC-1302, using the green liquid colorant (PP Green 5720). In each case 1.2% of the green liquid colorant were combined with 2500 ppm of Millad 3940 (MDBS), Millad 3988 (DMDBS), HPN-68 and NA-21. EXAMPLE 4 Polymeric Colorant Fibers with UV Absorbers [0068] To test the spinnablity of polypropylene fibers with both the liquid polymeric colorants and a range of UV stablizers, 10 samples using a 10% concentrate of Yellow 485 polymeric colorant and various UV stabilizers were generated. The 10 samples were spun under standard sampling conditions as described in Example 2 above. The table below details the combinations and amounts of UV stabilizers with two different concentrations of the yellow colorant from the COLORANT TABLE, above. Fiber Additives Table #4 Colorant UV UV Stabilizer Concentration Stabilizer Concentration Sample ID (%) (name) (ppm) Y1 2 Tinuvin 783 1000 Y2 1 N/A N/A Y3 1 Tinuvin 783 1000 Y4 1 Tinuvin 783 2000 Y5 1 Tinuvin 783 500 Y6 1 Tinuvin 783 10000 Y7 1 Tinuvin 783 15000 Y8 1 Tinuvin 622 10000 Y9 1 Chimassorb 844 10000 Y10 2 Tinuvin 783 10000 EXAMPLE 5 Textured Polymeric Colorant Fibers [0069] Yams containing 1% of the polymeric colorants PP Orange 9802 and PP Violet 9804 were air jet textured. The starting yams were 150 denier, 72 filament yams with standard physical properties produced in the same manner as those fibers described in Example #1 above. Two orange yams were air jet textured with one violet yam to produce a collaged air jet textured yam. EXAMPLE 6 Polymeric Colorant Fibers from Liquid Colorant Injection [0070] For two colors, a second set of filament yarns was produced by directly injecting the liquid colorant into the feed throat of the extruder of the fiber spinning equipment. Basell PDC-1302, a 35 MFI HPP, was fed into the extruder at an extrusion temperature of 200° C. The polymeric colors were then injected directly into the hopper of the extrusion line using a peristaltic pump (Maguire, Model MPA-6-18). In each case the pump was set to the lowest possible setting, due to the size of the extrusion line and the throughput of the melt pump. The two colorants used were 10 % concentrates of the violet and red colorants from the COLORANT TABLE, above. All yarns were produced under the spinning conditions described in Table 5 below. Procedural Conditions Table #5 Roll Speed Roll Temperature (m/min) ° C. Feed Roll 500 Not Heated Draw Roll 1 505 55 Draw Roll 2 1000 75 Draw Roll 3(A + B) 1250 120  Relax Roll 1240 Not Heated At these conditions, yarns of different deniers were produced by adjusting the melt pump speed. EXAMPLE 7 Polymeric Colorant Monofilament [0072] Polymeric colorant concentrates were let down into two PP resins: the first with an MFI of 12-18 g/10 min (Exxon 1154) and the second with an MFI of 4 g/10 min (Exxon 2252) at a level of 10% to give 1% colorant in the final polymer fiber. This mixture, consisting of PP resin and the polymeric colorant additive, was extruded using a single screw extruder through monofilament spinnerets with 60 holes. The PP melt throughput was adjusted to give a final monofilament denier of approximately 520 g/9000 m. The molten strands of filament were quenched in room temperature water (about 25° C.), and then transferred by rollers to a battery of airs knives, which dried the filaments. The filaments, having been dried, were run across the first of four sets of large rolls, all rotating at a speed of between 49 and 126 ft/min (dependent on draw ratio), before entering an oven approximately 14 ft long set to a temperature of 360° F. After leaving the first oven, the filaments were transferred to the second set of large rollers running at a speed of 524 ft/min (dependent on draw ratio) and then into second oven, set at a temperature of 360° F. The final two sets of rolls were both set at 630 ft/min and the oven between them was set at a temperature of 300° F. The individual monofilament fibers were then traversed to winders where they were individually wound. These final fibers are thus referred to as the PP monofilaments. Several monofilament fibers were made in this manner with the following PP Red 9803, PP Violet 9804, PP Blue 9805, and PP Green 9807. EXAMPLE 8 Melt Blown Non-Woven with Polymeric Colorants [0073] A colored melt blown non-woven fabric was produced using a Nordson Fiber systems pilot melt blown system. The equipment consisted of a ¾″ single screw extruder (24:1) L:D ratio manufactured by J/M Laboratories—Model DTMB. The airflow was set to 30 scfm with a max temperature of 625° F. The orange colorant from the COLORANT TABLE, above, in a 10% concentrate, was let down into Basell 35 MFI fiber grade resin to give a final color loading of 1% in the melt blown fabric. EXAMPLE 9 Polyester Polymeric Colorant Fibers from Liquid Color Injection [0074] A set of experiments similar to Example #6 was conducted using a low IV (0.62) PET resin. Two liquid polymeric colorants, PET Yellow 236 and PET Orange 226, available from Milliken & Company, were used to produce yam samples. Free fall fiber was collected from the spinneret, which had the similar vibrant color as seen with the polypropylene fibers of Example 6. EXAMPLE 10 BCF Fibers Including Liquid Polymeric Colorants [0075] Cyan 9806 (from Milliken & Company) polymeric colorant was used to produce a colored bulk continuous filament (BCF) textured PP yam. A three ply BCF 300 denier 72 filament yam was produced using standard BCF equipment. Additionally using the liquid polymeric PP Orange 9802 colorant a single ply BCF 250 denier 72 filament textured yam was also produced using standard BCF equipment. The colorant was added to the extrusion line using a 10% concentrate to give a final color level of 1% in the yams. [0076] Knitted structures (socks) of the above Examples (except for Example #8 which was already made into a non-woven fabric) were then produced. [0077] There are, of course, many alternative embodiments and modifications of the present invention which are intended to be included within the spirit and scope of the following claims.
Improvements in permitting brighter colorations within polypropylene fibers and/or yams while simultaneously providing more efficient production methods of manufacturing of such colored fibers as well are provided. Generally, such fibers and/or yams have been colored with pigments, which exhibit dulled results, or dyes, which exhibit high degrees of extraction and low levels of lightfastness. Such dull appearances, high extraction levels, and less than stellar lightfastness properties negatively impact the provision of such desirable colored polypropylene fibers and/or yams which, in turn, prevents the widespread utilization of such fibers and yams in various end-use applications. Thus, it has surprisingly been determined that brighter colorations, excellent extraction, and more-than-acceptable lightfastness characteristics can be provided, preferably, through manufacture with certain polymeric colorants that include poly(oxyalkylene) groups thereon. Fabric articles comprising such novel fibers and/or yams are also encompassed within this invention.
3
This invention claims the benefit of priority to U.S. Provisional Patent Application Ser. Nos. 60/512,660 filed Oct. 20, 2003, and 60/586,468 filed Jul. 8, 2004. FIELD OF INVENTION This invention relates to deep brain stimulation (DBS), in particular to methods, systems, and devices for enhancing both efficacy and efficiency of “in-vitro” electrical stimulation known to inhibit symptoms of neurological diseases, disorders, and the like, and utilizes: (a) methods that tailor the direction and shape of electrical fields towards the area of best effect; (b) systems that interactively trigger stimulation to terminate the onset of tremors, and such; and (c) devices that use the aforementioned efficiencies to reduce power and allow for self-contained miniaturization at the implant site, thereby improving patient comfort. BACKGROUND AND PRIOR ART A first line of defense considered for most neurological disorders is treatment with psychoactive medicines, prior to any surgical intervention. Psychoactive medicines or drugs are those capable of acting on the nervous system and affecting mental states and behavior. Many physiological mechanisms are aided by such drugs, but these medicines have unwanted side effects, drug interactions, and long-term physiological tolerances that render the drug less effective over time. In the case of Parkinson's disease that serves as the exemplar disorder herein, the underlying etiology is that neurons, located in the substantia nigra of the mid-brain, for some unknown reason begin to produce less dopamine. As these neurons progressively and relentlessly deteriorate over years, less dopamine dramatically affects the motor control of the basal ganglia and thus outward behavior and everyday living. An estimated 1.5 million Parkinson's patients have a visible cluster of diagnostically significant and debilitating Parkinson's symptoms, typically tremors, stiffness, slowness, and balance. Patients describe the internal feeling as frozen still in the “set” stage of the “ready, set, go” sequence that started of a race. The “gold” standard treatment for Parkinson's is frequent daily administration of an indirect dopamine replacement, L-Dopa, a psychoactive drug that crosses the blood-brain barrier, and then alters form to produce dopamine as a supplement to the brain's own production. This therapy, while initially quite beneficial, typically can lose much of its effectiveness over about five years, wherein patients have to take progressively larger and more frequent doses until eventually the result becomes inadequate. Without alternative drug therapies, patients are left to suffer both the ravages of primary symptoms and the manifestations resulting from the prolonged use of the drug itself, principally the repetitive spasmodic motions of dyskinesia. More than one million people endure these symptoms, including such notables as the Pope, Muhammad Ali, and Billy Graham, while thousands of others including Michael J. Fox have turned to surgical approaches. Past surgical techniques treated symptoms of these diseases by selectively and permanently destroying or ablating structural areas in the brain. The net effect is to “shut the door”, in a neurological fashion, before dysfunctional brain signals are sent to the muscles, thereby relieving many symptoms. The advantage of surgical ablation is that it reduces the reliance on drug therapy with its attendant side effects. The disadvantage is that the procedure is irreversible. This may render such patients as unacceptable candidates for newly discovered techniques/therapies, such as stem cell implantation or viral transport of genome-altered DNA (deoxyribonucleic acid), both of which show promise in helping to augment or even to regenerate the natural production of dopamine as well as a number of other substances involved in neurological disorders. Certain neurological disorders that produce debilitating motor symptoms are now being treated with Deep Brain Stimulation (DBS) through-skull implanted electrodes see FIG. 1 below. DBS essentially reversibly alters the local neurological structure(s) around the tip of an electrode implanted on the brain with electrical pulses that reduce or stop disabling symptoms, such as, but not limited to, severe tremor and rigidity found in Parkinson's disease. DBS functionally has the advantage of emulating ablation by changing the firing characteristics of nearby neurons, but it does so only while the pulsed stimulation persists. Since the structures remain intact and undamaged, when DBS is turned “off” these structures reactivate and symptoms return, unless otherwise treated. Thus, DBS overcomes the chief disadvantage of ablation in that it allows implanted simulators to be withdrawn later for new techniques, with minimal residual effects. In 1998, the Federal Drug Administration (FDA) approved DBS as an alternative for, or as an adjunct to powerful psychoactive drugs (neuro-medicines) burdened with strong and often unacceptable side effects. The only FDA approved DBS apparatus is currently being sold by Medtronic, Inc., 710 Medtronic Parkway, Minneapolis, Minn. 55432-560, see FIGS. 2 and 3 below, although other companies have substantial interests in implantable neuro-stimulation devices for a variety of neurological disorders, such as Advanced Bionics, Corp., 12740 San Fernando Road, Sylmar, Calif. 91342; see “http://www.advanced bionics.com.” However, there are problems with the approved apparatus. At the very least, the presently approved apparatus is cumbersome and uncomfortable for many in its present form. As an outgrowth of legacy components from heart “pacemakers,” it consists of one or two remote stimulator/battery packs embedded under muscle tissue in the upper chest area, and requires subcutaneous leads up along the neck to the skull entry point. All these components are subject to corrosion and breakage, as well as to resistance or attacks by the body itself attempting by encapsulate it or dissolve it, leading to infection. Medtronic currently uses a product called a Soletra™ Neurostimulator (see FIG. 4 below) to generate a continuous series of electrical pulses, typically at about 2-4 volts, to electrode(s) implanted in specific brain areas. Neurons, normally operating in the tens of milli-volts range, are massively over-stimulated by such voltage and temporally altered, thereby inhibiting the expression of certain motor dysfunctions. Pulse voltage is usually adjusted somewhat depending on the proximity of the electrode(s) to the targeted area, e.g., more voltage is needed for target variations. Typical pulse rates range around 130-185 pulses/second. This combination of large amounts of voltage, amperage, and duty cycle creates a power drain that normally requires a non-renewable battery replacement in about 3-5 years, at a price of about $10,000. Many patients turn “off” the stimulation when going to sleep while tremor is quelled, in order to conserve power. Current DBS stimulator(s) are designed to be turned “off” or “on” using a magnetic-switch placed briefly near the associated electronics. Thus, without considering the remote apparatus itself, or the power requirements of the present design, a goal in this field should be to reduce stimulation-related side effects and complications caused by stimulating in the vicinity of the target. Two key objectives to meeting that goal are for the surgical implant to hit the center of a targeted cellular region, often not more than 2 mm across in any direction, and for the current field to stimulate the appropriate cells for symptom reduction or cessation, without triggering side effects in adjacent structures. While the surgical techniques themselves are well documented, the surgery is still a unique combination of art and science [see Lozano, Andres M. (Ed): Movement Disorder Surgery: Progress in Neurological Surgery, vol. 15, pp. 202-208, Basel, Switzerland: Karger AG, 2000, ISBN 3-8055-6990-4.]. A key to a successful outcome is the precise positioning and placement of the electrode(s), aided pre-operatively by vast improvements in brain imaging techniques, but nevertheless requiring considerable surgical skill and judgment. Beside normal variations in brain structures themselves adding to the difficulty of targeting, during surgery the brain moves with each heartbeat, while its size and position vary somewhat as a result of the surgical probe itself altering internal pressure. During the procedure, the use of fluoroscope imaging assists y-z axis positioning, and awakening of the patient while in the operating room for testing of clinical signs can reveal and help avoid untoward side effects. However, but the final outcome can only be assessed post-operatively. Results can vary by patient and over time. Some post-surgical adjustment is normally done with electrical parameters and z-axis programming of one or more of the electrode contacts available on the current DBS electrode, as is described below, but not to the extent that many physicians would like and not with respect to the x-y axis. Current DBS electrodes have four (4) circumferential contacts that radiate current in a 360 degree configuration. This means that with any degree off-target, or unnecessary stimulation even on target adjacent cells are exposed to current and potential side effects. While some of these side effects may be adjustable when electrical parameters are altered, or even reversible when the stimulation is shut down, but the cost is decreased efficacy of stimulation on the symptoms. For example, in sub-thalamic nucleus DBS, stimulation-induced side effects may include increased dyskinesias, blepharospasm or so called “eyelid-opening apraxia,” confusion/memory disturbances, personality changes, mood changes, apathy, cognitive changes, dysphonia/dysarthria, and such. Medtronic Inc. has proposed a “Directional Brain Stimulation and Recording Leads, title, in U.S. Published Patent Application 2002/0183817 to Van Venrooij et al., which is incorporated by reference. The proposed technique uses a “controller” as shown and referenced to FIG. 32 for recording “brain activity signals” to activate electrodes. However, this technique requires continuously generating pulsed type signals once the electrodes are activated whether or not a brain type tremor has ended, which would result in needless, unwanted and potentially excessive electrical current being continuously generated inside the brain. The more unnecessary pulse type signals, the more undesirable side effects to the patient, for example, in thalamic DBS, stimulation-induced side effects may include paresthesias, muscular cramps, dystonia, dizziness, dysarthria, gait and balance disturbances, limb ataxia, impaired proprioception, and decreased fine motor movements. Additionally, this technique would require excessive power to operate, which is not only expensive since battery power supplies would need to be regularly replaced but also require large card-deck size batteries that must be mounted inside of the patient's upper chest area. This proposed Medtronic technique would also be prone to circuit problems since the electrodes would be simultaneously operating as both transmitters and sensors, causing excessive and unnecessary power drain, shortening the lifespan of any batteries being used as well as increasing the costs for replacing the batteries. According to the Movement Disorder Society ©2002, “Deep brain stimulation for the alleviation of movement disorders and pain is now an established therapy. However, very little has been published on the topic of hardware failure in the treatment of such conditions irrespective of clinical outcome. Such device-related problems lead to significant patient morbidity and increased cost of therapy in the form of prolonged antibiotics, in-patient hospitalization, repeat surgery, and device replacement [Joint, C., Nandi, D., Parkin, S., Gregory, R., and Aziz, T. Hardware - Related Problems of Deep Brain Stimulation. Movement Disorders, Vol. 17, Suppl. 3, 2002, pp. S175-S180.] Thus, the need exists for solutions to the problems encountered in the prior art. SUMMARY OF THE INVENTION A first objective of the present invention is to provide for deep brain stimulation (DBS) methods, systems and devices that avoid implanting large card-deck size batteries remotely in the chest area and the use of vulnerable wire leads under the skin from the chest area to connect with the implanted electrode on the skull. A second objective of the present invention is to provide for deep brain stimulation (DBS) methods, systems and devices that allow for substantially all electronics including but not limited to an on-site battery pack to be located at or near the implanted electrodes on the skull. A third objective of the present invention is to provide for deep brain stimulation (DBS) methods, systems, and devices that can use substantially less power than current DBS techniques and apparatus. A fourth objective of the present invention is to provide for deep brain stimulation (DBS) methods, systems and devices, that do not generate a continuous series of un-synchronized pulses that are continuously generated whether they are needed or not. A fifth objective of this invention is to provide for deep brain stimulation (DBS) methods, systems and devices, to generate pulses on demand. Specifically, inhibiting pulse(s) can be interactively triggered by the onset of each unwanted electro-physiologically signaled event, such as at the beginning of a tremor. A sixth objective of the present invention is to provide for deep brain stimulation (DBS) methods, systems and devices that are more compact, easier to use and last longer than current DBS techniques, thereby improving patient comfort. A seventh objective of the present invention is to provide for shaped electrodes and methods by using the electrode contacts in deep brain stimulation (DBS) methods, systems and devices, that orient configured electrical fields to specific points, preferentially directing current a targeted cellular region and facilitating the clinical effect. The best direction of the shaped current can be determined intra-operatively through recordings and clinical testing along the “X-Y” plane. An eighth objective of the present invention is to use shaped electrodes in deep brain stimulation (DBS) methods, systems and devices, in order to decrease off-target current stimulation, thereby minimizing or eliminating exposure to adjacent cellular regions that produce side effects. A ninth objective of the present invention is to use the decreased electrical “aperture” of shaped electrodes in deep brain stimulation (DBS) methods, systems and devices, in order to maintain current density on the target region, but with less overall current flow and less battery drain over time. Methods, systems and devices are provided for deep brain stimulation (DBS), that can include providing a pulse stimulator with battery supply and controls within one unit, imbedding the single unit on a head of a user, and generating a single treatment pulse from the stimulator to the brain of the user, the single pulse being generated on demand of a sensed initiation of an impulse burst from a condition. Another single pulse can be generated upon occurrence of a follow-up sensed impulse burst. The impulse bursts can come from a detected brain activity condition such as those associated with tremors, and the like. The methods, systems and devices can also include providing the battery power supply solely in a compact skull-mounted cylindrical disc cap without implanting of batteries in a chest area of the user and avoiding any use of wires under skin from the chest area to connect to the stimulator, mounted as a skull cap with the top cap disc cover and the bottom cylindrical disc housing underneath and covered by the scalp, with a single opening in the skull for the lead line, further improving patient comfort. Controls can also include filtering sensed signals from electrode sensors to a noise amplitude filter, followed by counting impulses in the filtered signals with an impulse counter, and then triggering the single treatment pulse when a selected threshold of the counted impulses has been reached. Furthermore, controls can allow for shutting off the noise amplitude filter, and the impulse counter when the triggering of the single treatment pulse has been initiated. Various types of directional components can be provided for directing the treatment signals to effected areas of the brain of the user. Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments, which are illustrated schematically in the accompanying drawings. BRIEF DESCRIPTION OF THE FIGURES FIG. 1 shows a deep brain stimulation (DBS) apparatus of the prior art. FIG. 2 is a front view of the current prior art DBS of FIG. 1 . FIG. 3 shows DBS head-mounting details of the prior art of FIGS. 1-2 . FIG. 4 shows another prior art product device. FIG. 5 a shows an open view of a miniaturized integrated battery/stimulator apparatus of the subject invention. FIG. 5 b shows a closed view of the apparatus of FIG. 5 a. FIG. 6 shows the novel invention apparatus of FIGS. 5 a - 5 b utilized in a head mounted application. FIG. 7 a shows enlarged side views of four shaped electrodes with projected fields used in the apparatus of FIGS. 5 a , 5 b and 6 . FIG. 7 b illustrates the axial views of the four shaped electrodes of FIG. 7 a with respective projected fields. FIG. 8 a shows a recording trace graph of neuronal impulse bursts in mill volts verses time that can occur with an untreated patient. FIG. 8 b shows a trace graph of associated tremor displacement for FIG. 8 a in millimeters verses time that can occur with the untreated patient. FIG. 9 shows an exemplary flow chart of a triggering algorithm steps that can be used with the invention. FIGS. 10 , 10 a and 10 b shows a layout of the electronic components that can be used in the apparatus of FIGS. 5 a , 5 b , 6 along with the triggering algorithm of FIG. 9 . FIG. 11 a shows a trace graph of the neuronal impulse bursts in milli-volts verses time of a patient being treated with a Medtronic type (prior art) technique. FIG. 11 b shows a trace graph of the associated tremor displacement for FIG. 11 b verses time of the patient being treated with the Medtronic type (prior art) technique. FIG. 11 c shows the continuing pulse train that occurs with the Medtronic type (prior art) technique which causes the trace graphs of FIGS. 11 a - 11 b. FIG. 12 a shows a trace graph of the neuronal impulse bursts in milli-volts verses time of a patient being treated from being treated by the subject invention. FIG. 12 b shows a trace graph of the associated tremor displacement for FIG. 12 a verses time of the patient being treated by the subject invention. FIG. 12 c shows the single pulses that occur with the subject invention technique which results in the trace graphs of FIGS. 12 a - 12 b. DESCRIPTION OF THE PREFERRED EMBODIMENTS Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. This invention provides methods, systems and devices to reduce power demands substantially for DBS (deep brain stimulation), allowing for miniaturized type components to be integrated with the implanted probe(s) themselves, see FIGS. 5 a , 5 b , 6 and 10 . The invention avoids implanting large and cumbersome card-deck size batteries in the chest area and the use of vulnerable wire leads under the skin from the chest area to connect with the implanted electrode(s) on the skull. Notably, the remote stimulator/battery with its associated wiring are the chief source of complaints in the use of this technique. Other advantages of this invention are also apparent. The invention substantially differs from that used in current techniques. Rather than generating a continuous series of un-synchronized pulses that act whether needed or not, pulses can be generated on demand. Specifically, inhibiting pulse(s) can be interactively triggered by the onset of an unwanted electro-physiologically signaled event, such as the beginning of a tremor. The same electrode(s) that now serves as a one-way input also can serve as a bi-directional conduit to sense the electrical beginnings of the event itself as well as delivering the pulse(s). Thus, with appropriately tailored, triggering algorithms, a preferred example of which is described below in reference to FIG. 9 , an inhibiting pulse can be timed for delivery so as to suppress the event's full expression. Using this approach, power drain reductions of conservatively 85% or more are achievable, with the percentage depending on the neurological events of interest. For example, most tremors are less than approximately 10 tremor cycles per second, and can be far less when the tremor is interrupted by another intentional activity such as purposeful movement, as in the case of Parkinson's disease. Thus, the constant power drain can be reduced from approximately 150 stimulating pulses/second using the current techniques described in the prior art to now to as little as one stimulating pulse counteracting each tremor onset using interactive triggering. Even greater power reductions are possible for “lower frequency” tremor, such as Essential tremor at approximately 5 to approximately 7 tremor cycles/second, or “low-frequency” Parkinson tremor at approximately 3 to approximately 5 tremor cycles/second. With dramatically reduced power demands for DBS, this invention then allows for miniaturized components to be integrated with the skull cap attachment to the implanted probe(s) themselves, as shown in FIGS. 5 a , 5 b , 6 and 10 . FIG. 5 a shows an open view of a miniaturized integrated battery/stimulator apparatus 1 of the subject invention. FIG. 5 b shows a closed view of the apparatus 1 of FIG. 5 a in a cylindrical disc housing where the top cap covers the bottom cylindrical disc of the disc housing. FIG. 6 shows the novel invention apparatus 1 of FIGS. 5 a - 5 b utilized in a head mounted application with the top cap disc cover and the bottom cylindrical disc housing mounted as a skull cap underneath and covered by the scalp with the imbedded probe extending downward from beneath a central portion of the cylindrical housing through the skull and into the brain. As shown in FIG. 6 , the novel size of the cylindrical disc housing and the cap mount application is compact and easier to use than the prior art, and is not uncomfortable and cumbersome to the user as in the prior art. The compact cylindrical disc housing with miniaturized components does not cause a noticeable protrusion above the scalp line and existing hair of the user. Referring to FIGS. 5 a - 5 b and 6 , the hole cap 20 can include a top cover 20 T, and bottom cylindrical disc housing 20 B to house components 100 (which are described and shown in greater detail in reference to FIG. 10 ). Underneath the cap 20 can be a lead line 30 , and approximately four (4) directional electrodes 40 , 50 , 60 and 70 attached thereon. FIG. 7 a shows enlarged side views of four shaped electrodes with projected fields used in the apparatus of FIGS. 5 a , 5 b and 6 . FIG. 7 b illustrates the axial views of the four shaped electrodes of FIG. 7 a with respective projected fields. Referring to FIGS. 6 , 7 a and 7 b , the electrodes 40 - 70 on the lead 30 can include a non-conducting material, such as but not limited to insulating material, and the like, on one side or on a portion of the electrode. Examples, of non-conducting material can include but are not limited to rubbers, elastomers, plastics, coated metals, and the like, and combinations thereof, and the like. This nonconductive material can also be used to help direct electrical field emissions to one side or to more specific regions, and/or points, rather than to a 360-degree emission. The invention can include a lead 30 can having a single electrode with a nonconductive surface region. Alternatively, more than one electrode can be used on the lead in series to one another. The nonconductive surface region can be applied on the same side of the electrodes, or to different side surface portions of the electrodes as needed. Additionally, different combinations can be used. For example, an upper electrode can emit up to 360 degrees while other electrodes are directed to emit in specific regions and/or points. Additionally, circuitry can be added to control which electrodes are being emitted at selected time periods, and the like. For example, electrodes can be further programmed with a microprocessor, to activate simultaneously and/or sequentially, and/or staggered and/or over different combinations, and the like. The invention can use directional type electrodes, such as those shown and described in reference to U.S. Published Patent Application 2002/0183817 to Van Venrooij et al., which is incorporated by reference. The miniaturized implantable electrode apparatus and stimulation systems can also include those described in U.S. Patent Application 20030023297, to Byers et al. filed on Jan. 30, 2003, which is incorporated by reference. This reference describes an eyelid stimulation system and circuitry that causes a paralyzed eyelid to close or open by passing an electrical stimulating current to a nerve. The invention can be used to treat brain impulse bursts and the resultant physical extremity tremors that result therefrom. FIGS. 8 a and 8 b represent untreated brain impulse bursts and resultant physical extremity tremor outcome that are untreated. FIG. 8 a shows the recording of impulse bursts from the brain B, that results from the leads 30 that are connected to the electrodes 40 - 70 (of the apparatus of FIG. 6 ). The large amplitude bursts represent the impulses that result in the tremors (impulses from brain to effected extremity). FIG. 8 b represents an extremity that is being affected by the impulse (here for example, a single index right hand finger). A laser measuring sensor was aimed at the index finger to record the results shown in FIG. 8 b . For example, a plus 5 mm apex reading would represent the finger moving forward from a horizontal plane, and −5 mm represents the finger moving aft in the horizontal direction. The invention can use a triggering algorithm to selectively activate electrodes and treat effected parts of the brain where impulse bursts occur. FIG. 9 shows an example flow chart of a triggering algorithm steps that can be used with the invention. The triggering algorithm can take a number of forms or be adaptive, based on patient neuro-generative responses. In a simple illustrative form, not intended to be limiting, triggering sensing can be based on exceeding a threshold-firing rate measured in impulses/second. FIG. 9 shows an exemplary triggering algorithm 200 for using the electrodes 40 - 70 of the preferred embodiment shown in the preceding figures that switches back and forth between a sensing mode and transmitting mode. In the first step 210 , signals coming from leads 30 from the micro-electrodes 40 - 70 in the implant receive a signal from the electrodes 40 - 70 (the first left trace signal from FIG. 8 a ) can be passed through a noise amplitude filter 220 (for example an high pass amplitude filter cutting off a low frequency of for example everything below approximately 20 mill volts is filtered out). Next during step 230 , the filtered signal goes to an impulse counter, such as a clock counter which can count the number of impulses passing through, which can be represented in impulses per second. Next step 240 , has an impulse firing threshold type circuit that can be used that filters out false alarms and allows for a selected threshold, such as for example, 5 impulses within 50 milli-seconds, would trigger the generator in step 250 to send a generated pulse SP back down the signal leads 30 to the electrodes 40 - 70 . When the generator is triggered, a signal can also be sent (along line Off) to simultaneously shut off the sensing mode of the electrodes, allowing the electrodes to be in a transmitting mode state. Sensing mode parameters of the electrodes 40 - 70 can be in approximately 20 to approximately 60 milli-volts, while the transmitting/triggering range of the electrodes 40 - 70 can be approximately 2 to approximately 4 volts. The novel triggering algorithm 200 allows the electrodes 40 - 70 to be switched back and forth between transmitting and sensing modes without overloading the circuit components, and thus maximizing power usage during operation. Once triggered, stimulation blocking continues until firing impulse firing rate drops below the critical threshold value. The sensing and stimulation can use the same micro-electrode leads, alternatively, wherein the sensing circuitry first uses an impulse counter/clock, then if threshold is exceeded, circuit switching turns “off” the sensor and turns “on” the stimulator for one or more pulses. Various triggering algorithms can be developed for effective symptom suppression with animal studies. However, the safety of this invention's procedure has already been established for humans with continuous and higher pulse rates through FDA (Food and Drug Administration) approval. Further, a market also exists for electronic retrofit to thousands of patients who have already been implanted previously, without further brain surgery since the existing DBS electrodes can serve as a two-way bi-directional conductor. In vitro testing of this approach also can be possible using current systems by sensing electro-magnetic forces from subcutaneous wires of a neurological event onset, such as the beginning of a tremor. These signals, then in turn, can allow the triggering of the existing magnetic switch for turn “off” and “on.” Other types of triggering mechanisms can include those described in U.S. Pat. No. 6,539,263 to Schiff; U.S. Pat. No. 6,366,813 to DiLorenzo; U.S. Pat. No. 6,301,492 to Zonenshayn; U.S. Pat. No. 6,038,480 to—Hrdlicka et al.; U.S. Pat. No. 5,833,709 to Rise et al.; U.S. Pat. No. 5,716,377 to Rise et al.; and U.S. Pat. No. 5,707,396 to Benabid, which are all incorporated by reference. Additionally, U.S. Patent Applications 20030181954 to Rezai; 20030085684 to Tsukamoto et al.; and 20020188330 to Frans et al., which are all incorporated by reference, FIGS. 10 , 10 a and 10 b shows a layout of the electronic components that can be used in the apparatus of FIGS. 5 a , 5 b , 6 along with the triggering algorithm of FIG. 9 . Referring to FIGS. 5 a , 5 b , 6 , 10 , 10 a and 10 b , the cap 20 can include miniaturized components that include a battery type power supply 110 , which provides power to a stimulation generator controller 120 , which is triggered by a triggering switch 250 which receives signals from a sensing circuit 140 all of which are connected to electrodes 40 - 70 on lead line 30 that is implanted into the skull 310 of the patient 300 . The invention can make use of ultra-miniature batteries 110 such as those, manufactured by Advanced Bionics Corp., which are only about 1/35 the size of a standard AA battery and now serve medical implants by emitting electrical micro-pulses that stimulate nearby nerves. These tiny batteries, or “Bions,” can also be can be programmed from outside the body for strength and frequency of the stimulation, and wirelessly recharged with an electrical field. The use of these ultra-miniature batteries would avoid both a chief source of complaints; the remotely implanted card-deck sized stimulator/battery [about 60 by about 80 by about 15 mm] in the chest area, its replacement, while also avoiding problems associated with vulnerable wire leads under the skin from the chest area to connect with the implant on the skull. The Stimulation Generator Controller 120 can be a solid-state device such as the one shown and described in the Medtronic's Model 3628 cited 0093 of U.S. Published Patent Application No. 2002/0183817 to Van Venrooij et al., which is incorporated by reference. Trigger Switch 130 can be a common mini-double throw “on-off” and “off-on” electronic switch, triggering based on sensing circuit threshold. The Sensing Circuit 140 can be a common solid-state impulse counter-clock, e.g. mini-version of cardiac-alarm, monitoring electrical impulses to heart The circuits are powered by miniature battery 110 as shown in FIG. 10 b . The sensing circuit 140 can include the noise amplitude filter 220 and impulse counter 230 of FIG. 9 . The trigger switch 130 is activated when threshold circuit 240 of FIG. 9 is exceeded to turn “off” the sensor input and turn “on” the stimulation generator 120 . This is reversed when the impulse is blocked, dropping below threshold. The components to run the novel invention can be fit into a space of approximately 60 mil by 15 mil compared to prior art. Conservatively less than 50% of the current 60 by about 80 by about 15 mm in a plastic skull-cap implant see FIG. 6 . The invention can be less expensive than the current techniques, since no surgery tunneling down the neck into the chest area is needed for the battery cards, and thus no repairs or surgery for those components—which currently about $10,000 every 3-5 years. Benefits of using the novel triggering algorithm of FIG. 9 and apparatus components of FIGS. 5 a , 5 b , 6 , 10 and FIGS. 11 a - 11 c, 12 a - 12 c. FIG. 11 a shows a trace graph of the neuronal impulse bursts in mill volts verses time of a patient being treated with a Medtronic type (prior art) technique such as the one shown and described in reference to U.S. Patent Application Publication 2002/0183817 to Van Venrooij et al., which is incorporated by reference. FIG. 11 b shows a trace graph of the associated tremor displacement for FIG. 11 b verses time of the patient being treated with the Medtronic type (prior art) technique. FIG. 11 c shows the continuing pulse train that occurs with the Medtronic type (prior art) technique which causes the trace graphs of FIGS. 11 a - 11 b. Referring to FIGS. 11 a - 11 c, results in a continuing pulse train ( FIG. 11 c ) in order to cause the effects of no impulse bursts ( FIG. 11 a ) and no resultant physical tremors ( FIG. 11 b ). As described in the background section of this invention this technique requires continuously generating pulsed type signals once the electrodes are activated whether or not a brain type tremor has ended, which would result in needless and excessive, unwanted and potentially dangerous electrical current being continuously generated inside the brain. The more unnecessary pulse type signals, the more undesirable side effects to the patient. Additionally, the technique proposed in this patent application publication would require excessive power to operate, which are not only expensive since battery power supplies would need to be constantly replaced but also require large card size batteries that must be externally mounted outside of a patient or mounted inside of the upper chest or be constantly connected to an external power supply. This proposed Medtronic technique would also be prone to short circuit since the electrodes would be simultaneously operating as both transmitters and sensors, which also causes excessive and unnecessary power drain, which also shortens the lifespan of any batteries being used as well as increase the costs for replacing the batteries. FIG. 12 a shows a trace graph of the neuronal impulse bursts in mill volts verses time of a patient being treated from being treated by the subject invention described above. FIG. 12 b shows a trace graph of the associated tremor displacement for FIG. 12 a verses time of the patient being treated by the subject invention. FIG. 12 c shows the single pulses that occur with the subject invention technique which results in the trace graphs of FIGS. 12 a - 12 b. Referring to FIGS. 12 a - 12 c, the invention causes single spaced apart pulses to occur over greater periods of time, where each pulse occurs on-demand, and not as a continuous series of pulses. As shown by FIG. 12 a , the initial impulse burst and subsequent impulse bursts have long delay time periods there between, which can result in substantially reduced or eliminated tremors resulting therefrom, FIG. 11 b. The novel invention allows for less undesirable electrical current to be generated within the brain, less side effects that result therefrom, less power consumption as well as other apparent benefits. The novel invention can use small batteries that were not able to be used in the prior art systems and techniques, and also results in power supplies that require less replacements as well. The novel invention is able to eliminate the need for large and cumbersome card type batteries or external power supplies, and results in a better system for treatment. Differences between the subject invention and that described in the Medtronic technique shown in U.S. Patent Application Publication 2002/0183817 to Van Venrooij et al. are compiled in Table 1. TABLE 1 Comparison of prior art(Medtronic) and Invention. Attribute Medtronic Invention Sensing Loss of Effectiveness Single Event Trigger Brain “Activity” Initial Impulse Burst Objective Select Electrodes Stop Single Tremor Stimulator Normally-On Normally-Off Power No “off” Only “on”as needed (continuing pulses) (individual pulse) Large Battery Small Battery Power Lifespan Limited Extended Battery Mounting “Implantable” Skull-Mounted in Cap Side Effects Continuous electrical current Limited Electrical Current Besides circuitry miniaturization, by triggering pulse generation only when needed, fewer pulses per second also can reduce some of the mild, but known side effects of DBS, and the timed delivery also can delay the onset of the next event by physiological feedback, that is also known to be effective against a known clinical phenomena Parkinson's Disease. Other advantages can also be realized. The timed pulse feedback speculatively could induce the brain to adaptively alter actual neural circuitry, allowing a further reduction of pulse rate and even more efficiency or even better help reduce symptoms naturally, just as brain circuitry is known to be altered by experience. While the invention has been described for use with tremors, the invention can have applicability to other medical applications, such as but not limited to movement disorders and cardiac dysfunctions, but extends to include other neurological diseases and disorders such as epilepsy, psychiatric and behavioral dysfunctions such as schizophrenia and drug-induced symptoms and the like. While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
Methods, systems, and devices to reduce power demands substantially for current deep brain stimulation DBS using smart technology type applications. The invention uses miniaturized components that allow integration with the implanted probe(s) themselves, and includes a skull-sited housing having all the controls and battery power supply needed. This avoids implanting obtrusive card-deck size batteries in the chest area and the use of vulnerable wire leads under the skin from the chest area to connect with the implanted electrode(s) on the skull, improving comfort. The Generating of non-continuous pulses on demand of conditions such as the occurrence of a tremor occurs, without having to continuously run pulses at all times, substantially increasing life spans over current techniques. Shaped electrodes and their methods further reduce power demands and efficacy by directing electric fields to focus towards specific areas and regions of the brain rather than inefficient 360-degree emission.
0
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a divisional of U.S. patent application Ser. No. 11/344,028, filed Jan. 31, 2006, now U.S. Pat. No. 7,467,556, which is in turn a continuation-in-part of U.S. patent application Ser. No. 10/528,515, which has an assigned filing date of Oct. 26, 2005, which was the National Stage of International Application No. PCT/US2003/029302, filed Sep. 19, 2003, and which claims the benefit of U.S. Provisional Application No. 60/412,125, filed Sep. 19, 2002. U.S. patent application Ser. No. 10/528,515 is also a continuation-in-part of U.S. patent application Ser. No. 10/470,372, which has an assigned filing date of Jul. 25, 2003, which was the National Stage of International Application No. PCT/US02/03920, filed Jan. 28, 2002, which claims the benefit of U.S. Provisional Application No. 60/264,877, filed Jan. 29, 2001, and which has since issued as U.S. Pat. No. 6,990,866, on Jan. 31, 2006. BACKGROUND OF THE INVENTION This invention relates to load indicating fasteners that are “thread-forming” (also referred to as “thread-rolling” or “self-tapping” fasteners), methods for making load indicating thread-forming fasteners, and methods for measuring the load in thread-forming fasteners. Thread-forming fasteners are well known in many industries, such as in high-volume automotive assembly. Examples of such fasteners are described in U.S. Pat. No. 5,242,253 (Fulmer), issued Sep. 7, 1993, for example. Such fasteners are also marketed commercially, for example, by Reminc, Research Engineering and Manufacturing Inc., Middletown, R.I., USA, under the trademark “Taptite” and “Taptite 2000”, and a description of such fasteners can be found in their product literature, entitled “Taptite 2000 Thread Rolling Fasteners”. The major advantage of thread-forming fasteners is that they can be installed directly into a drilled hole, eliminating the cost of tapping the hole. Additionally, the thread formed by a thread-forming fastener has very tight tolerance since it is formed by the fastener itself and therefore forms a better nut. Although thread-forming fasteners have been used in numerous applications in the automotive and aerospace industries to reduce cost, such fasteners are generally restricted to non-critical or less-critical applications. The difficulty in controlling the tightening process prevents their use in critical applications. The primary reason for this is that the thread-forming process requires torque, in addition to the tightening torque, and this thread-forming torque varies significantly with hole tolerance, material, friction conditions, etc. As a result, the precise tightening of a thread-forming fastener to a specified torque into a blind hole, where the thread is still being formed as the bolt is being tightened, will result in a 3 sigma load scatter of typically +/−50%, which is unacceptable in critical applications. SUMMARY OF THE INVENTION For some time, ultrasonics has been used to accurately measure the load in bolts. Initially, removable ultrasonic devices were the most commonly used. More recently, low-cost permanent ultrasonic transducers, which can be permanently attached to one end of the fastener, have come to be used. Permanent fasteners of this type are described, for example, in U.S. Pat. No. 4,846,001 (Kibblewhite), issued Jul. 11, 1989, U.S. Pat. No. 5,131,276 (Kibblewhite), issued Jul. 21, 1992, U.S. Provisional Patent Application No. 60/264,877 (Kibblewhite), filed Jan. 29, 2001, and International Application No. PCT/US02/03920 (Kibblewhite), filed May 17, 2002, the subject matter of which is incorporated by reference herein. In accordance with the present invention, it has been determined that such ultrasonics can be mated with an otherwise conventional thread-forming fastener to provide a load indicating thread-forming fastener that can be used for precise and reliable assembly of critical bolted joints, such as those in automobile engines (e.g., cylinder heads, connecting rods, main bearings, etc.), drive trains, steering, brakes, suspensions, and a variety of other applications, including aerospace applications. Steps can then be taken, using equipment and methods that are otherwise known and conventional, to accurately measure and control the load in the thread-forming fastener during tightening, and to inspect the load in the thread-forming fastener after assembly. For further detail regarding preferred embodiments for implementing the improvements of the present invention, reference is made to the description which is provided below, together with the following illustrations. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an example of a typical load indicating thread-forming fastener which is produced in accordance with the present invention. FIGS. 2 and 3 are graphs showing typical load and torque characteristics plotted against the angle of rotation of the load indicating thread-forming fastener of the present invention. DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a typical embodiment of a load indicating thread-forming fastener which is produced in accordance with the present invention. In this illustrative example, the load indicating thread-forming fastener has been implemented in conjunction with an otherwise conventional “Taptite” fastener, which is commercially available from Reminc, Research Engineering and Manufacturing Inc., Middletown, R.I., USA. It is to be understood, however, that this embodiment is shown only for purposes of illustration, and that the load indicating thread-forming fastener of the present invention can also be implemented using any of a variety of known and available load indicating devices, coupled or combined with any of a variety of known and available thread-forming fasteners. In the illustrative embodiment of FIG. 1 , the load indicating thread-forming fastener 10 generally includes a fastener 12 (e.g., the above-mentioned “Taptite” fastener) and a permanent piezoelectric polymer film transducer 14 (e.g., of the type disclosed in the above-mentioned U.S. Pat. No. 4,846,001, issued to Kibblewhite) attached to one end. The fastener 12 includes a head 16 , which can be suitably engaged by a tool (not shown) for applying torque to the fastener 12 , and a thread-forming body portion 18 . A suitable identifying element is applied to the thread-forming fastener which can be read and used to determine ultrasonic measurement parameters specific to the thread-forming fastener in order to provide more precise and more reliable load measurements by compensating for differences resulting from manufacturing variations in individual thread-forming fasteners. For example, as disclosed in U.S. Provisional Patent Application No. 60/264,877 (Kibblewhite) and International Application No. PCT/US02/03920 (Kibblewhite), the transducer 14 can further include a permanent mark such as a two-dimensional high-density bar code (not shown) or some other encodable medium, applied to the top electrode 20 of the transducer 14 for purposes of facilitating subsequent steps taken to obtain an indication of tensile load, stress, elongation or other characteristic of the fastener 12 during a tightening operation, or at various other times during the service life of the fastener 12 , as will be discussed more fully below. As an alternative, the permanent mark can be applied directly to the thread-forming fastener, and the ultrasonic transducer can then be applied on top of the mark in such a way that the mark can be detected through the transducer. As an example, the bar code can be marked on an end surface of the fastener and the ultrasonic transducer can then be provided on the surface with the bar code in such a manner that the bar code can be read through the transducer. In one such embodiment, the transducer layers are translucent or transparent, allowing the bar code to be read through the piezoelectric and conductive layers of the transducer. In another embodiment, the bar code is marked using an indentation technique, such as dot peening, so that the indentations are detectable, and the bar code is made readable, after application of the transducer. As a further alternative, a non-volatile memory device can be applied to the thread-forming fastener for purposes of storing desired information. Such memory devices can be powered, written to and read from serially through a single input/output connection and an AC coupled return through the capacitance of the ultrasonic transducer. Such devices are capable of storing data such as unique identification, ultrasonic measurement parameters, tightening and inspection data for use in a manner similar to that of the above-described use of a permanent mark for the storage of information. In one such embodiment, the previously described top electrode 20 is replaced with the non-volatile memory device, and portions of the top exposed surface of the memory device are made conductive by providing the surface with an electrical contact. This top conductive surface is then electrically connected to a conductive layer on the bottom of the memory device, adjacent to the active piezoelectric polymer film transducer 14 , to provide a suitable electrode for the ultrasonic transducer. The top conductive surface is also electrically connected to the non-volatile memory device for purposes of writing information to and reading information from the memory device. In another embodiment, the foregoing non-volatile memory device can be a radio frequency identification (RFID) chip or tag coupled with the transducer 14 for purposes of storing desired information. This can be accomplished with known RFID devices, such as the MetalSentinel (13.56 MHz) device available from Interactive Mobile Systems, Inc., Port Townsend, Wash., USA, which are capable of storing data such as unique identification, ultrasonic measurement parameters, and tightening and inspection data. In such an embodiment, the previously described top electrode 20 is replaced with the RFID device, and portions of the top exposed surface of the RFID device are made conductive by providing the exposed surface with an electrical contact. This top conductive surface is then electrically connected to a conductive layer on the bottom of the RFID device, adjacent to the active, piezoelectric polymer film transducer 14 , to provide a suitable electrode for the transducer 14 . The piezoelectric polymer film transducer 14 is an electrical insulator and further functions as an isolator for the antenna associated with the RFID device for purposes of RF transmission. The size, shape and location of the conductive portions of the top exposed surface of the RFID device can vary to suit the particular RFID device which is used. For example, the conductive portions of the top exposed surface can be placed along the periphery of the RFID device, leaving the central portions of the top exposed surface open to accommodate the antenna normally associated with the RFID device. The conductive portions of the top exposed surface should preferably cover as much of the top surface of the RFID device as is possible, while leaving sufficient open space to accommodate the function of the antenna. The conductive layer on the bottom of the RFID device preferably covers the entire bottom surface, to maximize contact with the transducer 14 . Various different couplings are used with RFID devices, including electromagnetic, capacitive and inductive couplings, with different coupling antennas. The antenna can be provided adjacent to non-conductive portions of the top exposed surface. Alternatively, the conductive portions of the top and bottom surfaces of the RFID device can be constructed in such a way as to function as the antenna for the transponder associated with the RFID device which is used. It will further be appreciated that non-contact inductive or capacitive couplings used for RFID transponder communication in the above described embodiments can also be used to couple the excitation signal to the ultrasonic transducer. Additionally, the RF communication frequency can be selected to correspond to a preferred ultrasonic transducer excitation frequency. This then eliminates the need for an electrically conductive top surface for electrical contact with the transducer for load measurement, allowing both the reading of information stored in the RFID device and the measurement of load to be performed even when the transducer is covered with paint or other protective coating. As an example, the transducer 14 can be implemented using a thin piezoelectric polymer sensor (e.g., a 9 micron thick, polyvinylidene fluoride copolymer film, of the type manufactured by Measurement Specialties Inc., Valley Forge, Pa., USA) permanently, mechanically and acoustically attached to an end surface 22 of the fastener 12 . The top electrode 20 of the transducer 14 can be implemented as a thin metallic foil (e.g., an approximately 50 micron thick, type 316, full-hard, dull or matte finished stainless steel) which has been treated to provide a black oxide finish, which is then preferably provided with a black oxide treatment to provide an extremely thin, durable, corrosion resistant and electrically conductive, black coating. A high-resolution bar code can be marked on the resulting surface by removing selected areas of the coating (e.g., by conventional laser ablation techniques), or by some other process, to provide a high contrast mark easily read with conventional, commercially available optical readers. As an alternative, a non-volatile memory device, such as an RFID device, can be applied to the transducer 14 to provide data storage which can similarly be read with conventional, commercially available readers. It is again to be understood that such implementations are described only for purposes of illustration, and that any of a variety of transducer configurations can be used to implement the transducer 14 applied to the fastener 12 , as desired. For example, the ultrasonic transducer 14 can be implemented as an oriented piezoelectric thin film, vapor deposited directly on the head of the fastener 12 , as is described in U.S. Pat. No. 5,131,276 (Kibblewhite), issued Jul. 21, 1992. As a further alternative, the ultrasonic transducer 14 can be implemented as a piezoelectric polymer film, chemically grafted on the head of the fastener 12 , as is described in U.S. Provisional Patent Application No. 60/264,877 (Kibblewhite), filed Jan. 29, 2001, and International Application No. PCT/US02/03920 (Kibblewhite), filed May 17, 2002. It will be readily understood that other alternative implementations are also possible. In the embodiment illustrated in FIG. 1 , the ultrasonic transducer 14 is permanently attached to the head 16 of the fastener 12 , as described in the above-referenced patents issued to Kibblewhite. An essentially flat, or spherically radiused surface 24 is provided on at least a portion of the threaded end of the fastener to provide an acoustically reflective surface to reflect the ultrasonic wave transmitted by the transducer back to the transducer. Load is then measured using standard, pulse-echo ultrasonic techniques, which are themselves known in the art and described, for example, in the above-referenced patents issued to Kibblewhite. Load control accuracies of +/−3% have been achieved when tightening thread-forming fasteners into blind holes during both the first and subsequent tightenings. In an alternative embodiment, an essentially flat surface is provided on the head 16 of the thread-forming fastener 12 and a removable ultrasonic transducer is temporarily attached to the fastener for the purpose of making load measurements. The threaded end of the fastener 12 is identical to the previous embodiment with the permanent ultrasonic transducer. In practice, heat is generated as a result of the thread-forming work that takes place during the thread-forming run-down stage of the installation of a thread-forming fastener. This results in a slight increase in temperature in both the fastener (the bolt) and the resulting joint. This increase in temperature can cause errors in the ultrasonic load measurements to be taken because of thermal expansion effects. For this reason, when using ultrasonics for inspecting the load in a fastener, it is usual to measure the temperature of the fastener or the joint in order to compensate for the effects of thermal expansion. However, in conjunction with a thread-forming fastener, the average temperature increase due to the heat generated during thread-formation can not be measured directly during the installation process and is subject to variations in material, friction, and heat conduction properties of the joint components. Without compensation, this thermal effect can result in inaccuracies of load measurement on the order of 5% to 20%, depending on the bolt, the joint and the assembly process being used. FIGS. 2 and 3 show typical load and torque characteristics plotted against the angle of rotation of a typical bolt. FIG. 2 shows the tightening curves for a typical through-hole application, in which the torque reduces after the thread is formed through the entire hole. FIG. 3 shows the tightening curves for a typical blind hole application, in which the thread is still being formed as the bolt is tightened. Further in accordance with the present invention, more accurate load measurements in the thread-forming load indicating fasteners are provided by eliminating the effects of fastener heating resulting from the thread-forming process. This is achieved by measuring the load (or acoustic time-of-flight) value immediately prior to the load-inducing stage of the assembly process, and by using this measured value as the zero-load reading. The load-inducing stage of the assembly process can be detected by any one of a variety of methods. For example, an increase in load above a predetermined threshold, a change in the increase in load with time, angle of rotation of the fastener or torque, an increase in torque above a predetermined threshold, or a change in the increase in torque with time, angle or load can be detected. Irrespective of the method used to detect the load-inducing stage of the assembly process, a new zero-load base measurement is taken as a value just prior to the load-inducing assembly stage by selecting or calculating a load measurement prior to the load-inducing stage. This can be achieved by selecting a load measurement corresponding to a fixed time or angle prior to the detection of the commencement of the load-inducing stage, for example. Alternatively, for through-hole applications, the end of the thread-forming phase can be detected by a reduction in torque. It is again to be understood that such methods are only illustrative, and that there are numerous other methods for determining the new zero-load base measurement prior to tightening, from load, time, torque and angle of rotation measurements recorded during assembly operations with hand and powered assembly tools. The thermal effect of thread forming causes an apparent positive load value at zero load just prior to tightening. An alternative to zeroing the load (or time-of-flight measurement) is to add this load offset, measured prior to the load-inducing stage of the assembly process, to the target load (or target time-of-flight). The result is the same since the increase in measured load is the same. Yet another alternative is to experimentally determine an average value of load error due to the thread forming and adjust the zero-load measurement or target tightening parameter to compensate for this effect using one of the above-described methods. This approach, however, does not compensate for variations with individual fasteners or joint components and is therefore presently considered less desirable. The result is that, for the first time, ultrasonic load measurement technology can be used with thread-forming fasteners. Errors in load measurement resulting from the thermal effects of thread-forming can be compensated. This then results in accurate load measurement and tightening control of the thread-forming fasteners. The above-described method of eliminating the effects of fastener heating resulting from the thread-forming process can also be used with other fastener assembly processes that generate heat prior to the load-inducing tightening stage. Thread-locking bolts and nuts, for example, are manufactured with a prevailing “locking” torque to prevent the fastener from loosening during service. Most often, the thread of either the bolt or nut has an irregular profile causing the threads to elastically deform slightly upon mating. Alternatively, the bolt or nut has an insert or patch of a soft material to provide the prevailing torque or resistance to loosening. The prevailing torque provided by these thread-locking features produces heating of the fastener during rundown in the same manner as the tapping torque does with a thread-forming fastener. Consequently, the above-described method for compensating for thermal-related errors in accordance with the present invention can be used with prevailing torque-locking fasteners to improve the accuracy of ultrasonic load measurement during assembly. It will be understood that various changes in the details, materials and arrangement of parts which have been herein described and illustrated in order to explain the nature of this invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the following claims.
An ultrasonic load measurement transducer is mated with a thread-forming fastener to provide a load indicating thread-forming fastener that can be used for the precise and reliable assembly of critical bolted joints, such as those in the automobile and aerospace industries, among others. Steps can then be taken to accurately measure and control the load in the thread-forming fastener during tightening, and to inspect the load in the thread-forming fastener after assembly. A similar result can be achieved for a thread-locking fastener by mating an ultrasonic transducer with the thread-locking fastener assembly.
5
This application is a divisional of application Ser. No. 08/067,676, filed May 26, 1993, now U.S. Pat. No. 5,473,397. BACKGROUND OF THE INVENTION This invention relates to a camera having an internal data imprinting device. More particularly, the invention involves a camera capable of taking pictures in both a full size format and a panorama size format wherein each format has a distinct data size and data position upon a film. Embodiments of cameras having data imprinting devices have employed fixed position systems wherein a size of a data image remained constant regardless of a format mode selected. In such systems the light path is fixed, for example, at a lower part of the film with the characters being imprinted in a center of a frame. Since the position of the data remained constant, data could not be imprinted within a framed area of a panorama size format picture. Another embodiment of a camera with a data imprinting device, as disclosed in Japanese Laid-open Patent Publication No. 63-27823, employs an optical system having movable elements. The data imprinting device disclosed in this publication comprises a plurality of optical elements capable of moving to appropriate positions dependent upon a selected format. A first optical element is disposed at a first position in order to produce characters having full size format dimensions. A second optical element, preferably with a different enlargement, moves from a first position to a second position in order to imprint panorama size format data images which are smaller than those of the full size format. Thus, the two optical elements provide appropriate character sizes respectively. However, movement of the first and second optical elements necessitates increased system complexity and is prone to produce blurred data images due to inaccuracies in the positioning of the optical elements. OBJECTS AND SUMMARY OF THE INVENTION It is an object of this invention to provide a camera equipped with a data imprinting devices which overcomes the drawbacks of the prior art. It is a general object of the present invention to provide a data imprinting device for imprinting data images at a first position in a full size format, and imprinting smaller data images at a second position in a panorama size format. It is a further object of the present invention to provide a device permitting the imprinting of data upon a film in a full size and a panorama size format wherein fixed optical components are solely employed. Still further, it is an object of the invention to provide a device for imprinting data upon a film which permits a width of a camera to be minimized. Yet another object of the present invention is to provide a data imprinting device, for use in a camera, which permits the depth of a camera to be minimized. Briefly stated, the present invention provides a camera with a data imprinting device having a plurality of in-line LEDs producing light focused by an optical system upon a photographic film at a first and a second position, corresponding to a full size format and a panorama size format, respectively. The focused light imprints data images upon the film at the first position which are larger than data images imprinted at the second position. The optical system has first and second prisms, with integrated lenses, for reflecting and focusing the light upon the film at the first and second positions, respectively. A shutter plate is selectively positioned over apertures through which the light is focused, thus blocking the light and allowing only a selected imprint to be made upon the film. A vertical pattern of the data image is created by a controller selectively illuminating the in-line LEDs while a horizontal pattern is produced by the controller illuminating the LEDs in coordination with the movement of the film past the apertures. The controller actuates a motor for advancing the film and has a sensor for detecting film travel. A first embodiment has the first prism positioned further from the film than the second prism, which is positioned further from the LEDs than the first prism, such that reflected light from the first prism has a path intersecting that of incident light of the second prism. A second embodiment has the prisms offset from each other in the plane of the film such that light paths do not intersect. The first embodiment has a narrower width than the second embodiment while the second embodiment has a shallower depth than the first embodiment. According to an embodiment of the invention, there is provided a camera comprising: a camera body, light emitting elements, optical means for focussing light emitted from the plurality of light emitting elements on a surface of a photosensitive means, means for selecting at least one of a first screen size and a second screen size, the optical means having optical elements for creating first and second images corresponding to each screen size, means for occluding the light focussed by the optical means, the means for occluding being responsive to the means for selecting, means for forming imprinted data from the light focussed on the surface of the photosensitive means, and means for exposing the surface of the photosensitive means to light from an object to be photographed. Furthermore, according to an embodiment of the present invention, there is provided a data imprinting device for use in a camera comprising: illumination means for emitting imprinting light, optical means for focusing the imprinting light upon a photosensitive surface at at least two positions, means for selectively blocking the imprinting light from focusing upon at least one position of the at least two positions, and control means for coordinating the illumination means with a movement of the photosensitive surface such that the imprinting light produces images upon the photosensitive surface. According to a feature of an embodiment of the present invention there is provided an optical means for focussing including crossing light paths permitting the optical elements to be in-line in a plane perpendicular to the surface. Still further, an embodiment of the present invention provides a data imprinting device for use in a camera comprising: illumination means for emitting imprinting light, optical means for focusing the imprinting light upon a photosensitive surface at at least two positions, the optical means including a first reflecting means for reflecting incident light of the imprinting light upon a first position of the at least two positions, the optical means including a second reflecting means for reflecting incident light of the imprinting light upon a second position of the at least two positions, the first position being above the second position, the first reflecting means being set back further from the photosensitive surface than the second reflecting means, means for selectively blocking the imprinting light from focusing upon at least one position of the at least two positions, control means for coordinating the illumination means with a movement of the photosensitive surface, and framing means for selectively shielding an upper and a lower portion of the photosensitive surface from subject image light in coordination with the means for selectively blocking. Another feature of the present invention provides a device for imprinting data wherein the control means comprises: sensing means for detecting travel of the photosensitive surface past a point of imprinting, advance means for advancing the photosensitive surface, a controller responsive to the sensing means, the controller actuating the advance means, and the controller selectively illuminating the illumination means in response to the sensing means. Yet another feature of the present invention provides for a data imprinting device wherein the framing means comprises: an upper framing member, pivotally mounted, having a framing portion extending laterally across an upper portion of the photosensitive surface such that the subject image light is selectively obstructed by the framing portion, a lower framing member, pivotally mounted, having a framing portion extending laterally across a lower portion of the photosensitive surface such that the subject image light is selectively obstructed by the framing portion, and the upper and lower framing member having geared portions mutually engaged such that the upper and lower framing members pivot in complementary directions. The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a longitudinal cross section of a camera showing a first embodiment of the invention as viewed from the top. FIG. 2 is a perspective view of a rear portion of a camera body according to the embodiment of the invention in FIG. 1. FIG. 3 is a transverse cross section of the camera of FIG. 1, as viewed from the side, depicting an optical system and a cutaway view of a framing mechanism operating in a full size mode position with double dashed outlines illustrating a panorama size mode position. FIG. 4 is a rear view of the camera body of the first embodiment of the present invention, shown in FIG. 1, illustrating a shutter plate and the framing mechanism in full size format positions. FIG. 5 is a view of a film imprinted upon by the present invention showing a panorama size format overlaid upon a full size format. FIG. 6 is a transverse cross section of the camera of FIG. 1, as viewed from the side, depicting the optical system and a cutaway view of the framing mechanism operating in a panorama size mode. FIG. 7 is a rear view of the camera body of the first embodiment of the present invention in FIG. 1 illustrating positions of the shutter plate and the framing mechanism in a panorama size mode. FIGS. 8a and 8b are schematic diagrams showing optical paths in the first embodiment in full and panorama size modes, respectively. FIG. 9 is a transverse cross section of a camera of a second embodiment of the present invention, as viewed from the side, depicting an optical system and a cutaway view of a framing mechanism operating in a full size mode position with double dashed outlines illustrating a panorama size mode position. FIG. 10 is a rear view of the camera body of the second embodiment of the present invention, shown in FIG. 9, illustrating positions the shutter plate and the framing mechanism in the full size format position and light paths of the optical system. FIGS. 11a and 11b are schematic diagrams showing the optical paths in the second embodiment of the present invention in full size and panorama size modes, respectively. FIG. 12 is a transverse cross section of a camera of a third embodiment of the present invention, as viewed from the side, depicting an optical system and a shutter plate configuration. FIG. 13 is a rear view of the camera body of the third embodiment of the present invention, shown in FIG. 12, illustrating the shutter plate and the framing mechanism in the full size format position. FIG. 14 is a transverse cross section of the third embodiment of the present invention, as viewed from the side, depicting the optical system and a cutaway view of the framing mechanism operating in the panorama size mode. FIG. 15 is a rear view of the camera body of the third embodiment of the present invention illustrating positions of the shutter plate and the framing mechanism in the panorama size mode. DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. 1, there is shown a first embodiment of the present invention having a camera body 1 with a dark chamber 2 integrally formed therein. Light, from an object to be photographed (not shown), is focused by a photographic lens L, through dark chamber 2, onto a surface of a film F when a shutter 52 is opened. An aperture 1c, in a back surface 1b of camera body 1, allows the light to strike a photosensitive surface of film F. Film F is drawn across aperture 1c into a take-up spool chamber 3A by a take-up spool 11, from a feed spool chamber 3B. The feed spool chamber 3B and take-up spool chamber 3A are both integrally formed within camera body 1. A partitioning wall la separates take-up spool chamber 3A from dark chamber 2. Referring to FIG. 2, aperture 1c is flanked, on upper and lower sides, by inner rails 4a and 4b, respectively. Inner rails 4a and 4b protrude into dark chamber 2 from back surface 1b of camera body 1. A pair of outer rails, 5a and 5b, are disposed outside inner rails, 4a and 4b, and protrude from back surface 1b further into dark chamber 2 than inner rails 4a and 4b. Outer rails, 5a and 5b, guide film F (not shown) as it is drawn across aperture 1c. A first pressing roller 12 is biased toward take-up spool 11 by a leaf spring 12a affixed to partitioning wall 1a. A boss 11a, disposed on take-up spool 11, engages a sprocket perforation in film F (not shown) and winds film F around take-up spool 11 as take-up spool 11 is rotated in a counterclockwise direction. Referring back to FIG. 1, a back cover 6 encloses a rear of camera body 1, and a front cover 7 encloses a front of camera body 1. A pressure plate 8, disposed on an inside surface of back cover 6, biases film F into contact with inner rails 4a and 4b shown in FIG. 2. A second pressing roller 13 is biased toward take-up spool 11 by a leaf spring 13a affixed to back cover 6. Pressure imposed by first and second pressing rollers, 12 and 13, upon film F ensures tight winding of film F on take-up spool 11. A circle Cmax, shown by a double dash line, indicates the maximum diameter of film F wound on take-up spool 11. When the diameter of film F is at or near maximum circle Cmax, roller 12 is urged into a position, shown by a two-dots-dash line into a recess 3a in partitioning wall 1a. Roller 13 is similarly urged outward to a position shown by a two-dots-dash line. Referring again to FIG. 2, a data imprinting device includes a plurality of light emitting elements 21, preferably light emitting diodes (LEDs), disposed in a line on a substrate 22 in a direction perpendicular to the photosensitive surface of film F. Substrate 22 is mounted on a top surface 1d of camera body 1 such that emitted light from light emitting elements 21 passes through an aperture 1e in top surface 1d of camera body 1. A driver circuit (not illustrated), for light emitting elements 21, is also disposed on substrate 22. An optical system including first and second prisms 23 and 29, is disposed in a substantially triangular space S (indicated in FIG. 1) defined by back surface 1b of camera body 1. The prisms, 23 and 29 reflect the emitted light 90 degrees such that reflected light passes through apertures 1f and 1g, respectively, thereby imprinting data upon the photosensitive surface of film F (not shown). A shutter plate 36, having an aperture 36b, is disposed at a rear side of camera body 1. The shutter plate 36 is shown in a first position, used for a full size exposure, wherein aperture 1f is unobstructed, permitting the emitted light to pass therethrough and expose film F (not shown) while aperture 1g is obstructed. Alternatively, shutter plate 36 may be moved upward into a second position such that aperture 1f is obstructed and aperture 1g is aligned with aperture 36b, permitting the emitted light to pass therethrough and expose film F. The second position allows imprinting of film F in a panorama size format. Referring to FIG. 3, a mechanism for the operation of shutter plate 36 includes an upper screen framing member 31 attached to shafts 32, 32. Shafts 32, 32, pass rotatably through partitioning walls 1a and 1k, as shown in FIG. 1, allowing upper screen framing member 31 to rotate through an angle. A screen frame actuator 33 has a slot engaging a pin 31b on an ear portion 31a of upper screen framing member 31. An external control (not shown) is used to displace screen frame actuator 33 from a full size frame position to a panorama size frame position, shown by a double dash outline in FIG. 3, thereby rotating upper screen framing member 31 from a full size frame position, shown by the solid outline, to a panorama size frame position, shown by the double dash outline. In the full size frame position, upper screen framing member 31 has a cropping portion 31', shown in FIG. 1, which is raised thereby permitting exposure of an upper portion of film F. In the panorama size format position, cropping portion 31' is lowered thereby masking the upper portion of film F. A lower screen framing member 34 is similarly mounted upon shafts 35, 35, which pass rotatably through walls 1a and 1k, as shown in FIG. 1. Lower screen framing member 34 has a geared portion 34c engaged with a geared portion 31c of upper screen framing member 31 such that motion of lower screen framing member 34 mirrors that of upper screen framing member 31, thereby cropping the lower portion of film F with a cropping portion 34' shown in FIG. 1. The shutter plate 36 has an ear portion 36c with a slot 36a therein. A boss 34a, of lower framing member 34, engages slot 36a. Shutter plate 36 is slidably mounted such that it is actuated along a vertical axis in accordance with a position of lower framing member 34. Shutter plate 36 is shown in the full size position, covering aperture 1g while aperture 1f is uncovered. Alternative methods of implementing a shutter mechanism would be recognized in view of this disclosure by those skilled in the art. For example, pivoting shutters and rod-type linkages may be employed. Such methods, while employing alternative actuating systems, remain within the scope and spirit of the present invention. An optical system comprises an optical system shaft 24 which has an upper taper 24a and a lower taper 24b supporting prisms 23 and 29, respectively. Upper taper 24a is set back further from the surface of film F than lower taper 24b thereby permitting emitted light from light emitting elements 21 to reach both lower taper 24b and upper taper 24a. Prisms 23 and 29 both have reflecting surfaces on planes of upper and lower tapers, 24a and 24b, respectively, for reflecting the emitted light onto the surface of film F. Reflected emitted light of prism 23 crosses a path of incident emitted light of prism 29. The crossing of light paths permits both prisms, 23 and 29, and their respective apertures, 1f and 1g, to be in a line in a plane perpendicular to film F, thus allowing the optical system shaft width to be narrow along an axis perpendicular to the plane of FIG. 3. A roller 25 contacts an inner surface of film F and a spring 26, aligned with roller 25, contacts an outer surface of film F biasing film F against roller 25. Friction between roller 25 and the surface of film F rotates roller 25 in step with the movement of film F. Roller 25 is coupled to a slit wheel 27 by a shaft 25a. A conventional photo interrupter 28 encircles the edge of slit wheel 27. Photo interrupter 28 includes a light source in one of its arms and a photo detector in another of its arms. Each time a slit in slit wheel 27 passes between the light source and the photo detector, the photo detector produces a pulse signal which indicates a length of film F passing roller 25. It would be realized by one skilled in the art that alternative means of tracking film advance exist such as magnetic hall effect devices and variable resistance devices. Use of such devices is within the scope and spirit of the present invention. The pulse signal from photo interrupter 28 is applied as a feedback signal to a controller 40. Controller 40 comprises a CPU, ROM, RAM and peripherals for controlling a motor driver 41 for driving a film advance drive motor 42. An exposure format detecting switch 43 is controlled by a position of screen frame actuator 33 and signals to controller 40 a selected exposure format. The exposure format detecting switch has a brush 43a, positioned by screen frame actuator 33, which engages a stationary portion 43b. Signals produced by controller 40 are applied to LED driver 44. LED driver 44 produces drive signals for the LEDs of light emitting elements 21. The timing of the drive signals applied to light emitting elements 21 is controlled according to whether full size or panorama size format mode is selected. It is recognized that embodiments of the present invention may employ other means for implementing the controller without departing from the scope and spirit of the present invention. Contact between brush 43a and stationary portion 43b produces an electrical signal which indicates to controller 40 that the panorama size format is selected. When the panorama size format is selected, controller 40 actuates LED driver circuit 44 such that positioning and timing of the imprinting of data produces imprinted data in the panorama format. Conversely, when brush 43a and stationary portion 43b are out of contact, controller 40 initiates imprinting corresponding to that required in full size mode. Referring to FIG. 4, a backside view of the camera shows shutter plate 36 positioned in the full size format position with aperture 1f open and aperture 1g occluded. Upper and lower screen framing members, 31 and 34, are adjacent to shutter plate 36 and its ear portion 36c. Roller 25 is shown disposed below inner rail 4b and shutter plate 36. Film F, shown cut-away to the right, is aligned so as to pass over roller 25 which signals to controller 40 the amount of film passing. When the panorama size format is selected, shutter plate 36 rises upward and aperture 36b is aligned with aperture 1g. Thus, reflected light passing through either one of aperture 1f and aperture 1g is used to imprint data upon film F as it travels. The travel of film F, as sensed by roller 25, is used to coordinate a sequentially implemented longitudinal imprinting pattern upon film F. A vertical imprinting pattern is determined by a selection of LEDs of light emitting elements 21, as depicted in FIG. 3, which are simultaneously illuminated. Alternative embodiments of the present invention may employ differing light emitting devices or light controlling devices without departing from the scope and spirit of the present invention. Referring to FIG. 5, format layouts are shown with the panorama size format cropping shown in double dash lines superimposed upon the full size format cropping. Imprinted data 101 is in a position used in the full size format and imprinted data 102 is in a position used in the panorama sized format. The vertical positioning of imprinted data, 101 and 102, is determined by the positioning of apertures 1f and 1g, respectively. Imprinted data 102 of the panorama size format is accordingly located inward from imprinted data 101 of the full size format. A pattern of imprinted data, 101 and 102, as noted above, is produced by selective sequential illumination of the LEDs of light emitting elements 21 in coordination with the travel of film F past apertures 1f and 1g. Imprinted data, 101 and 102, of the figure may represent, for example, the date of the exposure. It is recognized that various other types of information and data may be imprinted upon the exposure. As examples and not limitations, such data may include an f-stop setting, a shutter speed setting, light levels, and photo identifiers or titles. It is further recognized that embodiments of the present invention may include peripherals that interface with the camera to allow data to be entered for imprinting purposes. Referring to FIG. 6, the optical system and the mechanism for the operation of the shutter plate 36 is shown in the panorama size format mode. The incident emitted light of prism 29 crosses the path of the reflected emitted light of prism 23 and is reflected by prism 29 upon the surface of film F. Aperture 36b, of shutter plate 36, is place in alignment with aperture 1g of the optical system, permitting the emitted light to strike film F at a lower position than in the full size framing position, wherein the reflected emitted light passes through aperture 1f. Shutter plate 36 covers aperture 1f of the optical system thereby disabling full size format data imprinting. Referring to FIG. 7, the alignment of shutter plate aperture 36b with the optical system aperture 1g is shown from the rear side perspective. Cropping portions, 31' and 34', of upper and lower framing members, 31 and 34, respectively, are shown in their panorama mode positions, and aperture 1f is covered by shutter plate 36 thus disabling the imprinting of data in the full size format. Referring to FIGS. 8(a) and 8(b), the optical relationships of prisms 23 and 29 are shown wherein a size of the imprinted data is varied from the full size format to the panorama size format. While prisms 23 and 29 in prior figures have a reflecting surface, biconvex lenses, and are triangular in shape, prisms 23 and 29 are represented in FIG. 8 as simple biconvex lenses in the interest of simplicity. An arrow Y0 at the left of FIGS. 8(a) and 8(b) represents an object height of light emitting elements 21 while arrows, Y1 and Y2, on the right side represent image heights of the resultant imprinted data. While object height Y0 is constant in both figures 8(a) and 8(b), image height Y1 of the full size format imprinted data is larger than image height Y2 of the panorama size format imprinted data, shown in FIG. 8(a). The ratio of object and image distances, S 1 to S 1 ', is determined by a position of prism 23 in optical shaft 24 with respect to light emitting elements 21 and the surface of film F. The focal length f of the lens may then be selected to produce a focused image based upon this ratio. Similarly, the ratio of object and image distances, S 2 to S 2 ' is determined. It is realized that alternative embodiments of the present invention may employ other light directing and focusing means, such as mirrored surfaces and independent lenses, in place of the compound lens-prism of the presented embodiment, without departing from the scope and spirit of the present invention. The embodiment of the present invention, as described above, has prism 23 in a line with prism 29 in a vertical plane perpendicular to the surface of film F and set back further from film F than prism 29, as shown in FIG. 6. This arrangement results in image distance S 1 ' being greater than image distance S 2 ' and the crossing of paths of the reflected emitted light of prism 23 and the incident emitted light of prism 29. Furthermore, the selection of the distances S 1 , S 2 , S 1 ', and S 2 ' permits the use of a single type of prism having the same focal length f for both prisms 23 and 29. Finally, the crossing paths of light permits the in-line arrangement thus reducing the width of the space required for the optical system allowing a more compact camera to be produced. Referring to FIGS. 9 and 10, a second embodiment of the present invention is shown having features similar to those of the first embodiment, described above, except as note herein. An optical system shaft 124 has upper and lower tapers, 124a and 124b, upon which are mounted prisms 123 and 129, respectively. Prisms, 124a and 124b, are located a substantially equal distance from the surface of film F and are thus in a line with each other in a plane parallel with film F. In FIG. 10, it is clear that prisms, 123 and 129, are offset from each other. This offset arrangement produces an optical system requiring less depth in camera body 1 than the first embodiment of the present invention since there is no crossing of light paths. Referring to FIG. 11, wherein optical path lengths of the second embodiment of the present invention include image distances S 11 ' and S 12 ', representing distances from film F to prisms 123 and 129 respectively, being substantially equal. Object distances S 11 and S 12 represent distances from light emitting elements 21 to prisms 123 and 129 which are represented as simple biconvex lenses for purposes of simplicity. Object distance S 11 is shorter than object distance S 12 . Accordingly, image height Y1 produced in the full size format is greater than image height Y2 produced in the panorama size format. Focal lengths f 1 and f 2 of prisms 123 and 129 are either selected independently in order to focus images Y1 and Y2, or are equal provided that there is a sufficient depth of field for images to be adequately focused. It is recognized by those skilled in the art that various combinations of focal lengths and object and image distances may be chosen based upon requirements of a system. Referring to FIGS. 12 through 15, there is shown a third embodiment of the present invention which is similar to the first embodiment except as noted herein. A shading plate 136 is shown in a full size format position in FIGS. 12 and 13 wherein an upper portion of shading plate 136 covers aperture 1g and ends a distance H from aperture 1f. Shading plate 136 is in the panorama format position in FIGS. 14 and 15 with aperture 36b aligned with aperture 1g thereby permitting data imprinting in a panorama size format. Aperture 1f remains uncovered thus permitting simultaneous full size format data to be imprinted, however, the full size format data does not affect a photographed image because the full size format imprinting is on an area of film F which is masked by upper cropping portion 31' of upper framing member 31. Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
A camera with a data imprinting device has a plurality of in-line LEDs producing light focused by an optical system upon a photographic film at a first and a second position, corresponding to a full size format and a panorama size format, respectively. The focused light imprints data images upon the film at the first position are larger than data images imprinted at the second position. The optical system has first and second prisms, with integrated lenses, for reflecting and focusing the light upon the film at the first and second positions, respectively. A shutter plate is selectively positioned over apertures through which the light is focused, thus blocking the light and allowing only a selected imprint to be made upon the film. A vertical pattern of the data image is created by a controller selectively illuminating the in-line LEDs while a horizontal pattern is produced by the controller illuminating the LEDs in coordination with the movement of the film past the apertures. The controller actuates a motor for advancing the film and has a sensor for detecting film travel. A first embodiment has the first prism positioned further from the film than the second prism, which is positioned further from the LEDs than the first prism, such that reflected light from the first prism has a path intersecting that of incident light of the second prism. A second embodiment has the prisms offset from each other in the plane of the film such that light paths do not intersect. The first embodiment has a narrower width than the second embodiment while the second embodiment has a shallower depth than the first embodiment.
6
CROSS REFERENCE TO RELATED APPLICATIONS This application is based on and claims the benefit of U.S. Provisional Application No. 61/306,030, filed Feb. 19, 2010, which is incorporated herein by reference. FIELD OF THE INVENTION This invention relates in general to certain new and useful and required improvements in the protection of pipe insulated materials from outdoor physical and degradation damage as well as efficient and aesthetic methods to prevent atmospheric air leakage from entering a building. In particular, the invention relates to a pipe and duct installation system which seeks to improve long term optimal energy efficiencies in residential and commercial buildings and to follow the new 2012 Energy Model Codes. BACKGROUND There are many challenges with long term optimal energy efficient installations of outdoor insulated pipe and conduit, including the protection of these from ultraviolet exposure, weather, wind, physical and material degradation or both. The degradation of these pipe insulated materials is very important to maintain energy efficiency as the heating or cooling systems depend on the conveyed fluids and the maintaining of temperatures being controlled. These temperatures can be negatively affected by extreme outdoor temperatures and in turn, make the systems work harder and longer than would otherwise be necessary, therefore adding energy consumption. In addition, building fenestration has also become an important energy efficient issue. The stoppage of outdoor atmospheric air coming into the buildings is a very important issue, as this negatively affects the controlled indoor building temperature and will make the cooling and heating mechanical systems work harder and longer than would otherwise be necessary, and again therefore adding energy consumption. There are also many associated installation challenges when exterior wall penetration is required including sealing, connecting, aesthetics, maintenance, and flexibility. Many times the multiple amount of Air Conditioning or Heating unit systems and the respective line sets are ganged up in one central location making it difficult for the installer to install, seal, and protect each and every line set. Therefore, there is a need for a receiver that can accommodate the line sets in a quick, efficient, aesthetic, and a systematic battery or gang method. These installations are common in apartment buildings, office buildings and where more than one system is installed in the same area. There are many different ways that these installations are taking place. More specifically pipe insulation is generally not being protected and the weather exposure causes the degradation of the soft foamed polymers used as insulation. When the pipe insulation is protected, in many instances, adhesive tapes are used. The weather exposure eventually causes the tape adhesives to either fail due to unraveling or fusing to the polymer causing material permeation issues, corrosion, mold, and maintenance issues. Among the many different methods presently being used is the recess boxing method. This is done by the installer having a metal box fabricated and embedded into the exterior wall and having the line set passing through the box and then sealing all around with a urethane foam or other kind of sealant. In this method, aesthetics and proper long term sealing are inadequate, as the installations look unsightly with unaesthetic unfinished cavities in the wall and the hardened urethane foam materials fail and become cracked therefore leaving air leakage gaps. There are installations presently being used that make use of single inlet roof flashings which are attached and are embedded to the rough membrane of the exterior wall and which are made of sheet metal, plastic or a combination of both. The flashing is used to contain an area for the line set to go thru a single metal area and other flashings contain a neoprene resilient single area for the seal of the line set that stretches to accommodate different diameters. However there are several set backs to these installation methods. When metal only flashings are used, not only does it become a necessity to seal the line set gap left between the annular metal area of the flashing and the line set to seal for air leakage, but a very difficult to seal hollow area is created. This area is presently being sealed by the usage of adhesive tapes that fail or foam sealers that also eventually fail. The roof flashing is also limited in that it does not allow the installer an option of attachment as the installation always has to be made on the rough wall while construction is taking place. Therefore if the installer misses or forgets to do the installation during construction, it will be difficult to correct the problem later. The other limitation is that the single passageway holds a very thin area that requires a difficult angle to accommodate and lacks surface area continuance, making an efficient installation impossible. This is due to for the most part the extreme directional angles of the piping to be accepted. In addition, whether a plastic or a metal flashing is used or not, the non-supported exterior wall finish material that is terminated at the single neck area radius of the flashing, creates a difficult and unsupported surface area for application of the finish materials. This will leave areas with unfinished material gaps, crevasses, and cracks that cause air leakage. The other limitation of roof flashings is the lack of flexibility of the single opening as the line sets address the wall, from many different angles, before going into or out of the exterior walls. U.S. Pat. No. 5,588,267 to Rodriguez and U.S. Pat. No. 7,730,681 B2 to Gilleran show examples of roof and wall flashings. In addition there is another installation method that uses an exterior rigid plastic wall shield that is not always economically feasible. Most of the linear line sets are installed in the cavity of the exterior walls. Sealing to prevent air leakage is not a feature in this system. In addition there is a limitation with rigid shields as flexibility has become a challenge and an important requirement for full enclosure of these hard to follow line set patterns. There has been a need for a complete insulated pipe and duct mounting arrangement in the marketplace. The installer has been having to depend on make shift custom fabrications that leave much room for improvement and are limited on sealing, aesthetics, attachment, and that are time consuming to install. Therefore there is a need for an improved system which is easy to install and highly efficient in operation. OBJECTS OF THE INVENTION It is therefore an object of the present invention to provide a wall duct receiver assembly adapted to fit together with a flexible protective cover to provide a long term energy efficient line set installation that will not depend on adhesives, tape, or foam fillers. It is also an object of the invention to provide a wall duct receiver assembly that incorporates mechanical attachments with improved aesthetics for single and multiple inlets and connections to accommodate insulated pipes and ducts of different sizes. It is another object of the invention to protect pipe insulation line set materials from physical or ultraviolet degradation, and to provide a wall receiver assembly which is easily removable and reusable for maintenance and with flexible capabilities for full enclosure without the use of adhesive tape. It is another further object of the invention to mechanically connect a single insulated line set or a multiple insulated line set or a battery of insulated line sets to a single wall receiver that has the ability to seal and secure a single inlet or multiple inlets against air leakage and accommodate different diameters and to include one or more inlets within the same wall receiver. It is an additional object of the present invention that the wall receiver inlets have a high degree of flexibility that allows for sealing at an extreme angle and offer a 360 degree of high flexibility to accommodate difficult to seal line set patterns. It is also an object of the present invention that the wall receiver allow for an economic installation solution to allow the longest linear part of the line set to be installed in the exterior wall cavity and yet allow for the soft copper piping bending radius required, to exit at the equipment service point without the need for extra pipe joints or fittings. It is still a further object of the present invention that the wall receiver be insulated and will seal the area between the wall surface and the receiver to prevent air leakage and that allows for the installation to be directly installed to the finished surface of the exterior wall with mechanical fasteners that are directly anchored or attached to the wall surface. It is yet another object of the present invention that the wall receiver allows for the utility of an interior wall bracket that will not utilize or perforate the exterior finished wall surface for mechanical fastening attachments but rather will be attached to the rough interior wall by use of nails or screws and in turn will be the attachment or support for the wall receiver with all the required fasteners pre-arranged and for the proper receipt or mounting of the wall receiver. With the above and other objects in view, my invention resides in the novel features of construction, form, arrangement, and combination of parts and components presently described and pointed out in the claims. BRIEF SUMMARY OF THE INVENTION The present invention relates to an insulated pipe mounting arrangement system that fits over a section of an air conditioning line set and receives it at the service point where the mechanical equipment is installed outdoors. This combined system uses two main components each with its own separate components and features. A protective cover that goes over the exposed insulated line set, and a wall receiver that is installed as the connector or transition between the building envelope or exposed insulated line set and the exterior wall penetration. The line set protective cover can be made of resilient materials like poly vinyl chloride (PVC) or the like, and can be injection molded or plastic sheeting as these materials have been found to contain resistant degradation qualities when exposed in outdoor use. The other materials that can withstand outdoor use for this specific purpose are metal and canvas. However, metal has flexibility, corrosion and cost disadvantages and canvas has issues with moisture rot and attachment limitations. Therefore flexible plastic and the usage of fasteners such as hook and loop or other type of mechanical fastener is ideal for this specific usage. Since wind or tamper resistance is also desirable these protectors will also integrate an extra tamper resistant fastening method with the installation as optional for the installer. The cover can be made for easy on and off use with a slit and fasteners that are attached for ease of installation or it can be more of a conduit construction with a flexible design. The importance of a service person having access to the line set copper lines is important as this is an area that requires constant repair and maintenance and requires the copper lines to be repaired for leaks. This invention also intends to relate to and accomplish improved and incorporated methods on how to protect insulated pipe for easy, quick and more efficient installations and to make service maintenance inspections quicker and more efficient with removable and replaceable features. Regardless of the protectors having a slit or non-slit construction, one area of importance is the point of connection with the wall receiver. The wall receiver can be plastic injection molded and made of rigid poly vinyl chloride (PVC) or acrylic butylenes styrene (ABS) or the like and can also be either fabricated or molded and made out of metal. These plastic materials can resist long term outdoor exposure by the use of additives. The inlet that will be receiving the line set and that is mounted on the wall receiver has a radius construction made of plastic that is highly resilient flexible material such as neoprene, silicone or the like. The importance of this material to be highly flexible and resilient is that the specific point of connection is best suited with these features to accommodate different line set diameter sizes so the requirement for highly resilient material is important for multiple size fit capabilities. In addition the radius construction has a tapered design that allows added flexibility to ensure air leakage sealing even when extreme angled line set fitting is required. A tight and flexible fit can then be utilized to prevent building atmospheric air leakage from the inlet. In addition, a secondary holding fastener is also utilized to ensure continued connection security and long term sealing. Also important is the method of wall attachment that the wall receiver offers. The receiver can be installed with the wall receiver directly bolted to the wall whether backing is used or not. The preferred installation is the combination housing receiver with the wall bracket as this will not require the use of wall penetration for fasteners. The wall bracket is preferably made out of 18 gauge galvanize sheet metal, the bracket can also be made out of rigid plastic and can be injection molded or fabricated. The wall bracket installs to the rough wall membrane and has apertures for direct nailing or bolting to the rough wall to make the installation quick and easy. The wall bracket has integral fastener receivers that allow the wall receiver to be attached. Once the finish surface is complete, the bracket will then serve as a support and help enhance the sealing with a sandwiching effect as a weather gasket is placed between the wall surface and the back side rim of the wall bracket. Fasteners are also part of the wall receiver assembly and may come in different lengths depending on the wall membrane thickness requirement. The wall receiver also includes fastener openings or apertures that will allow easy installation either directly to the wall or to the wall bracket. The preferred fastener openings are scored with knockout capabilities so that the installer has the option of installation with or without the bracket. The knockout feature prevents air leakage through the fastener apertures which will not be needed to accommodate the fasteners. Caps can also be used to cover the fastener opening areas as well. This invention possesses many other advantages and has other purposes which may be made more clearly apparent from a consideration of the forms in which it may be embodied. These forms are shown in the drawings forming a part of and accompanying the present specification. For purposes of illustrating the basic principles they will now be described in detail. It is to be understood that the following detailed description and the accompanying drawings are not to be taken in a limiting sense. BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings: FIG. 1A is a front exploded perspective view showing a complete front view of the wall retainer housing and the wall bracket used with and connected to the insulated pipe line set with a protector; FIG. 1B is an enlarged and detailed sectional side view showing an outdoor exposed installation including a conventional insulated and protected air conditioning or heating exchanger line set and the wall receiver mounting assembly; FIG. 2A is a back view of a wall receiver housing only; FIG. 2B is a side view of an insulated wall receiver housing; FIG. 2C is a back side view of an insulated wall receiver housing; FIG. 2D is a partially cutaway side view of a wall receiver with a threaded mechanical connection construction; FIG. 3A is a front view of the wall receiver housing with elastic neck inlets; FIG. 3B is a sectional side view of an insulated wall receiver housing with the front elastic neck inlets of FIG. 3A showing a gasket abutted to the back edge at the perimeter of the wall receiver; FIG. 3C is a back side view of the insulated wall receiver of FIG. 3A showing the back side of the perimeter of the wall receiver that abuts with the gasket including the tapered inlet neck areas and the fastener passageways 127 . FIG. 4A is a front view of an exterior elastic inlet neck area and its open passageway; FIG. 4B is a side view of the exterior of the elastic inlet neck area of FIG. 4A with raised areas for secure clamp area and the tapered diaphragm attachment area that allows the wall area of the wall receiver to be accommodated in the tapered area for attachment; FIG. 4C is a front view of an angled neck inlet; FIG. 4D is a side view of the angled neck inlet of FIG. 4C ; FIG. 5A is a front view of an exterior elastic inlet neck area with a closed or sealed passageway and an end cap area with a score line cutting area to accommodate and seal smaller diameter pipe, conduit or wiring; FIG. 5B is a side view of the exterior elastic inlet neck area of FIG. 5A showing the cut score lines, tapered attachment area and the end cap area, including the raised area to secure clamping; FIG. 6A is a front view of an optional rough wall bracket for attachment of the wall receiver housing to a wall; FIG. 6B is a side view of the rough wall bracket of FIG. 6A showing a channel area between the large flanged perimeter area that is directly abutted to the rough wall and the smaller flanged perimeter area that abuts to the gasket and the finish surface area; FIG. 7A is a front view of the wall gasket that abuts between the finish surface of the exterior wall and the back side of the perimeter edge flange within the back side of the wall receiver housing; FIG. 7B is a side view of the gasket of FIG. 7A ; FIG. 8A is a front and enlarged sectional view of the pipe, pipe insulation, and pipe insulation protector; FIG. 8B is a side sectional view of the pipe, pipe insulation and pipe insulation protector line set assembly of FIG. 8A ; FIG. 8C is a front view of a non-slit protector or conduit construction with the pipe and pipe insulation inside; FIG. 8D is a side sectional view of the protector or conduit with an enlarged fastening joint area line set assembly; FIG. 8E is a front view of the protector or a conduit for pipe insulation with a slit construction: FIG. 8F is a front view of a protector or a conduit for pipe insulation with an overlapping edge construction; FIG. 9A is a front view of a clamp or ring type securing fastener; FIG. 9B is a side view of a clamp or ring type securing fastener of FIG. 9A ; and FIG. 9C is a front perspective view of a threaded type securing fastener. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The preferred embodiments described herein are only for purposes of illustration and are not to be understood to be any limitations on the inventive subject matter being described. The preferred embodiment of the insulated pipe ducting and mounting arrangement is a system of FIG. 1A that incorporates a wall receiver 100 with one or more attached continuous inlet ducts 400 and 500 for receiving a pipe or piping 900 covered by insulation 800 and that includes a protector system 700 for the insulated pipe or piping 900 that has been adopted by the new 2012 Energy Codes for the Residential and Commercial Building Energy Model Code Requirements. The codes require that the exposed insulated piping 900 be protected from the outdoor weather exposure and physical damage without the use of adhesive tape. The preferred embodiment described below incorporates many detailed solutions for the many challenges associated with this requirement. In the preferred embodiment shown in FIG. 1A , the wall receiver 100 has a predetermined and configured angle making it possible to accommodate the piping 900 within a wall cavity defined between adjacent 2×4 studs 1200 , and enabling the pipe to be bent to the exterior without kinking. Installations using the least possible fittings are the most desirable ones, as this is a way to minimize friction within the fluids for better efficiency in the running of the equipment that will result in energy efficiencies as well. The refrigerant fluids are carried by the piping 900 which is made of soft copper. The copper piping 900 can be bent by the installer up to a certain degree, which is the standard practice in the plumbing, heating and cooling industry. The Residential and Commercial Building Energy Model Codes are gravitating into improved and increased pipe insulation, outdoor protected insulation, and fenestration, which is the elimination of heat or cold from atmospheric air leakage and entering into the building and negatively affecting the energy consumption. Therefore in another preferred embodiment, the wall receiver 100 is insulated by a layer of insulation 130 on the back side of the cavity area of the wall receiver 100 as shown in FIG. 2C . The wall receiver 100 in another preferred embodiment has a respective wall bracket 300 shown in FIG. 6A and FIG. 6B that is attached to the rough 2×4 wall studs 1200 of a building as shown in FIG. 1A , by use of nails 1100 or screws which pass through apertures 302 shown in FIG. 6A . The bracket 300 receives a finish wall receiver housing 100 shown in FIG. 1A , assisted and held by fasteners which pass through apertures 301 shown in FIG. 6A that are threaded housings. In a preferred embodiment shown in FIG. 7A , a gasket 200 is provided for sealing between the wall receiver 100 and the bracket 300 to prevent air leakage. The gasket 200 is assisted by the use of fasteners 1000 shown in FIG. 1A , that engage with threaded apertures 301 as shown in FIG. 6A and threaded housings or fastener receivers 303 shown in FIG. 6B . The wall bracket 300 has a channel 304 shown in FIG. 6B that is formed between the large flange 305 that is nailed or screwed to the rough wall and the small flange 306 shown in FIG. 6A that holds the wall receiver 100 . The channel 304 can be changed in dimension, made either wider or narrower, to accommodate thicker or thinner exterior wall thicknesses and the combined wall membrane thicknesses required. In a preferred embodiment the large flange 305 of the wall bracket shown in FIG. 6A can also be formed, bent or constructed into different shapes such as extended ear-like shapes to assist in installing the bracket 300 and to make it easy and efficient to accommodate for different exterior construction types such as masonry exterior wall construction and the like. The preferred embodiment shown in FIG. 18 incorporates the bracket 300 and the finish wall receiver housing 100 , the gasket 200 and the exterior wall membrane 1300 that creates a pressure system to not only seal from air leakage but also offers a fully pressure supported distributed system that creates clamping pressure applied inside and outside the wall to prevent long term cracking, spacing, and a more efficient, uniform, consistent wall surface finished gap and sealed installation. The wall receiver housing 120 shown in FIG. 2A incorporates apertures 121 for fasteners and has a finish edge or rim 124 that supports and allows for any added sealing that may be applied such as weatherproof silicone material caulking around the narrow edge perimeter of the receiver 100 . An entry point 122 or points 123 are formed as openings in the slanted front panel 125 the wall receiver 100 . As shown in FIG. 1B , the front panel 125 is slanted to provide a cavity area 126 inside the wall receiver 100 . The wall receiver 100 shown in FIG. 1A and the respective wall bracket 300 can also accommodate different exterior wall thicknesses with the simple use of either longer or shorter bolts 1000 , or threaded rods and threaded nuts, or other type of anchoring fasteners. FIG. 2C shows that the wall receiver 100 can also be insulated by providing a layer of insulation 130 on the back side of the cavity area 126 defined by the slanted front panel 125 . The wall receiver 100 , shown in FIG. 1A in a preferred embodiment can also be installed on its own without the use of the rough wall bracket 300 . The wall receiver 100 has apertures 121 shown in FIG. 2A to accommodate different types of fasteners that are available to the installers and that are capable of passing through the receiver and wall area, such as bolts, anchor fasteners, toggle fasteners or any combination thereof. In a preferred embodiment the wall receiver 100 may have one or more inlets 400 and 500 with different sizes that are mounted over the wall receiver openings of 122 and 123 shown in FIG. 2A . The inlets may be attached with the wall receiver 100 by the use of elastic material over molding or an attached molded sandwich type insert. As shown in FIG. 5B , a molded plastic insert 404 can be inserted at the back of the inlet 400 to attach the insert 500 to the front panel 125 of the wall receiver 100 . The molded plastic insert 404 has a back face or flange 405 which together with a back face or flange 408 of the inlet 400 provides a channel to receive the material of the wall receiver housing 100 in a sandwich-like fashion between the flanges 405 and 408 . A molded plastic insert 503 shown in FIG. 4B can be inserted at the back of the inlet 500 to attach the inlet 500 to the front panel 125 of the wall receiver 100 . The molded plastic insert 503 has a flange 506 which together with a flange 508 of the inlet 500 provides a channel to receive the material of the wall receiver housing 100 in a sandwich-like fashion between the flanges between the flanges 506 and 508 . In the preferred embodiment, the inlets 400 and 500 of FIG. 1A can be constructed to accommodate pipes of different sizes. Each of the inlets 400 shown in FIG. 1A can have an integral cap 401 or end point with score lines 402 in the end areas so the installer can cut the opening to the desired fit size on the job. Therefore the installer will have a choice of the desired inlet to be opened and used. The inlets shown in FIG. 5A not to be utilized can be air leak sealed within the integral end cap area 406 . The end cap area 406 can also contain score lines 407 within different sized diameter areas which can be cut by the installer to accommodate different sizes of pipe conduit and the like. The inlet 500 can be provided with a similar end cap and score lines to allow the size of the opening to be adjusted to accommodate different sizes of pipe conduit. In a preferred embodiment shown in FIG. 4B , the inlet 500 has raised lines or guides 502 which are spaced apart to provide an area for a clamp or ring fastener. Also, as shown in FIG. 5B , the inlet 400 has raised lines or guides 402 and 403 which are spaced apart to designate the area for the clamp or ring fastener. The raised lines 402 , 403 and 502 can also be used as cutting line guides or score lines with integral weakened or exterior or internal thinner material lines for cutting to required size, diameter and or length that can be integrated for multiple sizes with a taper or graduated form. The inlet 500 shown in FIG. 1A , that is attached to the wall receiver 100 has several unique features in its preferred embodiment. The inlet 500 provides a flexible 360 degree universal entry angle capability which is important as the direction of the entry point will be different for the installer in different installations. The receiver inlet 500 may also have a housing that will be integrated into the wall receiver or attached by mechanical means, allowing the inlet 500 to be fully rotatable or to swivel to accommodate any angle that the insulated piping 900 is to be received from shown in FIG. 4C and FIG. 4D . The preferred embodiment inlet shown in FIG. 4C and FIG. 4D can combine an integral angled inlet 504 that can have a built-in orientation in the approximate range of 45, 60, or 90 degrees. The angled inlet embodiment provides for easier accommodation of the insulated piping 900 and the protector 700 that are connected with the inlet 500 , mostly from a lower or higher elevation position but most importantly away from the exterior wall. The angled inlet 504 shown in FIG. 4D can easily be rotatable to accommodate piping 900 from different directions. The angled inlet 504 can be cut along the angled score line 505 shown in FIG. 4D for a straighter directional installation. The preferred embodiment of the inlet 500 has a continuous elongated neck area shown in FIG. 1B and has an inlet continuance that conventional roof flashing of the prior art do not have. The inlet 500 incorporates an internal passageway area 501 shown in FIG. 4A for a higher degree of air leakage deterrence. At the same time the exterior inlet neck area 500 allows for a weather resistant or tamper-resistant connection with the pipe insulated protector, by the added security of a mechanical clamping means 600 shown in FIG. 1A either secured to the wall receiver 100 and or the inlet 500 or both. The preferred embodiment of the inlet neck 500 shown in FIG. 1A can be made of a highly resilient and resistant plastic. The inlet neck 500 can be an exposed part or it can be a protected part with a respective housing cover or shade directly attached to the inlet neck 500 or to the wall receiver base or both by means of mechanical attachment. The inlet neck cover 500 shown in FIG. 4B is attached preferably by plastic over molding snap on fastening, bolted, threaded, inserted, or other co-acting fastening components 503 . In a preferred embodiment the wall receiver 100 , as shown in FIG. 2D , can have a threaded connection 101 , which can be integrally molded or attached as a separate part to the construction, to assist in connecting the arranged pipe insulated protector with the wall receiver 100 and also serving as an inlet passageway 102 . In a preferred embodiment shown in FIG. 4A of the exterior neck inlet base area 500 , a universally directional and adjustable housing or cover can be provided to cover the highly resilient plastic to prevent atmospheric air leakage into the building. The adjustable housing or cover can be attached to the inlet neck area base 500 or the wall receiver base 100 shown in FIG. 1A or both by means of mechanical attachment. The inlet, its respective cover, or a combination can be both preferably attached or connected by a snap on, bolted or other co-acting mechanical fastening elements. In the preferred embodiment of the inlets 400 and 500 shown in FIG. 3A , the score lines can be arranged with different diameters to allow the selection of multiple diameter sizes by cutting along the score lines to provide the desired diameter needed to be fitted into and or connected to the piping 900 . In a preferred embodiment FIG. 1A both of the inlet neck internal areas 500 and 400 are able to be sized for a multiple diameter passageway of pipe and or conduit types or wiring with score lines 407 for air leak sealing. In a preferred embodiment this can also be used by a step down or tapered diameter down sized constructed inlet. This can also be accomplished in a preferred embodiment by the use of an end cap 406 or an accommodating ring end cap. The preferred embodiment of the pipe insulated protector 700 shown in FIG. 1A , that connects to the wall receiver inlets 400 and 500 , is made of a plastic molded or extruded material that has a flexible construction and is sized to accommodate a multiple and combined amounts of insulated pipe, pipe, wiring, conduit and can be cut to the desired length needed. In the embodiment shown in FIG. 8A and FIG. 8B , the insulated pipe protector 700 can be a larger conduit with an internal hollow core passage or a hose-like flexible conduit with a non-slit design, that fits over the pipe 900 and the pipe insulation 800 . The installer simply slips or feeds the non-slit protector 700 over the insulated pipe or conduit 900 . The protector 700 is then connected with the assistance of a mechanical fastening member shown in FIGS. 9A and 9B which can be embodied as a fastener ring 600 having an integral means of locking and hinging that assist in connecting and securing the ring 600 to the inlet neck 500 that is attached to the wall receiver 100 . In a preferred embodiment shown in FIG. 9A , the ring 600 includes a hinge 601 which allows the ring 600 to be clamped to the inlet 500 and to the pipe insulated protector 700 . In a preferred embodiment shown in FIG. 9C , the ring 600 has an internal threaded area 602 that co-acts with the threaded area 101 shown in FIG. 2D on the wall receiver housing 100 and allows for the full rotation of the inlet 500 to accommodate the different angles associated with the installation. The flexible hose-like duct 700 can also have an end connection ring or fastener 701 to assist with the co-acting connection as shown in FIG. 8D . In a preferred embodiment a cap fits on the opposite end of the arranged pipe insulation protector 700 to assist in air sealing the passageway from the opposite end. In another preferred embodiment of the pipe insulated protector 700 shown in FIG. 1A that connects to the wall receiver inlet 500 , the protector 700 can be embodied as an elongated sleeve 701 of a plastic material that is molded or sheeted and flexible and has a longitudinal slit 703 as shown in FIG. 8E . In a preferred embodiment shown in FIG. 8F , the protector 700 is a protective cover arrangement 702 with an overlapping construction 704 , that wraps around the pipe insulation 800 shown in FIG. 1A . The overlapping sections 704 are attached to each other by the use of mechanical fastening such as bolts and apertures, snap on co-acting plastic or metal molded fasteners, or self contacting fiber fasteners or self contacting molded fasteners. The snap on or nut and bolt fasteners can also be installed with the use of eyelets. In another preferred embodiment the pipe insulation protector 700 shown in FIG. 1A , the protector 700 can be constructed with self contact fasteners such as hook and loop and can also be arranged to accommodate a universal fit for different diameters of insulated pipe by applying a thicker fastening strip or strips on a horizontal manner or a perpendicular manner adjacent to the matching slit closed edges or the over lapped edge closure. The fasteners can be bonded and preloaded with use of molded, sonic welding, radio frequency welding, hot air welding and non adhesive bonding. If hook and loop fasteners are to be used the non adhesive bonding can also be reinforced with threaded stitching for extra weather resistant security. The protective cover 700 can then also be cut to fit and can be cut to the desired length needed. The invention in its broader aspects is not limited to the specific details of the preferred embodiments shown and described, and it will be appreciated that variations and modifications can be made without departing from the scope of the invention.
An outdoor insulated pipe and duct mounting system includes a wall mounted receiver arranged to receive an insulated pipe or duct provided with an insulation pipe protector which connects and seals to the receiver. The combined system is able to accommodate insulated pipes of different sized diameters and can accommodate one or more inlets within the same receiver with a high degree of flexibility and unique mechanical connection security. The mounted wall receiver system is arranged to receive the insulated piping from any directional angle with a unique full rotation inlet capability. The system serves buildings with outdoor installed air conditioning line sets, insulated pipes, and conduit that have the need to penetrate the building envelope in order to be connected to the buildings indoor mechanical, plumbing, or electrical systems. The system is designed to be installed as an option for new construction applications, to upgrade existing installations, to replace existing installations and for addition to existing installations, but all in an aesthetic and efficient way.
4
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of printers and to method of loading an inking ribbon into a printer. 2. Brief Description of the Prior Art Co-owned U.S. Pat. No. 4,776,714 granted on Oct. 11, 1989 to Ikuzo Sugiura et al relates to the printer used with the present invention and the disclosure of U.S. Pat. No. 4,776,714 is incorporated herein by reference. This patent discloses a printer equipped with an ink ribbon cassette. U.S. Pat. Nos. 2,464,042; 2,764,934; 3,710,915; and 4,492,159 are also made of record. SUMMARY OF THE INVENTION The invention relates to an improved printer which is easy to load and unload with inking ribbon without the use of an inking ribbon cassette, and it also relates to an improved method of loading an inking ribbon into a printer. It is a feature of the invention to provide an arrangement by which an inking ribbon supply roll can be loaded into a printer and by which the inking ribbon can be threaded through its normal path but away from the print head and its cooperating platen. This is particularly useful when the inking ribbon is wide. After the inking ribbon has been threaded along the path, the inking ribbon is shifted into a space between the print head and the platen. Thereafter, the print head and platen can be moved relatively toward each other for printing on a record medium. This separation of the loading function of the inking ribbon into two stages obviates difficulties encountered in attempting to load an inking ribbon cassette and simultaneously position the inking ribbon between the print head and the platen. In accordance with a specific embodiment of the improved method of the invention, the method involves providing an inking ribbon wound into a supply roll, providing a take-up spool, providing a printer having a print head and a platen, the print head and the platen being relatively movable between a printing position and an open position, the print head and the platen being spaced apart in the open position to provide clearance space into which a portion of the inking ribbon is insertable, the printer having a supply spindle, a take-up spindle and guides mounted for shifting movement as a unit, the guides providing a guide path for the inking ribbon, a portion of the guide path being aligned with but spaced from the clearance space during threading of the ink ribbon along the path, inserting the supply roll onto the supply spindle, inserting the take-up spool onto the take-up spindle, thereafter threading the inking ribbon about the guides along the path, thereafter shifting the supply and take-up spindles and the guides as a unit to bring the aligned portion of the inking ribbon into the clearance space, and thereafter moving the print head and platen into the printing position with the inking ribbon in inking contact with a record medium. In accordance with a specific embodiment of the printer there is provided a frame, a print head mounted on the frame, a platen cooperable with the print head to print on a record medium, the print head and the platen being relatively movable between an open position in which the print head and the platen are spaced apart to provide clearance space and a printing position, a supply roll spindle for receiving an inking ribbon wound in roll form, a driven take-up spindle about which spent ribbon is wound, means for guiding the inking ribbon along a path from its roll to the take-up spool, and an arrangement for movably mounting the spindles and the guide means as a unit between an inking ribbon threading position where the inking ribbon is spaced from the clearance space and an inking position within the clearance space. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary front elevational view of a printer embodying the invention; FIG. 2 is a fragmentary perspective view of the printer shown in FIG. 1; FIG. 3 is an exploded perspective view of an improved arrangement by which an inking ribbon can be easily threaded and subsequently moved to its operating or inking position; FIG. 4 is an elevational view showing the mounting arrangement in the inking ribbon threading position, taken from the right side of FIG. 1; FIG. 5 is an enlarged elevational view showing the detent mechanism in detail; and FIG. 6 is a fragmentary perspective view of structure for enabling inking ribbons of wider widths to be accommodated. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIG. 1, there is shown a printer generally indicated at 10 including a housing or frame 11 to which a printing mechanism generally indicated at 12 is mounted. The printing mechanism 12 includes a cantilever-mounted thermographic or thermal print head 13 and a platen generally indicated at 14 in the form of a platen roll 15. FIG. 1 shows the print head 13 in an open, inoperative position spaced from the platen roll 15 by a gap or clearance space S. By pivoting a lever 16 clockwise, the print head 13 is moved toward the platen roll 15 into printing cooperation with the platen roll 15 as in U.S. Pat. No. 4,776,714. The space S allows the inking ribbon IR and record medium RM to be inserted between the print head 13 and the platen roll 15. With reference to FIG. 2, there is shown a supply roll shaft 17 which is D-shaped in construction. A continuous braking force is applied to the shaft 17. A take-up shaft 18 is D-shaped in construction. During advance of the record medium RM, the shaft 18 is driven to advance the inking ribbon IR. The shafts 17 and 18 are parallel and are rotatably mounted in a vertically extending frame plate 19. Fixedly secured to the frame plate 19 are parallel mounting pins 20, 21 and 22. With reference to FIG. 3, there is shown an arrangement by which the inking ribbon IR can be readily threaded and moved to its operating or inking position. A mounting plate 23 has a pair of vertically spaced keyhole-shaped openings 24 and 25. The opening 24 mounts a supply roll spindle generally indicated at 26 and the opening 25 mounts a take-up spindle 27. The spindle 26 has a pair of spaced flanges 29 and 30 which define an intervening groove 31. The spindle 27 has a pair of spaced flanges 32 and 33 which define an intervening groove 34. The opening 24 has an enlarged portion 35 through which the flange 29 of the spindle 26 can be inserted. The opening 24 also has a mounting portion 36 rotatably received in the groove 31. The opening 25 has an enlarged portion 37 through which the flange 32 of the spindle 27 can be inserted. The opening 25 also has a mounting portion 38 rotatably received in the groove 34. With reference to FIGS. 1 and 4, an inking ribbon supply roll R is securely mounted on an internally splined supply roll spool 39 so that there is no relative rotation between the roll R and the spool 39. As shown, the spindle 26 has external splines 40 in keying relationship, preferably loosely, with the internally splined spool 39. The flange 30 is larger than the diameter of the spindle 26 at the splines 40. The flange 30 is received in an enlarged annular groove or recess 40' in one end portion of the spool 39. The spool 39 also has an enlarged annular groove or recess 41 in its other end portion. The recesses 40' and 41 are of the same diameter and length. A retainer generally indicated at 42 is frictionally held onto the spindle 26 by an O-ring 43 which extends into contact with splines 40 at four spline grooves 44. The retainer 42 has a sleeve portion 45 received in the recess 41. The flange 30 and the sleeve portion 45 support the spool 39, whereas the spline connection provided by the splines 40 positioned in internally splined spool 39 is solely for the purpose of traction or keying between the spindle 26 and the supply roll spool 39. It should be noted that the flange 30 is longer than the recess 40' so that neither the spool 39 nor the inking ribbon IR can rub on the metal plate 23 as the spool 39 and the roll R turn as a unit. Likewise, the sleeve 45 is longer than the recess 41 so that the inking ribbon IR cannot rub on the flange 46. The retainer 42 also includes a manually engageable portion 47 by which the retainer 42 can be manually grasped and inserted onto or removed from the spindle 26. The spindles 26 and 27 are identical, the spools 39 and 39' are identical, and the spindle 27 is provided with a retainer 42 identical to the other retainer 42. Accordingly, the spindle 27, the spool 39' and the retainer 48 are not described in further detail. The D-shaped shafts 17 and 18 are received in respective D-shaped bores 49 in respective spindles 26 and 27. The spindles 26 and 27 are thus keyed to respective shafts 17 and 18 but are slidable along straight lines on respective shafts 17 and 18. The shaft 17 applies a braking force or drag to the spindle 26 which applies a braking force or drag to the spool 39 and in turn to the inking ribbon roll R. This maintains tension in the inking ribbon IR between the roll R and the place where the inking ribbon IR is rewound into a roll R' on a take-up spool 39'. The take-up spool 39' is driven by the take-up spindle 27 which is driven by take-up shaft 18. Thus, as the record medium RM is advanced the ribbon IR is maintained under tension. The inking ribbon IR is guided by four spaced, parallel identical guides 50, 51, 52 and 53. The guides 50 through 53 are shown to be rotatable tubular guides or guide rolls. The guides 51 through 53 are mounted on the pins 20 through 22. An elongate tab or projection 54 formed integrally with the plate 23 mounts a bracket 55. The projection 54 has sets of holes 56, 57 and 58 and the bracket 55 has sets of holes 59, 60 and 61. The bracket 55 is illustrated as being secured to the projection 54 by screws passing through sets of aligned holes 58 and 61. Each roller 50 through 53 has a flange 62 and a flange 63 spaced apart by an intervening groove 64. One end portion of the guide 50 is insertable into an opening 65 and its groove 64 is rotatably received in reduced portion 66. The other end portion of the guide 50 is rotatably received in an annular hole 67 in the bracket 55. The groove 64 of one end portion of the guide 51 is received in a recess portion 68 in the plate 23. The other end portion of the guide 51 is rotatably received in an annular hole 69 in the bracket 55. The groove 64 in one end portion of the guide 52 is received in a recess 70 in the plate 23, and the groove 64 in the other end portion of the guide 53 is received in a reduced portion 71 of an opening 72 in the plate 23. A molded plastics outwardly projecting member or projection generally indicated at 73 is secured to the plate 23 by screws 74. The projection 73 includes a manually engageable tab or handle 75. By pulling outwardly on the handle 75, the plate 23, the bracket 55, the spindles 26 and 27, the spools 39 and 39', the inking ribbon IR, and the guides 50 through 53 slide outwardly as a unit along a straight line from an operating position in which the ink ribbon IR in the space S (FIG. 1) to an open or threading position (FIG. 4) in which the ink ribbon IR is clear of the space S. The mounting plate 23, the guides 50 through 23, the spindles 26 and 27, the bracket 55 are considered to comprise a slide assembly SA. A stationary bracket 76 suitably secured to the frame 11 mounts a detent generally indicated at 77. The detent 77 has a pair of opposed flexible resilient spring fingers or detent members 78 which selectively detent either with a pair of detent members 79 or with a pair of detent members 80. The detent members 78 cooperate with the detent members 79 when the slide assembly SA is in the operating position to releasably hold the slide assembly SA in the operating position, and the detent members 78 cooperate with the detent members 80 when the slide assembly SA is in the threading position to releasably hold the slide assembly SA in the threading position. The invention is also adaptable to printers having print heads, platens and inking ribbons of different widths. For example, if the slide assembly SA is to be used in a printer having a wider print head and platen for use with a wider inking ribbon IR, the bracket 55 is adjusted so that the bracket 55 is secured to the tab 54 as shown in FIG. 6, namely, the screws pass through sets of holes 58 and 59 as shown in FIG. 5, or through sets of holes 57 and 60. Longer guides 50L and 51L are shown in FIG. 6. However, guides longer than the guides 50 through 53 are required and spindles longer than the spindles 26 and 27 are required. Also, a longer outwardly projecting member 73 with more widely spaced detent members is required. In using the invention, the slide assembly SA is shown in its operating position in FIG. 1 in which the inking ribbon IR is in the clearance space or gap S between the print head 13 and the platen 14. The print head 13 is movable into the open position when the lever 16 is moved from the phantom line position to the solid line position. This facilitates threading of the record medium RM between the print head 13 and the platen 14 and enables the slide assembly SA to be readily slid from the operating position to the threading or loading and unloading position shown in FIG. 4. Once the record medium RM and the inking ribbon IR are in the operating or printing position, the lever 16 can be moved from the solid line position shown in FIG. 1 to the phantom line position, whereupon the print head 13 is moved into printing cooperation with the platen 14, with the inking ribbon IR in contact with the print head 13 and the record medium RM and with the record medium RM in contact with the platen 14. During printing, the take-up shaft 18 rotates clockwise (FIG. 1) and causes the inking ribbon IR to be unwound from the supply roll R and to be wound onto the take-up roll R'. When the inking ribbon IR has been almost entirely used up from the roll R, printing is interrupted. To remove the spent ink ribbon, the lever 16 is first moved to the solid line position (FIG. 1) which moves the print head 13 to the position shown. Next the user grasps the handle 75 and pulls the entire slide assembly SA outwardly to the FIG. 4 position, in which the detent members 78 cooperate with detent members 80 to hold the slide assembly SA releasably in the threading position. The inking ribbon IR may now be conveniently removed and the spools 39 and 39' slid off the respective spindles 26 and 27. A new inking ribbon IR may now be loaded onto the spindle 26 and a new take-up spool 39' mounted onto the spindle 27. The free end of the inking ribbon IR can be threaded partly about guides 50 and 51, to partially about guides 52 and 53 and onto the take-up spool 39'. Thereupon, the handle 75 can be used to push the slide assembly SA from the position of FIG. 4 to the position of FIG. 1. When the lever 16 is again moved to the phantom line position, the printer is again ready to be operated to print on the record medium RM. Other embodiments and modifications of the invention will suggest themselves to those skilled in the art, and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims.
There is disclosed a printer with an improved arrangement to facilitate changing of inking ribbons. A slide assembly is placed in a load position and loaded with an inking ribbon supply roll. Thereafter, the inking ribbon is threaded about guides. With the print head and the platen of the printer separated, the slide assembly is slid to a printing position where the inking ribbon is disposed in space between the print head and the platen. Thereafter, the print head and platen are moved relatively together so that the printer is now able to print on a record medium.
1
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates generally to a method and device using a targeted light source and a photosensitizer to streamline the process of repairing internal body passageways, prevent restenosis, and minimize re-injury after angioplasty treatment. [0003] 2. Invention Disclosure Statement [0004] The most common problem with any angioplasty procedure is restenosis, a re-closing of the affected passageway opened by the procedure. This effect is believed to be due to cell proliferation, triggered by the exerted pressure and the lesion caused by the balloon angioplasty. Restenosis occurs in about 30% of patients. The use of stents, or tiny expanding metal scaffolds, is the most common method used to prevent restenosis. However, restenosis through the stent or around the stented area is quite common. [0005] Constrictions in the coronary artery are caused by a buildup of plaque. Plaque can occur in many forms, from a thick viscous consistency (similar to toothpaste) to a rock-hard consistency depending on the proportion of components, which may include calcium, fibrous tissue, fatty deposits, organized clots and thrombus. [0006] Atherosclerosis is a common problem among humans. Fatty substances (lipids), or plaques, form deposits in and beneath the intima—the innermost membrane lining arteries and veins. Atherosclerosis commonly affects large and medium sized arteries. Most commonly affected are the aorta, and the iliac, femoral, coronary, and cerebral arteries. Health problems result from atherosclerosis when reduced blood flow due to constriction of one of the passageways restricts blood flow to a particular tissue or organ. Restricted blood flow compromises and restricts organ or tissue function. [0007] Approximately four million people in the United States suffer from artherosclerotic coronary artery disease. Many of these people are likely to suffer or die from myocardial infarction, commonly known as heart attack. Heart disease is, in fact, the leading cause of death in the United States. Thrombosis in the coronary artery beyond the artherosclerotic constriction is the usual cause of heart attacks. A procedure that can open artherosclerotic constrictions thereby permitting the normal flow of blood to the heart can reduce many deaths and disabilities caused by heart disease. [0008] Modern treatment of atherosclerotic blood passageways usually involves one of two treatments: bypass and/or angioplasty. In bypass treatment, a portion of a blood passageway is borrowed from another area in the body and grafted around the affected passageway. This treatment involves invasive surgery, especially when dealing with the aorta, coronary artery, or other vessels involving the heart. Furthermore, bypass surgery does not heal the affected site, and occurrences of atherosclerosis in the grafted passage are relatively common. [0009] Another method of treating atherosclerosis is angioplasty. In angioplasty, a catheter of some sort is introduced into the passageway. In most methods, the angioplasty catheter, usually equipped with a guidewire, moves along the body passageway to the sclerotized area. A balloon contained inside of the catheter inflates, displacing the plaque and re-opening the passageway. [0010] In another use of the prior art, a photosensitizer is introduced at the sclerotized area prior to introduction of the catheter. After time for the photosensitizer to target and saturate the sclerotized area, a catheter is introduced into the body passageway. Fibers are then inserted into the catheter. The fibers conduct light from some kind of source, i.e. a laser. The laser or other light source activates the photosensitizer in the sclerotized area in order to destroy the plaque. A balloon may or may not be used in this approach to further treat the sclerotized area of the blood passageway. This form of angioplasty is called Photodynamic Therapy (PDT), or intracoronary brachytherapy. [0011] The photoactivating device employed for intracoronary brachytherapy usually comprises a monochromatic light source such as a laser, the light output of which may be coupled to an invasive light delivery catheter for conduction and delivery to a remote target tissue. Such interventional light delivery catheters are well known in the art and are described, for example, in U.S. Pat. No. 4,512,762 (Spears). In that invention a balloon is illuminated to activate the photosensitizer. [0012] Generally, the prior art of intracoronary brachytherapy involves at least five steps: insertion of a guidewire; insertion of a catheter over the guidewire; removal of the guidewire; insertion of a fiberoptic wire; and finally, irradiation. The present invention is a method to prevent restenosis by using a novel catheter with light conducting means and a targeting mechanism for focusing that light source on a photosensitizer to treat a sclerotized area of a human body passageway. Most balloon angioplasty procedures do not involve radiation to prevent cell growth in the intima. Instead, they aim to compress or displace cells in a sclerotized vessel with a stent or other means. These treatments tend to encourage restenosis by stimulating a responsive force in the vessel wall, or stimulating the proliferation of cells in the area to re-take its original shape. [0013] The present invention provides a non-mechanical method and product for preventing restenosis by irradiation. A “fiberoptic guidewire” assists the doctor or technician in navigating body passageways, and also conducts radiation to its own diffuser to engage in PDT. Alternatively, a balloon catheter is manufactured to conduct radiation to an obstructed body passageway. Either embodiment streamlines the angioplasty procedure. OBJECTIVES AND BRIEF SUMMARY OF THE INVENTION [0014] It is an object of the present invention to provide a method to prevent or minimize occurrences of restenosis after angioplasty. [0015] It is also an object of the present invention to streamline the process of angioplasty to reduce patient exposure and increase the safety of the process. [0016] It is another object of the present invention to provide a guidewire capable of transmitting radiation, hereinafter referred to as a “fiberoptic guidewire,” to streamline the angioplasty process and prevent restenosis. [0017] It is a further object of the present invention to provide a fiberoptic guidewire with a diffuser end capable of transmitting radiation to a sclerotized body passageway. [0018] It is still another object of the present invention to provide a catheter manufactured to conduct radiation, either by insertion of optical fibers in the tubular structure or by manufacturing the catheter of a homogeneous light-conducting polymer. [0019] Briefly stated, the present invention provides a novel device and method for preventing restenosis and streamlining the angioplasty procedure. The device and method provide a fiberoptic guidewire, or, alternatively, a light-conducting catheter, to decrease the size of the angioplasty device, decrease the overall time of the process, and increase the safety of the procedure. The present invention delivers radiation to a sclerotized area after balloon angioplasty treatment to prevent restenosis. Radiation delivered via the catheter or fiberoptic guidewire discourages the cell proliferation and cell growth after angioplasty, thereby improving the chances of avoiding restenosis. [0020] The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF FIGURES [0021] [0021]FIG. 1 shows a fiberoptic guidewire with a diffuser in a sclerotized body passageway. [0022] [0022]FIG. 2 is a continuation of FIG. 1, showing a balloon catheter circumscribing the fiberoptic guidewire in the sclerotized body passageway. [0023] [0023]FIG. 3 shows a balloon catheter equipped with optical fibers in its tubular structure circumscribing a conventional guidewire. [0024] [0024]FIG. 4 is a cross section of the catheter described in FIG. 3 down its longitudinal axis. [0025] [0025]FIG. 5 is another embodiment of the catheter in FIG. 3 manufactured of a light-conducting polymer. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0026] The entire angioplasty process is streamlined considerably by the present invention. In the present state of the art, there are several steps to the angioplasty procedure: Introduction of a standard guidewire; introduction of a catheter over a guidewire; removal of the guidewire; introduction of an optical fiber; inflation of the balloon, irradiation, and removal of the entire system. In the present invention, light radiation is transmitted through the fiberoptic guidewire, or alternatively the catheter. The length and complication of the angioplasty process is greatly decreased. A fiberoptic guidewire eliminates the need for of different means for navigation and irradiation. The prior art provides for separate fibers or possibly separate lumens in the catheter for movement over the guidewire and transmission of radiation. The present invention streamlines the process by combining the functions of the guidewire and radiation transmitter, or by transmitting radiation via the catheter itself. The manufacture of a catheter with light-conducting properties also alleviates the need for removal of the guidewire and insertion of a means of irradiation. Decreasing the amount of time that a vessel is subject to a foreign body increases the safety of the process. In addition, the size of the device decreases with the decreased need for lumens for a guidewire, gas, and fiberoptic transmission. [0027] In one preferred embodiment, a fiberoptic guidewire is manufactured in accordance with FIG. 1. This fiberoptic guidewire alleviates the need for a separate fiber or wire for irradiation. [0028] A photosensitizer is introduced at a sufficient time prior to beginning the minimally invasive procedure to allow for, preferably, location and targeting of the sclerosis and/or plaque. The fiberoptic guidewire is then introduced into the body passageway. The fiberoptic guidewire has a diffuser located near the distal end. The diffuser will allow for homogeneous and/or differential distribution of radiation at a selected power and intensity to discourage growth and proliferation of the cells in either the vessel walls or the plaque. Various methods of creating homogeneous diffusion are known in the prior art. U.S. Pat. No. 5,196,005 (Doiron & Narcise) describes a method for placing diffusion tips on optical fibers. U.S. Pat. No. 5,231,684 (same inventors) describes the use of a microlens attached to the end of an optical fiber for diffusion of radiation. The present invention envisions a diffuser with a section of guidewire extending distally for optimal navigation in a body passageway. A variation of the prior art that allows an extension of guidewire distally from the distal end of the diffuser is used in the present invention. [0029] Extending distally from the diffuser, a short piece of guidewire allows for conventional navigational advantages of a guidewire for location of the affected area of the body passageway. The proximal end of the fiberoptic guidewire extends from the diffuser through the body passageway to the portion exiting from the patient and connected to the light source. Methods and devices to allow handling and movement of the guidewire by a doctor or technician are known in the prior art. [0030] By using the described fiberoptic guidewire, the means to transmit radiation are in place. A balloon catheter is then introduced that circumscribes the guidewire, as shown in FIG. 2. After proper positioning of the catheter, the balloon is inflated to displace the plaque. The light source connected to the proximal end of the guidewire is then activated, irradiating the plaque and vessel walls. Irradiating the plaque and activating the photosensitizer located within the plaque discourages cell proliferation and growth—two responses by the cell wall and/or plaque buildup to an exerted force (the angioplasty balloon) that cause restenosis in 30% of patients that receive angioplasty treatment. [0031] In another preferred embodiment, the light conducting means are located within the catheter. In this device, a photosensitizer is again introduced. A standard, non-fiberoptic guidewire is introduced to assist the doctor or technician in navigating the body passageway to the sclerosis or constriction. The balloon catheter, again circumscribing the guidewire, is introduced and navigated along the guidewire to the affected area. [0032] The catheter is manufactured to conduct radiation to the affected area. In one variation of the present embodiment, the tubular structure of the balloon catheter is manufactured in accordance with FIG. 4. Optical fibers embedded in the tubular structure are enclosed in lumens that allow space for differential bending and extension/contraction of the fibers as opposed to the catheter body itself. Fibers of quartz, glass, and plastic are known in the field of fiberoptics and are suitable for use in this embodiment. At least one other lumen exists for free movement of the guidewire relative to the catheter. [0033] The larger lumens for optical fibers can also be used for transmission of a gas or liquid for inflation of the balloon. The use of gases or liquids for inflation of a balloon catheter is well known in the art. U.S. Pat. No. 4,512,762 (Spears) describes the use of a lumen to transmit pressurized gas to a balloon catheter for inflation. The optical fibers extend distally to the balloon itself, where they transmit radiation to the balloon. Upon inflation of the balloon and displacement of the plaque, the light source is activated, transmitting radiation along the optical fibers and to the inflated balloon. The means of transmission is designed for homogeneous or, if desired, differential transmission of radiation throughout the balloon to the sclerotized area for maximum irradiation. [0034] The irradiation of the plaque and vessel walls activates the photosensitizer and prevents restenosis by discouraging cell growth and cell proliferation in the vessel walls and the plaque. These processes of growth and proliferation are generally attributed as causes of restenosis. [0035] In another variation of this preferred embodiment, the catheter body itself is manufactured using a homogeneous light-conducting polymer in accordance with FIG. 5. This polymer will conduct radiation from a light source on its proximal end to the affected area through the angioplasty balloon. At the distal end of the catheter, a diffuser section of the catheter transmits radiation from the catheter walls to the balloon or directly to the plaque and vessel wall. There are several diffusers that are well known in the field of PDT that can be used, or variations of those diffusers can be manufactured to ideally suit the present application. [0036] The catheter contains at least one lumen for circumscribing the guidewire and transmission of a liquid or gas for inflation of the catheter balloon. In this variation, the angioplasty procedure would be similar to the previous variation. The photosensitizer is introduced; a guidewire is inserted. The catheter is inserted over the guidewire, and the balloon is inflated, displacing the obstruction in the body passageway. The area is then irradiated, preventing restenosis. [0037] Once again, the angioplasty procedure is streamlined by introduction of a catheter with light-conducting properties designed specifically for transmission of radiation to an obstruction in a human blood vessel or other body passageway eliminates the need for a separate fiber introduced solely for the purpose of transmitting radiation. The time saved in the procedure translates into increased safety for the patient undergoing angioplasty treatment. [0038] The present invention is further illustrated by the following examples, but is not limited thereby. EXAMPLE 1 [0039] [0039]FIG. 1 shows body passageway 100 affected with obstruction 102 . The distal end 106 of guidewire 104 extends beyond diffuser 108 , which is positioned at obstruction 102 . The guidewire 104 is constructed of a fiberoptic material, allowing for conduction of radiation during the angioplasty process. As shown in FIG. 2, balloon catheter 206 is inserted into body passageway 200 , circumscribing the guidewire 204 up to the end of the diffuser 210 . When the catheter 206 is properly positioned, balloon 208 is inflated, displacing plaque or other obstruction 202 . After displacement, a light source connected to the proximal end of guidewire 204 is activated, transmitting radiation to diffuser 210 and through balloon 208 . The irradiation stops the re-growth and proliferation of plaque or other obstructions that cause restenosis. EXAMPLE 2 [0040] [0040]FIG. 3 shows a conventional guidewire 302 circumscribed by a catheter in an affected body passageway 300 . The guidewire 302 is inserted, the distal tip extending a distance beyond the affected area 304 . The balloon catheter 306 is then introduced, circumscribing the guidewire 302 . Optical fibers 308 are contained within the tubular structure of catheter 306 . The angioplasty balloon is positioned at obstruction 304 and inflated. The balloon 310 displaces plaque 304 . A light source connected to the proximal end of optical fibers 308 is activated, transmitting radiation to balloon 310 . Irradiation of the plaque 304 prevents cell growth and regeneration, the causes of restenosis. FIG. 4 shows a cross section, looking down the longitudinal axis, of catheter 400 . Lumens 402 are circular or otherwise shaped for optimal sizing of the catheter structure 400 . Optical fibers 404 are smaller than lumens 402 to allow for movement and prevent cracking or breaking of fibers 404 . At least one lumen 406 exists in the catheter body 400 for circumscribing the guidewire 408 and for transmission of a gas or liquid for inflation of the angioplasty balloon. Example 3 [0041] In a variation of Example 2 shown in FIG. 5, catheter body 500 is manufactured as a light-conducting polymer. The catheter 500 contains at least one lumen 502 for transmission of gas or liquid to inflate the catheter and to circumscribe the guidewire 504 . The processes of angioplasty and irradiation are similar to Example 2. Radiation is transferred through the light-conducting body of the catheter 500 to an angioplasty balloon in sufficiently homogeneous form to transfer to the angioplasty balloon when inflated, irradiating the obstruction in the body passageway. This homogeneous transmission can be accomplished by use of a simple diffuser. The diffuser transmits radiation from the polymer-based catheter body 500 to the balloon or directly to the obstructed area of the body passageway. [0042] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to the precise embodiments, and that various changes and modifications may be effected therein by skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
A novel device and method for preventing restenosis and streamlining the angioplasty procedure. The device and method provide a fiberoptic guidewire, or, alternatively, a light-conducting catheter, to decrease the size of the angioplasty device, decrease the overall time of the procedure, and increase the safety of the procedure. The present invention delivers radiation to a sclerotized area after balloon angioplasty treatment to prevent restenosis Radiation delivered via the catheter or fiberoptic guidewire discourages the cell proliferation and cell growth after angioplasty, thereby improving the chances of avoiding restenosis.
0
TECHNICAL FIELD [0001] The present invention relates to a medicine comprising a mixture of a prostaglandin compound and a nitric oxide (hereinafter referred to as “NO”) donating compound that is effective in the treatment of ocular hypertension and glaucoma. BACKGROUND ART [0002] Presently, eye drop solutions and internal medicines are principally used for reducing ocular tension in the treatment of ocular hypertension and glaucoma. As examples of eye drop solutions, β-blockers such as timolol maleate, carteolol hydrochloride, befunolol hydrochloride, and betaxolol hydrochloride, sympathetic nerve stimulants such as epinephrine and dipivefrine hydrochloride, parasympathetic nerve stimulants such as pilocarpine hydrochloride and carbachol, α-blockers such as bunazosin, αβ-blockers such as nipradilol, and prostaglandin derivatives such as isopropyl unoprostone and latanoprost can be given. As examples of internal medicines, carbonic anhydrase inhibitors such as acetazolamide, methazolamide, and diclofenamide can be given. [0003] In many cases, the use of only one of these medicines cannot sufficiently control ocular tension. Therefore, the combined use of two or more of these medicines has increased. However,there are cases where the combined use of these medicines does not significantly reduce ocular tension, thereby making the selection of these medicines very difficult. [0004] Accordingly, an object of the present invention is to provide a medicine that significantly reduces ocular tension resulting from ocular hypertension and glaucoma, in particular, a medicine that effectively reduces ocular tension in cases where the combined use of conventional medicines is not effective. DISCLOSURE OF THE INVENTION [0005] To achieve the above object, the present inventors have conducted extensive research of a medicine comprising a prostaglandin compound and a NO-donating compound. [0006] Of the above medicines, prostaglandin compounds are already known to be effective in reducing ocular tension when used alone. However, the action mechanism of this effect has not yet been fully understood. It is commonly believed that this effect is due to the increased uveoscleral flow rate and there are several opinions regarding the reason. One opinion is that prostaglandin F 2 α causes secretion of MMP. MMP degrades the extracellular matrix of the smooth muscle fibers of the ciliary body (uveoscleral outflow pathway) thereby decreasing outflow resistance and increasing outflow (Lutjen-Drecoll E. and Tamm E., Exp. Eye. Res 47, 761-769, 1988). Another opinion is that the smooth muscle fibers of the ciliary body become relaxed and the cell spacing expands thereby decreasing outflow resistance and increasing outflow (Poyer J F. , Inv. Opht. Vis. Sci. 36, 2461-2465, 1995). [0007] The inventors of the present invention paid particular attention to the following reports on prostaglandin. As a result of combining a prostaglandin compound (a derivative of prostaglandin F 2 α. in particular) with a prostaglandin receptor, phospholipase A 2 is stimulated, thereby causing arachidonic acid to be produced and released from the biomembrane phospholipid. This arachidonic acid is converted into prostaglandin G 2 by the action of cyclooxygenase then converted into various types of endogenic prostaglandin. In this instance, prostaglandin E 2 and prostaglandin F 2 α are produced and cause the ciliary muscle to become relaxed thereby increasing the uveoscleral flow rate, and as a result, the ocular tension is reduced (Y. K. Sardar, Exp. Eye. Res. 63, 305, 1996 and the like) [0008] The ocular tension reducing effect of NO donating compounds has already been known in the art. The nitric oxide released by the NO donating compound activates the guanylate cyclase, which increases the amount of cyclic GMP (S. A. Waldman et al, J. Biol. Chem 259, 5946, 1984), and results in reduced ocular tension (J. A. Nathanson et al, Invest. Ophthal. Vis. Sci. Abstr. 29, 323, 1988). [0009] In general, the combination of several components effective in reducing ocular tension does not greatly improve the overall effect. However, the inventors of the present invention conducted research based on the assumption that a mixture of a prostaglandin compound and an NO donating compound could significantly reduce ocular tension, wherein the nitric oxide released by the NO donating compound not only activates guanylate cyclase but also activates cycloxygenase (D. Salvemini, et al, Proc. Natl. Acad. Sci. USA 90, 7240, 1993) thereby enhancing the conversion of arachidonic acid in the ocular tension reducing mechanism of the prostaglandin compound. As a result, the inventors have discovered that this combination is in fact highly effective in reducing ocular tension, thereby completing the present invention. [0010] Accordingly, the present invention provides a medicine comprising a prostaglandin compound and an NO donating compound. [0011] The present invention also provides a method for treating and/or preventing ocular hypertension or glaucoma using the above medicine. [0012] Since ocular hypertension and glaucoma can be very difficult to treat, there are many cases where these disorders cannot be completely cured using conventional medicines for reducing ocular tension. Experimented use of various combinations of these medicines, which resulted in either no improvement or only a slight improvement in effect, could not achieve a significant improvement in the treatment of these disorders. [0013] In the medicine of the present invention comprising the combination of a prostaglandin compound and an NO donating compound, the nitric oxide is released from the NO donating compound and enhances the conversion of the arachidonic acid in the ocular tension reducing mechanism of the prostaglandin compound, thereby exhibiting a synergistic effect of the two compounds of significantly increasing the ocular tension reducing effect. Thus, the medicine is not only effective in regular ocular hypertension and glaucoma patients but is also effective in those patients wherein the combined use of several conventional medicines does not significantly reduce ocular tension. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0014] As the prostaglandin compound used in the medicine of the present invention, all pharmaceutically acceptable prostaglandin compounds, derivatives, and analogues thereof can be given, wherein the derivatives include pharmaceutically acceptable esters and salts thereof. [0015] As examples of the prostaglandin compound, naturally occurring prostaglandins such as prostagladin (hereinafter referred to as “PG”) D 1 , PGE 1 , PGE 2 , PGE 3 , PGF 1 α, PGF 2 α, PGF 3 α, PGG 2 , PGH 2 , PGI 2 , and PGI 3 , thromboxane A 2 , latanoprost, isopropyl unoprostone, PGF 2 α 1-isopropyl ester, salt of PGF 2 α 1-isopropyl ester-15-propione, and 15-deoxy PGF 2 α can be given without any limitations. These prostaglandin compounds may be used singularly or in combination of two or more. [0016] Of those given above, prostaglandin F 2 α derivatives are preferably used as the prostaglandin compound in the medicine of the present invention, with PGF 2 α, latonoprost, and isopropyl unoprostene being particularly preferable. [0017] In the medicine of the present invention, the prostaglandin compound is preferably used in an amount of 0.0001-0.05 w/v %, and particular preferably 0.001-0.01 w/v % of the total amount of the compound. [0018] As the NO donating compound used in the medicine of the present invention, those that release NO (nitric oxide) in vivo can be given. Examples of the NO donating compound include, but are not limited to, nipradilol, nitroglycerine, isosorbide dinitrate, sodium nitroprusside, N-nitrosoacetyl penicillamine, 3-morpholino-sydnonimine hydrochloride, S-nitroso-N-acetyl-DL-penicillamine (SNAP), S-nitrosoglutathione, 4-phenyl-3-furoxanecarbonitryl, arginine, and sodium nitrite. These NO donating compounds may be used singularly or in combination of two or more. [0019] Of the above NO donating compounds, nipradilol is particularly preferable. In addition to releasing NO, nipradilol is known to be effective in α,β blocking, which adds an increased effect to the treatment of ocular hypertension and glaucoma. [0020] In the medicine of the present invention, the NO donating compound is preferably used in an amount of 0.01-5 w/v %, and particular preferably 0.1-1.0 w/v % of the total amount of the compound. [0021] The medicine of the present invention may be used in the form of an eye drop solution and the like, wherein the prostaglandin and NO donating compounds may be combined into a single preparation or each compound may be separate preparations and administered in order in the form of a medicine kit or the like. [0022] In the medicine of the present invention, the use of a single preparation comprising both compounds is advantageous in view of convenience. On the other hand, the use of each compound in separate preparations is also advantageous because the method of administration can be determined and the amount of each compound administered can be controlled. [0023] The medicine of the present invention is preferably used in the form of an eye drop solution. This eye drop solution may comprise the prostaglandin compound and the NO donating compound in separate containers or both the prostaglandin compound and NO donating compound in the same container. [0024] In the preparation of the above medicine, commonly used base materials, dissolution agents, solubilizers, solvents, wetting agents, emulsifiers, excipient, adhesives, viscous agents, binders, preservatives, antioxidants, stabilizers, surfactants, antiseptics, pH adjustors, and the like may be appropriately used in accordance with the form of the preparation. EXAMPLES [0025] The present invention will be described in more detail by the way of examples, which should not be construed as limiting the present invention. Example 1 [0026] 100 ml of an aqueous solution containing 0.25 w/v % of nipradilol and 100 ml of an aqueous solution containing 0.005 w/v % of latonoprost were prepared separately and combined into a single package to prepare a medicine kit. Example 2 [0027] 100 ml of an aqueous solution containing 0.1 w/v % of sodium nitroprusside and 100 ml of an aqueous solution containing 0.005 w/v % of latonoprost were prepared separately and combined into a single package to prepare a medicine kit. Examples 3 and 4 [0028] The medicines of Examples 3 and 4 were prepared using the ingredients and amounts shown in Table 1. TABLE 1 Example 3 Example 4 nipradilol  0.25 g nitroprusside  0.10 g Na latanoprost 0.005 g latanoprost 0.005 g purified appropriate amount purified water appropriate amount water total amount   100 mL total amount   100 mL Test Example 1 [0029] Domesticated rabbits intravenously administered with 100 μl of a 5 w/v % hypertonic saline solution were used as ocular hypertension models. After intravenously administering the hypertonic saline solution, 50 μl of each of the eye drop solutions were administered and the ocular tension was measured 60 and 120 minutes thereafter. [0030] A physiological saline solution, a 0.005 w/v % latonoprost aqueous solution (latanoprost), a 0.25 w/v % nipradilol aqueous solution (nipradilol), a combination of latanoprost and nipradilol (Example 1), and a combination of a 0.5 w/v % indomethacin aqueous solution (indomethacin), latonoprost, and nipradilol were used as the eye drop solutions. [0031] When nipradilol and latanoprost were used in combination, nipradilol was administered first and latanoprost was administered five minutes thereafter. Furthermore, when indomethacin was used, the indomethacin was administered five minutes before the administration of nipradilol. The results are shown in Table 2, wherein the ocular tension change (mmHg), the change in ocular tension after administration, is shown as the mean value ± the standard error. TABLE 2 No. of Ocular tension change (mmHg) Eye drop solution specimens 60 minutes 120 minutes Physiological saline 6 24.8 ± 1.7 16.2 ± 1.6 solution Latanoprost 6 22.7 ± 1.2  9.8 ± 1.9 Nipradilol 6 14.7 ± 1.7*  7.3 ± 1.6* Nipradilol + Latanoprost 6  5.3 ± 3.3** ♯♯b  1.7 ± 2.7** ♯ (Example 1) Indomethacin + 6 13.3 ± 3.7* ♯  8.2 ± 1.7* Nipradilol + Latanoprost Test Example 2 [0032] Domesticated rabbits intravitreously administered with 100 μl of a 5 w/v % hypertonic saline solution were used as ocular hypertension models. After intravitreously administering the hypertonic saline solution, 50 μl of each of the eye drop solutions was administered, and the ocular tension was measured 60 and 120 minutes thereafter. [0033] A 0.1 w/v % sodium nitroprusside aqueous solution (sodium nitroprusside), a combination of the sodium nitroprusside and a 0.005 w/v % latanoprost aqueous solution (latanoprost) (Example 2) and a combination of a 0.5 w/v % indomethacin aqueous solution (indomethacin) , latanoprost, and sodium nitroprusside were used as the eye drop solutions. [0034] When sodium nitroprusside and latanoprost were used in combination, sodium nitroprusside was administered first and latanoprost was administered five minutes thereafter. Furthermore, when indomethacin was used, the indomethacin was administered five minutes before administration of sodium nitroprusside. The results are shown in Table 3, wherein the ocular tension reduction (mmHg), the change in ocular tension after administration, is shown as the mean value ± the standard error. TABLE 3 No. of Ocular tension reduction (mmHg) Eye drop solution specimens 60 minutes 120 minutes Sodium nitroprusside 5 18.0 ± 2.4    9.4 ± 2.5 Sodium nitroprusside + 5  4.8 ± 3.9  −2.8 ± 1.3** latanoprost (Example 2) Indomethacin + sodium 5 22.8 ± 2.9 ##   12.4 ± 6.3 ## nitroprusside + latanoprost [0035] The results of the above Test Examples 1 and 2 show that the combination of the NO donating compound and prostaglandin compound significantly suppresses an increase in ocular tension when compared with the case where these compounds are individually used. The effect of this combination disappeared with the addition of indomethacin. This suggests that the effect of preventing an increase in ocular tension possessed by the combination of the NO donating compound and latanoprost is a result of cycloxygenase activation. The strengthened production of various endogenic prostaglandins resulting from a synergistic effect of the endogenic arachidonic acid derivative produced by the activation of phospholipase A2 by latanoprost and the activation of cycloxygenase by NO is believed to have stimulated production of PGE 2 , which is known to be effective for ocular tension reduction in domesticated rabbits. INDUSTRIAL APPLICABILITY [0036] A medicine comprising a combination of a prostaglandin compound and NO donating compound significantly suppresses an increase in ocular tension when compared to the compounds used individually. [0037] Therefore, the medicine of the present invention is effective in treating persons affected by ocular hypertension and glaucoma.
It is intended to provide medicines having a higher ocular tension-lowering effect on ocular hypertension and glaucoma. Because of showing an excellent effect of lowering ocular tension, medicines comprising a combination of a prostaglandin compound with an NO-donating compound are useful in treating ocular hypertension and glaucoma.
0
BACKGROUND OF THE INVENTION The invention is principally concerned with a process for direct preparation of enantiomers of a substituted fluorenyloxyacetic acid. Certain fluorenyloxyacetic acids useful for treating brain edema are disclosed in U.S. Pat. No. 4,316,043. These acetic acids have a chiral center and exist as racemic mixtures, racemates and individual isomers. A process has been discovered for directly preparing individual isomers of a fluorenyloxyacetic acid. SUMMARY OF THE INVENTION A process for preparing an isomer of a substituted fluorenyloxyacetic acid. DETAILED DESCRIPTION OF THE INVENTION An embodiment of the present invention is a process for preparing the (+) isomer of a compound having the formula: ##STR1## which comprises: a. treating a compound of the formula: ##STR2## wherein X is Cl or Br and R is C 1 -C 6 -alkyl in a basic medium to obtain: ##STR3## b. treating III with C 3 H 7 --X in the presence of a chiral catalyst to obtain: ##STR4## rich in the (-) isomer. c. crystallizing IV to obtain pure (-) isomer, i.e., (-) isomer substantially or completely free of (+) isomer, d. treating the IV isomer from (c) with NaNO 2 in an aprotic solvent or LiCl in N-methylpyrrolidinone to obtain: ##STR5## e. alkylating V to obtain: ##STR6## f. treating VI with H 2 SO 4 /CH 2 Cl 2 to obtain: ##STR7## and go treating VII with a base to obtain I. The compound VI is useful for treating brain edema as described in U.S. Pat. No. 4,316,043. Any suitable chiral catalyst may be used such as N-aryl cinchoninium halide wherein aryl is substituted or unsubstituted phenyl or pheny-C 1 -C 4 -alkyl, wherein substituents (1 or 2) are selected from CF 3 , halo, C 1 -C 3 alkyl, OCH 3 , CN, and the like. Preferred catalysts are 3,4-dichlorobenzyl cinchoninium chloride and p-trifluoromethyl benzyl cinchoninium bromide. Using these type catalysts, formula IV compound containing the (-) isomer predominantly is obtained; the ratio of (-):(+) isomer will range from 75:25 to 80:20 or higher. Step (a) involves alkenylation of the racemic formula II substituted indanone with a formula IIa haloalkene in a basic medium. The basic medium is generally an aqueous strong base, e.g. KOH, NaOH, etc. A nonaqueous solvent is also required. This solvent may be any suitable hydrocarbon such as benzene, toluene, an alkane, mixtures thereof and the like. The step (a) reaction is conveniently carried out at atmospheric pressure and at temperatures ranging from about 0° C. to about 30° C., and preferably at room temperature. The formula III product from step (a) is obtained as a racemic mixture. Compound III is then alkylated in step (b) in the presence of the aforesaid chiral catalyst to obtain compound IV rich in the (-) isomer. The IV compound is obtained a mixture rich in the (-) isomer. This mixture is subjected to crystallization from a suitable hydrocarbon solvent such as hexane-and substantially pure (-) isomer of IV is obtained. The ether group OR in IV is then cleaved to obtain V having the --OH group using conventional procedures, e.g. by treatment with NaNO 2 in an aprotic solvent or with LiCl in N-methylpyrrolidinone (NMP). Compound V is alkylated using conventional reagents illustrated by β-haloacetic acid ester/KI/Na 2 CO 3 . The alkylated derivative VI is then treated with H 2 SO 4 /CH 2 Cl 2 to produce the formula VII dione. The formula VII dione as then treated with a strong base such as NaOH, KOH, LiOH, Na 2 CO 3 and the like to obtain the formula I product. The following example illustrates the process of the present invention. All temperatures are in °C. unless otherwise indicated. EXAMPLE 1 Step A. Preparation of 6,7-dichloro-2-(3-chloro-2-butenyl)-2,3-dihydro-5-methoxy-1-inden-1-one 1b 1b was prepared from indanone 1 following Negishi's method [J. Org. Chem. 1983, 48, 2427-2430]. ##STR8## Indanone 1: 2.1951 g (9.5026 mm) KN(SiMe 3 ) 2 : 16.9 ml of 0.6M solution (10.16 mm) 1,3-dichloro-2-butene: 1.2751 g (10.2 mm) Pd(φ 3 P) 4 : 1 g (0.87 mm) Et 3 B: 10.2 ml of 1M solution (10.2 mm) The indanone 1 was added to 10 ml dry THF in a 100 ml 3-neck flask equipped with N 2 -inlet and magnetic stirring. To this suspension was slowly added the KN(SiMe 3 ) 2 solution in toluene (about 20 minutes) at -78° [dry ice-acetone cooling]. Solution occurred; it was stirred at -78° for 30 minutes. After 30 minutes triethylborane solution in THF was slowly added (about 10 minutes) to this mixture at -78°. The solution was warmed up to 0°. A clear solution thus formed was added to a mixture of 1,3-dichloro-2-butene and Pd(φ 3 P) 4 in 20 ml THF kept at 0° under N 2 . The mixture was stirred for 12 hours at room temperature and was treated with 50 ml, 2N HCl. The organic layer was separated and the aqueous layer was extracted with 3×20 ml CH 2 Cl.sub. 2. The combined organic layer was washed with 1N NaHCO 3 solution and dried over MgSO 4 (6 g). After removal of the solvent under vacuum, off white colored solid crystals were obtained. These solid-crystals were washed with 10 ml hexane, filtered and dried to yield 2.73 g of 1b (90%). This was used in the next reaction without further purification. Step B: Preparation of 2b ##STR9## Indanone (1b): 0.3352 g (1.049 mm) Toluene: 18 ml 50% NaOH: 3 ml 1-Bromopropane: 5.85 ml pCF 3 benzylcinchoninium bromide (catalyst): 0.05 g (0.09 mm) A 100 ml 3-neck flask fitted with magnetic stirring and N 2 -inlet was charged with indanone 1b (0.3352 g), toluene (18 ml), 1-bromopropane (5.85 ml) and catalyst (φCF 3 BCNB) (0.05 g). To this suspension at room temperature was added slowly 3 ml 50% NaOH via syringe (about 1 minute) under stirring. The mixture was stirred at room temperature for 24 hours. Disappearance of starting material observed by TLC. The mixture was then transferred in a separatory funnel with 30 ml isopropyl acetate and 20 ml water. Aqueous layer was discarded. The organic layer was washed with 2×20 ml 4N HCl and 1×20 ml 1N NaHCO 3 solution. The organic layer was dried over MgSO 4 (1 g) and solvent removed under vacuum to produce a yellow oil [0.379 g (99% yield)]. NMR, CDCl 3 , tris [(3-heptafluoropropyl)hydroxymethylene)-d-camphorato]Eeuropium III analysis of this product (2 b) showed it to be 80:20 (-):(+) enantiomeric ratio mixture. Conversion of 2b to Formula I via steps (c), (d), (e), (f), and (g) is carried out as described in pending U.S. application Ser. No. 656,577 filed Oct. 1, 1984 (incorporated herein by reference). Claims to the invention follow.
A process for direct preparation of an enantiomer of a substituted fluorenyloxyacetic acid is disclosed. The acetic acid derivative is useful for treating brain edema.
2
CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of provisional patent application Ser. No. 61/308,808, filed 2010 Feb. 25 by the present inventor. FEDERALLY SPONSORED RESEARCH Not Applicable SEQUENCE LISTING OR PROGRAM Not Applicable FIELD OF THE INVENTION The present invention relates to a non-lethal self defense device that uses a chemical spray to disable a potential attacker. BACKGROUND OF THE INVENTION Since the beginnings of time, individuals have felt the need to defend themselves from others who might be attempting to harm them. Often a potential victim is forced to either submit to the attacker or try and defend themselves. While defending themselves an individual may use a weapon or security device to gain an advantage over a potential attacker, if they happen to be carrying a self defense device at the time of the attack. Ideally, this device will be non-lethal allowing the potential victim to escape from harm without permanently injuring the attacker. One method of non-lethal self defense is to spray the attacker with a chemical that causes a burning or pain sensation. This chemical enters the attacker's mucous membranes and temporarily stuns the attacker, providing the potential victim much needed time to escape and reach an area of safety. During this attack it is desirable for the device to be unable to function should an attacker remove the device from the grasp of the victim. U.S. Pat. No. 5,310,086 shows a canister holder for an aerosol device that is disarmed when the canister support is removed from the canister holder, but the canister support is only removable in one direction and does not provide a mechanism to adjust the removal tension. U.S. Pat. No. 5,531,359 shows a housing for holding an aerosol canister that includes a removable arming member that prevents the operation of the device upon removal of the arming member, but the arming member is only removable in one direction, can be easily armed without the use of the arming member, does not allow the user to adjust the amount of tension required to remove the arming mechanism, and will not work with a material that does not flex. Although there are a few personal self defense devices with disarming capabilities, there is absent from the art a device that allows disarming in multiple directions and provides the user the ability to adjust the tension required to disarm the device, while at the same time offering convenience of use and ease of manufacture. In addition, a device is needed that offers a disarming feature and the ability to capture an image of an attacker to be used for identification purposes. SUMMARY OF THE INVENTION A device is provided that dispenses a chemical spray to protect the user from potential attackers. This device contains a mechanism that disables the device if it is taken away from a potential victim during a struggle. More specifically, the mechanism is attached to a key ring, the user's hand or wrist, or the worn around the user's neck, and when an adequate amount of force is applied to the device to remove it from the user, the device will separate from the user and at the same time be disabled from operation. According to one embodiment of the invention, a device includes a canister assembly containing a chemical such as pepper spray or other non-lethal irritant. A housing comprising a front canister assembly support structure and rear canister assembly support structure partially encapsulates the canister assembly. The canister assembly includes a valve and hollow valve stem. The valve stem is moveable relative to the canister in an extended closed position and compressed open position. Depression of the valve stem will open the valve and allow propellant to escape the canister and enter the atmosphere. An actuator is disposed on the valve stem and includes a nozzle and through orifice. The through orifice of the actuator establishes open communication between the nozzle and valve stem, wherein depression of the actuator will allow fluid to flow through the valve, valve stem, through orifice and into the nozzle. The housing further comprises a front wall and grip section. Front wall includes an aperture through the housing and aligned with the nozzle, wherein fluid leaving the nozzle will travel through the aperture and enter the atmosphere, disabling a potential attacker outside the housing. The grip section extends the length of the canister and terminates at a bottom section of the housing. The grip section includes a shaft. The shaft is moveable in a direction parallel to the canister. The shaft integrity is protected by transverse support ribs perpendicular to the canister within the grip section to provide further structure and support to the interior components of the housing. In one embodiment of the present invention, the shaft contains a spline which is moveably received in a channel extending parallel the length of the canister and through the transverse support ribs. In addition an elastic member may be disposed on the shaft and biased in a direction parallel to the shaft to aid its movement. The shaft has a bottom end and top end. Bottom end terminates at the bottom section. The shaft top end includes an inclined block. Inclined block is inclined at an angle between 0 degrees and 90 degrees from parallel to the shaft and opposite the canister. Bottom section includes a canister lip, socket, and means to adjust the socket. Canister lip encapsulates the bottom of the canister to aid in securing the canister within the housing. A ball is received in the socket and supports the shaft. The ball places pressure on the shaft and loads an elastic member. The ball has an upper end and lower end. The lower end includes a stud with a through bore. The through bore allows for the attachment of objects to the stud including, key rings, wrist straps, lanyards, neck straps, arm straps and other similar means for attachment to a user. The means to adjust the socket allows the user adjust the amount of tension or force required to remove the ball from the socket. In the preferred embodiment the means to adjust the socket comprises an assembly of a helical spring and screw which tighten or loosen the housing which is assembled in two halves. The ideal range of tension is between 5 and 30 pounds of force required to remove the ball from the socket. Although a helical spring and screw are the preferred means to adjust the socket size and keep the ball in the socket, other means to keep the ball in the socket may include a latch, pin, stop, magnet or other similar combination. A ball and socket connection is the preferred embodiment as it allows the housing to be manipulated in several directions while still being engaged within the socket. In addition, the ball and socket connection allows the ball to be pulled out of the socket from a variety of angles should a struggle ensue between the user and attacker. The housing further comprises a channel perpendicular to the canister extending from the front wall to a rear wall. A slide plate is movably received in this channel. Slide plate comprises a central actuator aperture and incline aperture. The central actuator aperture is similarly sized to the actuator and positioned below the actuator, wherein depression of the actuator will pass through the central aperture of the slide plate compressing the valve stem and allowing the discharge of propellant. The incline aperture is located above the incline block and shaped to slidably receive the incline block, wherein slidable receipt of the incline block into the incline aperture moves the slide plate in a direction perpendicular to canister assembly. The slidable movement of the slide plate displaces the central actuator aperture in relation to the actuator, wherein the actuator cannot be depressed, preventing compression of the valve stem and therefore preventing propellant from exiting canister. The actuator will be able to be depressed when the incline block is slidably engaged with the incline aperture. When the ball is removed from the socket, the incline block will slide downward along with the shaft and displace the slide plate relative to the actuator. Slide plate further comprises an indicator. The indicator is visible via a through hole in the housing, wherein the user can visibly determine the position of the slide plate relative to the actuator based upon this indicator. In the preferred embodiment, this indicator is mounted on the side of the slide plate and consists of the colors green and red. When the color green is visible in the through hole in the housing the actuator will be able to move through the slide plate and disperse the propellant. When red is visible, the actuator and slide plate central aperture will not be aligned and the actuator will not be able to compress the valve stem allowing for the dispersal of propellant. Housing further comprises a top wall. Top wall is adapted via an appropriately sized cylindrical bore to receive the pivotally attached top flap. Top flap comprises a hinge pin adapted to pivotally attach top flap to the cylindrical bore of the housing. The top wall includes a stop to align the top flap with the top wall and to prevent the top flap from contacting the actuator. The top flap is pivotally moveable in a direction upwards from the housing allowing the user access to the actuator, wherein the actuator cannot be accessed by the user until the top flap is pivotally moved upwards. In the preferred embodiment, the top flap is snap fit into the cylindrical bore. Although snap fit is the preferred embodiment, due to its simplicity, the hinge pin could also be spring loaded to automatically move the top flap downward to the stop after the top flap has been lifted to access the actuator. This spring will also allow the top flap to be forcefully engaged with the stop preventing accidental depression of the actuator when the device is placed into a users pocket, bag, purse, or other enclosed article. In a further embodiment the top flap is communication with a gate adjacent to the aperture of the front wall, wherein manipulation of the top flap will move the gate. An upwards movement of the top flap will open the gate allowing the propellant to exit the aperture. A downward movement of the top flap will close the gate and prevent the accidental discharge of propellant and prevent debris from entering the nozzle or housing to prevent malfunction. It is preferred that the housing is made of two halves of injection molded material, which pieces are joined together by mutually compatible male/female interlocking joints. These joints may be friction fit, snap fit, the combination of a threaded hole and screw, or other similar conntection that tightly secures the two halves. This combination will securely hold the canister within the housing and prevent the removal of the canister from the housing. According to another embodiment of the invention, the housing includes a camera in communication with the actuator, a light source or flash in communication with the actuator, a memory storage device, a USB port, and a power source. A depression of the actuator will result in the release of chemical spray and at the same time take an illuminated picture that is stored on the device memory, where it can be accessed by the user or authorities for later identification of the attacker. In addition, other devices could be placed into the housing to enable the user to properly aim the device, such as a laser sight. According to another embodiment of the invention, the housing also includes an audible generating device and speaker in communication with a power source and the actuator. When the trigger is depressed an audible noise is also heard to attempt and alert others to the attack and scare away the attacker. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and together with the description serve to further explain the principles of the invention. Other aspects of the invention and the advantages of the invention will be better appreciated as they become better understood by reference to the Detailed Description when considered in conjunction with accompanying drawings, and wherein: FIG. 1 is a perspective view of device, according to the present invention; FIG. 2 is a perspective cross sectional view of the device, according to the present invention; FIG. 3 is a perspective cross sectional view of the top half of the device, according to the present invention; FIG. 4 is a cross sectional side view of the bottom view of the device, according to the present invention. FIG. 5 is perspective cross sectional view of the top half of an additional embodiment, according to the present invention. DETAILED DESCRIPTION OF THE INVENTION Referring now to FIGS. 1-4 there is shown an embodiment of the self defense device of the present invention, generally designated by the reference numeral 10 . Housing 20 comprises a front canister assembly support structure 21 and rear canister assembly support structure 22 , which structures securely attach a canister assembly 30 within the housing. Canister assembly 30 is not completely encapsulated within the housing 20 with a majority of its body length and sidewalls being visible and located outside housing 20 . Canister assembly 30 , for example, contains an aerosolized propellant with an irritant, and comprises a valve and hollow valve stem 31 . The valve stem 31 is movable relative to the canister between an extended closed position and compressed open position in which propellant is free to leave the canister. An actuator 40 is disposed on the valve stem 31 and includes a nozzle 41 . The actuator 40 has a through orifice 42 adapted to establish open communication between the valve stem 31 and the nozzle 41 , wherein depression of the actuator 40 will compress the valve stem 31 , open the valve, and allow propellant to be dispersed through the nozzle 41 . The housing 20 further comprises a front wall 23 and a grip section 24 . The front wall 23 includes an aperture 231 aligned with the nozzle 41 , wherein fluid exiting the nozzle 41 will travel through the aperture 231 and enter the atmosphere outside the housing 20 . The grip section 24 extends the length of the canister assembly and terminates at the bottom section 25 of the housing 20 . The grip section 24 further includes a shaft 50 . The shaft 50 is moveable in a direction parallel to the canister assembly 30 . The integrity of the shaft is supported by transverse support ribs 201 perpendicular to the canister assembly 30 within the grip section 24 to provide structure and support for the interior components of the housing 20 . In one embodiment, the shaft contains a spline 501 which is moveably received in a notch 503 in the transverse support ribs 201 . The shaft 50 further comprises an elastic member 502 biased in a direction parallel to the shaft 50 to aid in the movement of the shaft 50 . The shaft 50 has a bottom end 52 and a top end 53 . The bottom end 52 terminates at the bottom section 25 . The shaft top end 53 includes an inclined block 55 . The inclined block 55 is inclined at an angle greater than 0 degrees and less than 90 degrees from parallel to the shaft 50 and opposite the canister assembly 30 . The bottom section 25 includes a canister lip 251 , a socket 60 , and a means to adjust the socket diameter 601 . A ball 61 is received in the socket 60 and supports the shaft 50 . The ball 61 in the socket 60 places pressure onto the shaft 50 and loads the elastic member 502 . The ball 61 has an upper end 610 and a lower end 611 . The lower end 611 includes a stud 612 with a bore 613 . The bore 613 allows for the attachment of objects such as a key king, wrist strap 614 , neck strap, arm strap or other such looped device easily attached to the user of the device. The means to adjust the socket diameter 601 puts tension on the ball 61 in the socket 60 allowing the user to adjust the amount of force required to remove the ball from the socket. In the preferred embodiment, adjustment means 601 consists of a screw 602 and spring 603 which tightens the socket around the ball by flexing the housing. This combination allows the tension to be adjusted to between 5 and 30 pounds of force required to remove the ball from the socket. Ball 61 can be re-inserted into the socket 60 after it has been removed. Although the socket 60 and ball 61 connection can be tightened it is desired that the tension not be enough to prevent movement of the ball within the socket. The ideal tension is one that allows the ball to move freely within the socket, while at the same time requiring force to be removed. Five to thirty pounds of force is the ideal range of tension as it allows the ball to rotate in the socket during normal use but will still allow the ball to be separated from the socket during a struggle. Other adjustment means 601 could include a tab, slide, pin, latch, or other like mechanism which could increase the amount of tension necessary to remove the ball. The ball 61 and socket 60 connection is the preferred embodiment as it allows the housing 20 to be manipulated in several directions while the ball 61 will remain engaged within the socket 60 . In addition, the ball 61 and the socket 60 connection allows the ball 61 to be pulled out of the socket 60 from a variety of angles should a struggle ensue between the user and attacker. The housing 20 comprises a channel 202 perpendicular to the canister assembly 30 extending from the front wall 23 to the rear wall 25 . A slide plate 70 is moveably received in the channel 202 . The slide plate 70 comprises a central actuator aperture 701 and a incline aperture 702 . The central actuator aperture 701 is positioned below the actuator 40 and the central actuator aperture 701 and the actuator 40 are of a similar shape wherein depression of the actuator 40 will pass through the central aperture 701 and the slide plate 70 compressing the valve stem and allowing the discharge of propellant. The incline aperture 702 is located above the incline block 55 and correspondingly shaped to receive the incline block 55 , wherein slidable receipt of the incline block 55 into the incline aperture 702 , moves the slide plate 70 in a direction perpendicular to the canister assembly 30 . The slidable movement of the side plate 70 displaces the central actuator aperture 701 in relation to the actuator 40 wherein the actuator cannot be depressed, preventing compression of the valve stem and therefore preventing propellant from exiting canister. Slide plate 70 further comprises an indicator 703 . The indicator 703 is visible via a through hole 203 in the housing 20 , wherein the user can visibly determine the position of the slide plate 70 relative to the actuator 40 based upon this indicator. In the preferred embodiment, this indicator 703 is mounted on the side of the slide plate 70 and consists of the colors green and red. When the color green is visible in the through hole 203 in housing 20 the actuator 40 will be able to move through slide plate 70 and disperse the propellant. When red is visible, the actuator 40 and slide plate central actuator aperture 701 will not be aligned and the actuator 40 will not be able to compress the valve stem allowing for the dispersal of propellant. Although the colors red and green are the preferred indicator, other color or symbol combinations may used to designate when the device is able to be operated and when it is not. Housing 20 further comprises a top wall 29 . Top wall 29 is adapted via an appropriately sized cylindrical bore 291 to receive the pivotally attached top flap 292 . The area below top flap 292 is open to allow the user access to actuator 40 . Top flap 292 comprises a hinge pin 293 adapted to pivotally attach top flap 292 to the cylindrical bore 291 of housing 20 . The top wall 29 includes a stop to align the top flap 292 with the top wall 29 and to prevent the top flap 292 from contacting the actuator 40 . The top flap 292 is pivotally moveable in a direction upwards from the housing allowing the user access to the actuator 40 , wherein the actuator 40 cannot be accessed by the user until the top flap 292 is pivotally moved upwards. Although a snap fit between the top flap 292 and cylindrical bore 291 is the preferred embodiment, due to its simplicity, the hinge pin 293 could be spring loaded to automatically move the top flap 292 downward to the stop after the top flap 292 has been lifted to access the actuator 40 . This spring will also allow the top flap 292 to be forcefully engaged with the stop preventing accidental depression of the actuator when the device is placed into a users pocket, bag, purse, or other enclosed article. In a further embodiment, the top flap 292 is communication with a gate adjacent to the aperture of the front wall, wherein manipulation of the top flap will move the gate. An upwards movement of the top flap 292 will open the gate allowing the propellant to exit the aperture 231 . A downward movement of the top flap 292 will close the gate and prevent the accidental discharge of propellant and prevent debris from entering the nozzle or housing to prevent malfunction. It is preferred that the housing 20 is made of two halves of injection molded material, which pieces are joined together by mutually compatible male/female interlocking joints 204 . These joints may be friction fit, snap fit, threaded and screwed, or other joint combination that tightly secures the two halves. It is desired that the combination of joints securely hold the canister within the housing and prevent the removal of the canister from the housing. Referring now to FIG. 5 , another embodiment of the device is shown. In this embodiment, housing 20 includes a camera 80 , a light unit 81 , a power source 82 , and a memory storage device 83 . These elements are coupled together, such that activation of the actuator 40 will spray fluid, activate the camera 80 , activate the light unit 81 , and the memory storage device 83 . Therefore, the user will activate the actuator 40 to spray the victim and a picture illuminated by a flash will be taken and stored onto the memory device. Data can then be downloaded from the memory storage device to retrieve the photographic images. The photograph can then be used for identification purposes. Camera 80 could be used to take still pictures and capture video. In addition, the housing 20 could include a laser aiming device to ensure that the device is pointed at the proper target. This laser aiming device would also be coupled to the power source and memory storage device. The housing 20 could also include an audio recording device that would be coupled to the power source and memory storage device.
A personal self defense device containing a housing, grip section, canister, actuator, a slide plate, and disarming device. The disarming device prevents operation of the device should the device be removed from the grasp of a victim. The disarming device can rotate in several directions and the force required for its operation can be adjusted. The device further includes a camera, illumination device, power source, and memory storage device.
5
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to wellbore completion. More particularly, the invention relates to apparatus and methods of connecting two tubulars. More particularly still, the invention relates to apparatus and methods of connecting two expandable tubulars at the well site. [0003] 2. Description of the Related Art [0004] In the drilling of oil and gas wells, a wellbore is formed using a drill bit that moves downwardly at a lower end of a drill string. After drilling a predetermined depth, the drill string and bit are removed, and the wellbore is typically lined with a string of steel pipe called casing. The casing provides support to the wellbore and facilitates the isolation of certain areas of the wellbore adjacent hydrocarbon bearing formations. The casing typically extends down the wellbore from the surface of the well to a designated depth. An annular area is thus defined between the outside of the casing and the earth formation. This annular area is filled with cement to permanently set the casing in the wellbore and to facilitate the isolation of production zones and fluids at different depths within the wellbore. [0005] It is common to employ more than one string of casing in a wellbore. In this respect, a first string of casing is set in the wellbore when the well is drilled to a first designated depth. The well is then drilled to a second designated depth, and a second string of casing, or liner, is run into the well to a depth whereby the upper portion of the second liner overlaps the lower portion of the first string of casing. The second liner string is then fixed or hung in the wellbore, usually by some mechanical slip mechanism well-known in the art, and cemented. This process is typically repeated with additional casing strings until the well has been drilled to total depth. [0006] However, one drawback of this process is that as the wellbore is extended, the inner diameter of the well progressively decreases. This is because subsequent liners must have an outer diameter that is smaller than an inner diameter of earlier casings in order to pass through the earlier casings. As a result, top-hole sizes must be sufficiently large so that the final casing has the desired inner diameter size. [0007] Recently, expandable tubular technology has been developed to overcome this problem. Generally, expandable technology enables a smaller diameter tubular to pass through a larger diameter tubular, and thereafter expanded to a larger diameter. In this respect, expandable technology permits the formation of a tubular string having a substantially constant inner diameter, otherwise known as a monobore. Accordingly, monobore wells have a substantially uniform through-bore from the surface casing to the production zones. [0008] A monobore well features each progressive borehole section being cased without a reduction of casing size. The monobore well offers the advantage of being able to start with a much smaller surface casing but still end up with a desired size of production casing. Further, the monobore well provides a more economical and efficient way of completing a well. Because top-hole sizes are reduced, less drilling fluid is required and fewer cuttings are created for cleanup and disposal. Also, a smaller surface casing size simplifies the wellhead design as well as the blow out protectors and risers. Additionally, running expandable liners instead of long casing strings will result in valuable time savings. [0009] Typically, expandable liners are constructed of multiple tubulars connected end to end. The tubulars are generally connected using a threaded connection. As the threads are made up, a metal-to-metal seal is created between the two tubulars. Thereafter, the entire length of the expandable liner is deployed into the wellbore. The expandable liners are typically expanded by the use of a cone-shaped mandrel or by an expander tool, such as a rotary expander tool having one or more rollers. [0010] A problem arises when the threaded connection is expanded. Generally, the male and female threads of a threaded connection are specifically designed to mate with each other to form a fluid tight seal. However, the specifications of the threads do not take into account the expansion of the threaded connection. By plastically deforming or expanding the threaded connection, the requirements of the threads to form a fluid tight seal are necessarily altered. For example, the tight metal-to-metal seal created between the female thread and the male thread becomes slack, thereby jeopardizing the seal at the threaded connection. [0011] A need, therefore, exists for an expandable tubular connection. There is a further need for a method of forming a tubular connection that maintains a fluid tight seal upon expansion of the tubular connection. SUMMARY OF THE INVENTION [0012] The present invention generally relates to methods of connecting two expandable tubulars. In one aspect, the method includes flash welding the ends of the tubulars together. The flash welding process provides a highly reliable joint for expansion. [0013] In another aspect, the present invention provides an apparatus for connecting a first tubular to a second tubular. The apparatus includes a housing disposed around an end of the first tubular and the second tubular. The apparatus may also include one or more sealing elements disposed within each of the tubulars. A conductive member may be connected to each end of the tubulars to conduct a current. The apparatus may also include a translational member for moving the first tubular toward the second tubular to join the heated tubular ends. [0014] In another aspect, the present invention generally relates to methods of completing a well. In one embodiment, the method includes flash welding the ends of two expandable tubulars together. Thereafter, the connected tubulars are lowered into the wellbore to a predetermined location. Then, the connected tubulars are expanded in the wellbore. [0015] In another aspect, the present invention provides a method of completing a well. The method involves flash welding a first tubular to a second tubular. The method includes disposing a housing around an end of the first tubular and an end of the second tubular. Thereafter, a non-flammable gas may be provided within the housing to facilitate the welding process and/or prevent ingress of flammable mixtures of hydrocarbons. After the tubulars have been joined, the tubulars may be expanded downhole. BRIEF DESCRIPTION OF THE DRAWINGS [0016] 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. [0017] [0017]FIG. 1 is a cross-sectional view of a tubular positioned above another tubular held in a wellhead. [0018] [0018]FIG. 2 is schematic view of an apparatus for flash welding two tubulars. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0019] Aspects of the present invention provide apparatus and methods of connecting expandable tubulars using flash welding. FIG. 1 is a schematic view of a first tubular 10 ready to be joined with a second tubular 20 . As shown, the first tubular 10 at least partially extends above the wellhead 5 and is held in place by a spider (not shown). The second tubular 20 is suspended above the first tubular 10 by an elevator 25 operatively connected to the rig 30 . A tubular handling device 40 attached to the rig 30 may be used to help position the second tubular 20 . [0020] In one embodiment, the first and second tubulars 10 , 20 are expandable tubulars to be joined and expanded downhole. Examples of expandable tubulars include expandable solid tubulars, expandable slotted tubulars, expandable screens, and combinations thereof. Further, the first and second tubulars 10 , 20 , as used herein, may include a single tubular or a tubular string formed by more than one tubular. [0021] [0021]FIG. 2 shows an apparatus 100 for flash welding the second tubular 20 to the first tubular 10 according to aspects of the present invention. The apparatus 100 includes a tubular housing 110 at least partially disposed around the first and second tubulars 10 , 20 . One end of the housing 110 overlaps the first tubular 10 while the other end of the housing 110 overlaps the second tubular 20 . Preferably, an inner diameter of the housing 110 is larger than an outer diameter of the tubulars 10 , 20 such that an annular space 115 is formed therebetween. The housing 110 should be made from a material capable of tolerating high temperatures, such as metal. In one embodiment, the housing 110 defines a single sleeve tubular. In another embodiment, the housing 110 defines two arcuate portions hinged together. Spacers 120 may be placed at each end of the housing 110 to seal off the annular space 115 . The spacers 120 may be made from an elastomeric material, metal, or combinations thereof. [0022] One or more sealing elements 131 , 132 may be placed within the first and second tubulars 10 , 20 to seal off the bores of the tubulars 10 , 20 . In one embodiment, inflatable packers 131 , 132 are used to seal off the tubulars 10 , 20 . The inflatable packers 131 , 132 may be connected to a tubular conveying member 140 for positioning the inflatable packers 131 , 132 . The conveying member 140 may be in fluid communication with the packers 131 , 132 so that it may provide pressure to actuate the packers 131 , 132 . In another embodiment, the sealing elements 131 , 132 may be formed of a water soluble material. The water soluble sealing elements 131 , 132 may be caused to dissolve immediately after flash welding the tubulars together. Alternatively, the water soluble sealing elements 131 , 132 may remain in the tubulars 10 , 20 after the connection is made and dissolved at a later time. [0023] In another aspect, the conveying member 140 may optionally include a second conveying member 142 for providing gas into the area enclosed by the packers 131 , 132 and the housing 110 . Preferably, the supplied gas is an inert gas, a non-flammable gas, or combinations thereof. The inert gas may supplant or dilute the air in the enclosed area, thereby decreasing the possibility of oxide forming on the heated tubulars 10 , 20 . Impurities such as oxide formed during the welding process are undesirable because they weaken the bond between the joined tubulars 10 , 20 . In another embodiment, the inert gas may be delivered through one or more ports 150 formed in the housing 110 . As shown in FIG. 1, the ports 150 are formed on a wall of the housing 110 . However, the ports 150 may also be formed in the spacers 120 or other suitable surface of the housing 110 as is known to a person of ordinary skill in the art. It must be noted that the ports 150 may be used in combination with the second conveying member 142 to inject inert gas into the enclosed area. [0024] The apparatus 110 may also include a welding tool 160 , which is schematically shown in FIG. 1. The welding tool 160 may be used to supply the current necessary to perform the flash welding process. The welding tool 160 may be selected from any suitable flash welding machine as is known to a person of ordinary skill in the art. An exemplary flash welding tool may comprise a bank of 12 volt lead-acid batteries or a direct current generator with appropriate tubular gripping members to handle the relative positioning of the tubular members throughout the joining process. As schematically shown in FIG. 2, the welding tool 160 has at least one conductive member 161 , 162 for contacting each tubular 10 , 20 . In one embodiment, clamps 161 , 162 are used to contact the tubulars 10 , 20 to provide current to the tubulars 10 , 20 for the flash welding process. The welding tool 160 may further include a translational member 167 for moving the tubulars 10 , 20 toward each other. In one embodiment, the translational member 167 may comprise a piston and cylinder assembly to bring the clamps 161 , 162 closer to each other. Upon actuation, the piston and cylinder assembly 167 may cause the first tubular 20 to move closer to the second tubular 20 . [0025] In operation and as one example of the process, the second tubular 20 is positioned above the first tubular 10 in the wellbore as shown in FIG. 1. Once in position, a clamp 161 , 162 is attached to each tubular 10 , 20 proximate the ends of the tubular 10 , 20 to be joined. Thereafter, the housing 110 is disposed around the tubulars 10 , 20 . An inflatable packer 131 , 132 is then placed in the bore of each tubular 10 , 20 . Fluid is supplied to the inflatable packers 131 , 132 to actuate the packers 131 , 132 , thereby sealing off the bores of the tubulars 10 , 20 . After the packers 131 , 132 are actuated, inert gas is injected into the enclosed area to displace most of the air. Preferably, the inert gas is injected through the ports 150 of the housing 110 . [0026] The welding process begins by bringing the tubulars 10 , 20 into contact with each other. During the flash welding process, current is applied to each tubular 10 , 20 through the clamps 161 , 162 . The current applied initially results in heating of each tubular 10 , 20 due to the electrical circuit formed by contacting the tubular ends. The resistance that naturally occurs at the interface between the tubulars 10 , 20 causes the “flashing” for which the joining process is known. The flashing action continues until the ends of the tubulars 10 , 20 reach a plastic state and a predetermined temperature. The plastic portion and the adjacent heated portion of the tubulars 10 , 20 are commonly referred to as the heat-affected zone, or HAZ. [0027] The flash welding process concludes with the upset or forging action. When the tubulars 10 , 20 have reached the plastic state and the proper temperature, the ends of the tubulars 10 , 20 are brought together with enough force to cause the tubular ends to upset. Particularly, the piston and cylinder assembly 167 of the welding tool 160 is actuated to cause the contacting end of the second tubular 20 to move into the contacting end of the first tubular 10 . The speed of the movement between tubulars 10 , 20 for the upset action may be controlled by adjusting the piston size or rate of pressure increase. The upset action forces the plastic portions and most of the impurities out of the formed joint. EXAMPLE [0028] In one example, two expandable tubulars having about 2″ outer diameters and about 0.156″ wall thickness are joined in accordance with the aspects of the present invention. The initial spacing gap between the tubulars was 0.25″. The starting flash was set when the relative position between the two clamps was about 3.5″. The upset was initiated at a relative clamp position of about 2″ with an upset pressure of 600 psi. During the welding process, the voltage was set at about 12 VAC and the total cycle time including positioning was about 30 seconds. The final relative clamp position was between about 0.8″ to about 1.2″. [0029] The flash welding process may optionally include an additional preheating action. In one embodiment, the ends of the tubulars 10 , 20 may be caused to oscillate against each other. Initially, the ends are brought together to allow heat to be generated from the resistance of the tubulars 10 , 20 . [0030] When the ends begin to cool and solidify, the preheating action is repeated and continued in a rapid motion until heat is generated at both ends of the tubulars 10 , 20 . The preheat stage is performed until the proper HAZ is obtained. Thereafter, the flash weld stage is performed and the two tubular ends are forged together. [0031] Advantages of the preheating the tubulars include the ability to weld a large cross-sectional area with lower current demand. Additionally, the temperature gradient may remain more uniform during the process. Finally, heat may be generated in high strength alloys without a large loss of material by the flashing action. [0032] After the proper length of tubular has been formed, the tubular may be lowered into the wellbore along with an expander tool. When the tubular reaches the proper depth in the wellbore, the expander tool is actuated to expand the tubular. Examples of the expander tool include rotary expander tools and coneshaped mandrels. In this respect, the flash welded joint is plastically deformed, but retains its fluid tight seal. In this manner, expandable tubulars may be joined and expanded downhole. [0033] While the foregoing 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, and the scope thereof is determined by the claims that follow.
The present invention generally relates to methods of connecting two expandable tubulars. In one aspect, the method includes flash welding the ends of the expandable tubulars together. Thereafter, the connected tubulars are lowered into the wellbore for expansion. The flash welding process provides a highly reliable joint for expansion.
1
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority from International Patent Application No. PCT/GB2006/050136, filed Jun. 1, 2006, published as WO 2006/131764 A1, which claims priority from British Patent Application No. 0511883.1, filed Jun. 10, 2005. [0002] This invention relates to the manufacture of ferrous alloys (“ferroalloys”) from steel scrap, and particularly to the manufacture of stainless steel. [0003] Stainless steel is a low carbon ferrous alloy typically including chromium and nickel as alloying elements. A typical composition contains 18% by weight of chromium, 8% by weight of nickel and less than 0.1% by weight of carbon, the balance being iron and any other alloying elements (excluding incidental impurities). Stainless steel is typically made by melting a charge of mild steel scrap and high carbon ferroalloys in an electric arc furnace to form a crude alloy containing up to 0.5% by weight more chromium than is desired in the product and having a carbon content in the range of 0.25% to 2.5% by weight and a silicon content in the range of 0.2% to 1.5% by weight. The particular levels of carbon and silicon depend on the product specification, steel making practice and vessel size. The crude alloy is transferred in molten state to a converter in which the molten alloy is blown from beneath the surface of the molten metal with oxygen so as to oxidise the carbon content of the resultant stainless steel to less than 0.1% by weight. In many cases submerged blowing is supplemented by the use of a top lance to deliver additional oxygen for part of the refining cycle. [0004] As the carbon level progressively decreases during the blow so there is a tendency for the oxygen to react with the chromium to form chromium oxide. There is also an associated tendency for an excessive temperature to be created in the converter because of the exothermic nature of the oxidation reactions. In practice, this tendency can be counteracted by adoption of Argon-Oxygen Decarburisation (AOD) practice, whereby the oxygen is progressively, or in steps, diluted with argon so as to reduce the partial pressure of carbon monoxide and so promote oxidation of carbon in preference to oxidation of chromium. By this means most of the chromium is retained in the molten metal. The avoidance of oxidation of chromium helps keep temperatures to an acceptable level, for example to a temperature no higher than 1750° C. Sometimes, additions of non-particulate scrap are made to facilitate temperature control further. In a typical example, the blow is commenced with an oxygen to nitrogen ratio (by volume) of 3:1. This ratio is changed in a series of steps, with argon being substituted for the nitrogen at a given step, to one in which oxygen, rather than argon, is the minor component of the gas mixture. The exact series of gas mixtures and other details of the process depend upon the grade of steel being produced. After the blow, some ferrosilicon can be added to reduce chromium oxide in the slag, and lime can be introduced as a desulphurisation agent. [0005] The Creusot-Loire-Uddeholm (CLU) process may be used as an alternative to the AOD process in order to make stainless steel. The CLU process is analogous to the AOD process but typically uses steam instead of argon to dilute the oxygen that is blown into the melt from beneath its surface. [0006] During the melting of the steel scrap and alloying materials in the electric arc furnace some oxygen atoms may be added in chemically combined form as part of the raw materials, for example if the scrap is in oxidised state, or if an oxygen-containing fluxing agent such as lime or limestone is used. Further, some oxygen and possibly some moisture from the surroundings reacts with the molten metal. As a result a proportion of the alloying elements, particularly the chromium, is oxidised, and as a result the chromium is lost to the slag layer that is formed on top of the molten metal during the melting of the steel scrap in the electric arc furnace. [0007] Not only is the loss of chromium oxide to the slag layer disadvantageous because, in consequence, an unnecessarily large amount of chromium needs to be added to the steel scrap in the electric arc furnace, but it is also disadvantageous because it has an adverse effect on the properties of the slag layer. During conventional operation of an electric arc furnace to form mild steel, rather than an alloyed steel, carbon-containing materials are added to the slag so as to create bubbles of carbon monoxide by reaction between the carbon and reducible oxides in the slag. The formation of the bubbles of carbon monoxide gives rise to a foamy slag. Operation of the electric arc furnace with a foamy slag is recognised to give several advantages over operation with a quiescent slag. In particular, energy consumption is less in the former case and consumption of electrodes and the refractory lining the walls of the furnace is also less in foamy slag operation than in quiescent slag operation. However, the presence of a considerable proportion of an amphoteric oxide such as chromium oxide adds to the viscosity of the slag and reduces the amount of oxygen available for formation of reducible oxides such as ferrous oxide. For practical purposes it is not possible to operate the electric arc furnace with a foamy slag in the manufacture of stainless steel. [0008] WO-A-00/34532 discloses that molten steel can be transferred from the electric arc furnace to the converter via a ladle, and that fine particulate ferrosilicon can be added to the slag in the electric arc furnace before the molten steel and slag are tapped from the furnace. As a result, the ferrosilicon reacts with chromium oxide in the slag and resultant molten chromium metal is formed which descends into the molten metal. Such a procedure is, however, difficult to control satisfactorily. The exact amount of oxygen which enters the melt in the arc furnace cannot be known exactly. If too little silicon is added, the chromium oxide content of the slag will remain too high; if too much silicon is added, the resulting content of silicon in the steel which is transferred to the converter will be too high, thus increasing refining time and increasing the amount of slag that is formed in the converter. WO-A-03/104508 discloses a method of refining a ferroalloy, such as stainless steel, including the step of blowing molecular oxygen or a gas mixture including molecular oxygen into a melt of the ferroalloy, wherein a metallurgically acceptable particulate material, such a ferrochrome or chromite, is introduced from above into the melt, the particulate material being carried into the melt in a first supersonic gas jet which travels to the melt shrouded by a second gas jet. WO-A-03/104508 does not however address problems in initially melting the steel in the electric arc furnace. BRIEF SUMMARY OF THE INVENTION [0009] According to the present invention there is provided a method of making stainless steel, comprising the steps of: a) melting a charge of steel; b) refining the resultant molten steel at least in part by blowing molecular oxygen into the molten steel from a lance positioned above the surface of the molten steel; and c) during the refining step introducing into the molten steel from the lance at least one first metallurgically acceptable particulate material selected from chromium metal, chromium-containing alloys and chromium ores; wherein the steel is melted under foamy slag conditions. [0013] Introducing particulate chromium and, if desired, other alloying constituents (or their precursors) during the refining step facilitates foamy slag practice at the electric arc furnace by eliminating minimising or keeping down the entry into the slag of species such as chromium oxide that are deleterious to its foaming characteristics, the amount of chromium employed in the melting step may be minimised or eliminated. Hence a sufficiently low viscosity slag forms, which contains an adequate proportion of reducible oxides and hence does not present any difficulty in foaming the slag by a conventional method, for example, by the injection into the slag of particulate carbon from a lance. Indeed, we believe it possible to operate the method according to the invention without any chromium metal, chromium-containing alloy or chromium ore being added to the charge of steel that is melted in the said step (a) (although the steel that is melted may inevitably contain scrap of a kind which includes chromium as an alloying component). Nonetheless, if desired, some chromium metal or chromium-containing alloy may be deliberately added to the charge of steel that is melted provided, of course, that not so much is added as to cause difficulty in foaming the slag [0014] Preferably, the steel that is melted in the said step (a) is a low-carbon steel, for example mild steel. By a low-carbon steel is meant a steel containing less than 0.3% by weight of carbon. Such a low-carbon steel is able to equilibrate with a slag of sufficiently high iron oxide content (typically greater than 5% by weight) to sustain a degree of foaming. [0015] Preferably, the charge of steel is melted in an electric arc furnace, although, if desired, another kind of melting furnace may be used instead. [0016] Preferably, the molecular oxygen is ejected from the lance at a supersonic velocity. Use of such a supersonic velocity facilitates penetration of the molecular oxygen into the molten steel and may therefore in turn facilitate rapid reaction between oxygen and carbon in the molten steel. The molecular oxygen is preferably ejected from the lance at a velocity in the range of Mach 1.5 to Mach 4, more preferably at a velocity in the range of Mach 2 to Mach 3. [0017] Typically the first metallurgically acceptable particulate material is conveyed to the lance in a carrier gas. The carrier gas may be pure oxygen, but in order to minimise risk of fire, is preferably air, nitrogen or a noble gas. The first metallurgically acceptable particulate material may be conveyed as a dilute phase or a dense phase. [0018] The lance may simply comprise an arrangement of two pipes, there being a first pipe for ejecting the molecular oxygen and a second pipe for ejecting the first metallurgically acceptable particulate material. Various different configurations of the pipes are possible. For example, the first and second pipes may be coaxial with the first pipe surrounding the second pipe. An advantage of such a configuration is that the first metallurgically acceptable particulate material is able to be introduced into the flow of molecular oxygen ejected from the lance and carried with it into the molten steel. In consequence, there is generally no need to employ a shrouding gas jet, particularly in the form of a flame, as disclosed in WO-A-03/104508. Thus the more complex forms of lance disclosed therein need not be used, although such forms may be advantageous if the additional energy imparted by the flame can be used to aid dissolution or compensate for endothermic reactions. [0019] One of the advantages offered by the method according to the present invention is that if the first metallurgically acceptable particulate material contains a reactive species, it is possible to facilitate the reaction of that species by using the molecular oxygen to create a localised, intensely superheated region in the molten steel into which the first metallurgically acceptable particulate material can be introduced. The higher temperature of such region relative to the average temperature of the molten steel helps to promote more rapid dissolution of the first particulate material and more rapid chemical reactions, thus helping to shorten the overall duration of the refining step in comparison with what it would otherwise be. In addition, increasing temperature favours oxidation of carbon over chrome. By localising the high temperature region, risk of a significantly enhanced rate of wear of refractory materials protecting vessel walls is kept down. [0020] The first metallurgically acceptable particulate material is advantageously ferrochrome. Ferrochrome is an alloy of iron and chromium that contains typically from 5 to 10% by weight of carbon. It is accordingly desirable to introduce into all the ferrochrome into the molten steel during a first part of the refining step and then to reduce the carbon level to an acceptable value in a second part of the refining step in which no ferrochrome is introduced into the molten metal. Preferably the first part of the refining step takes up no more than 60% of the total duration of the refining step. Surprisingly, simulations that we have conducted predict that notwithstanding the high carbon content of ferrochrome, its use as the first particulate material makes possible a shortening of the duration of the refining step in comparison with a comparable conventional method in which no alloying additions are made during the refining step and in which all gas introduced into the molten steel is supplied from tuyeres (which terminate beneath the surface of the molten steel). A contributory factor to this result may be a cooling effect that the particulate ferrochrome has. This cooling effect helps to limit or control the temperature rise resulting from the exothermic reaction between carbon and oxygen to form carbon monoxide. There are two main contributions to the cooling effect. The first is from sensible cooling provided by the ferrochrome. The second is from its enthalpy of melting. [0021] The mean particle size of the first metallurgically acceptable particulate material is preferably less than 5 mm. It is particularly preferred that a fine particulate material is used. A fine particulate material is one that if it were simply fed under gravity into a converter, in which the refining step of the method according to the invention is typically performed, it would not penetrate the surface of the molten metal and would therefore have at most only a negligible effect. [0022] The first metallurgically acceptable material may alternatively, but still advantageously, be an ore of chromium, preferably an oxide ore. One such ore is chromite which is a mixed oxide of iron and chromium. The use of such an ore significantly changes the metallurgy of the refining step. Now, it is necessary to reduce the ore in order to release chromium metal. Thus, the chromium ore is dissolved in the molten steel and reacted with a suitable reducing agent. Further, because the reduction of chromium oxide is endothermic, it is desirable to add further fuel, typically in the form of particulate carbon. Accordingly, it is preferred to introduce through the lance into the molten steel a second particulate material comprising a mixture of carbon and at least one deoxidising agent. Suitable deoxidising agents, when metallurgically acceptable, include ferrosilicon, ferromanganese, aluminium and ferroaluminium. [0023] Since stainless steel typically contains other alloying elements in addition to manganese, it is necessary to ensure that the product of the method according to the invention includes any such desired additional alloying element. If desired, such alloying elements may be added to the molten steel during the refining step. Accordingly, a third metallurgically acceptable particulate material selected from sources of such alloying elements is preferably introduced into the molten steel during the refining step. The third metallurgically acceptable particulate material may, for example, comprise at least one of nickel metal, alloys of nickel (for example, ferronickel), nickel ores, molybdenum metal, alloys of molybdenum (for example, ferromolybdenum) and molybdenum ores. [0024] Typically, in the refining step the lance is not the only source of molecular oxygen. Molecular oxygen is typically also blown into the molten steel during the refining step through at least one tuyere terminating below the level of the molten steel. Analogously to conventional stainless steel refining methods, at least one gas other than oxygen may be introduced into the molten steel during the refining step so as to increase the propensity of the refining conditions to favour oxidation of carbon over oxidation of chromium. The other gas may be at least one selected from argon, nitrogen and steam and may be introduced at least in part through the same or a different tuyere from the oxygen. It is also possible to mix with other gas the molecular oxygen that is introduced from the lance into the molten steel. The use of the lance in the method according to the invention can therefore be employed to help control its thermodynamic variables. [0025] The method according to the present invention offers a number of general advantages. It can improve operation of the steel melting operation by conducting the operation under a foamy slag. It makes possible shorter refining times, therefore offering productivity increases. In addition, it can make use of fine particulate materials which might otherwise be waste materials. BRIEF DESCRIPTION OF THE DRAWINGS [0026] The method according to the present invention will now be described by way of example with reference to the accompanying drawings, in which: [0027] FIG. 1 is a schematic diagram of a converter that can be used to perform the refining step. [0028] FIGS. 2 to 4 are graphs presenting simulated operating parameters for operation of the converter shown in FIG. 1 . DETAILED DESCRIPTION OF THE INVENTION [0029] The first step of the method according to the invention involves melting a batch of mild steel scrap in an electric arc furnace. Melting of steel in an arc furnace is conventional. Typically, a fluxing agent such as lime is added so as to promote the formation of a basic slag. Some alloying elements such as nickel and molybdenum may also be included in the initial charge, although they may both be added at a later stage of the method according to the invention. [0030] Striking an arc in the furnace will cause the steel scrap to melt. Calcium oxide reacts with impurities in the steel to form a basic slag on the surface of the molten steel. The slag typically includes an iron oxide component. In order to render the slag foamy and thereby to obtain the above-mentioned advantages in terms of the operation of the electric arc furnace, a lance is employed to introduce from above a particulate carbonaceous material into the slag. The particulate carbonaceous material is conveyed to the lance in a carrier gas and ejected therefrom at a sufficient velocity that it penetrates the slag layer. The particulate carbon reduces iron oxide in the slag to form carbon monoxide. Bubbles of carbon dioxide are thereby formed. As a result, the slag is rendered foamy. [0031] If desired, one or more oxy-fuel burners may be used to direct heat into the charge so as to reduce the time taken to melt the steel. In general, the operator of the furnace has more latitude in the use of oxy-fuel burners than in a conventional procedure because the relative absence of chromium in the charge makes it possible largely to avoid the increased formation of oxides such as chromium oxide that are difficult to reduce back to the metal. [0032] A further consequence of employing a charge with no or only a low chromium content, is that the addition to it, either before, during or after melting, of ferrosilicon or other deoxidising agent to reduce chromium oxide back to chromium, can be reduced or eliminated altogether. [0033] Once the steel scrap has been melted it is typically transferred to a ladle from which it is transferred to a converter of the kind shown in FIG. 1 . The transfer of molten steel from an electric arc furnace via a ladle to a converter is a standard operation in the manufacture of stainless steel and need not be described further herein. [0034] Referring to FIG. 1 of the drawings, a converter 2 is in the form of a vessel 4 having walls 6 provided with an internal refractory lining 8 . The vessel is open at its top and is provided with an axial lance 10 which terminates in its interior. In operation the vessel 4 is charged with molten steel which is transferred from the ladle referred to above. The vessel 4 is charged up to a level such that, in operation, a plurality of tuyeres 12 have outlets submerged in a volume 16 of molten steel. The lance 10 comprises two coaxial pipes 22 and 24 . The inner pipe 22 is adapted to be placed in communication with a source (not shown) of carrier gas into which a particulate material is able to be fed. The outer pipe 24 is placed in communication with a source (not shown) of commercially pure oxygen. The outer pipe 24 typically terminates in a Laval nozzle 25 and the oxygen is supplied at a pressure such that it is ejected from the Laval nozzle 25 at a supersonic velocity. In operation, the particulate material issuing from the pipe 22 becomes entrained in the jet of oxygen that issues from the Laval nozzle 25 and is carried into the molten steel typically through a layer of slag 28 that is formed on top of the molten steel. [0035] The oxygen which is introduced into the molten steel from the lance 10 reacts exothermically with oxidisable components or impurities in the molten steel and therefore provides heat to maintain the steel in its molten state. Further oxygen is supplied to the molten steel from the tuyeres 12 . The oxygen that is supplied to the tuyeres 12 is able to be mixed selectively with one or both of argon and nitrogen. Accordingly, the partial pressure of the oxygen supplied to the molten steel is able to be adjusted by adjusting the mole fraction of argon and nitrogen which are mixed with the oxygen. [0036] In one typical example of the operation of the converter shown in FIG. 1 of the drawings, the particulate material which is introduced into the molten steel from the lance 10 is ferrochrome in fine particulate form. The ferrochrome typically contains 5 to 10% by weight of carbon. If desired, other alloying elements can be added to the molten steel via the lance 10 . For example, nickel can be added in the form of ferronickel and molybdenum in the form of ferromolybdenum. Silicon in the form of ferrosilicon can also be added. The amounts of these alloying elements that are added will depend in part on the desired stainless steel composition. It is a noteworthy feature of the present invention that the addition of such alloying elements to the molten steel in the converter enables their addition to the electric arc furnace to be kept to a level which does not hinder the foaming of the slag therein or to be eliminated altogether. [0037] Because the ferrochrome has a high content of carbon, not only does the operation of the converter shown in the drawing involve the dissolution of the ferrochrome in the molten steel, it also involves the removal of substantially all the carbon by reaction with oxygen. Both the dissolution of the ferrochrome and the refining reaction are aided by the fact that the oxygen jet that issues from the lance 10 creates in the vicinity of the region where it enters the molten steel a localised intensely superheated volume of molten metal. The high temperature in this region particularly favours the reaction between dissolved carbon and oxygen to form carbon monoxide. The lance is typically located on the vertical axis of the converter 2 such that the superheated region is central and does not substantially affect the temperature of the molten steel in the vicinity of the refractory lining 8 . Accordingly, the introduction of oxygen into the molten steel from the lance 10 does not substantially increase the rate of erosion of this lining. [0038] Similarly to conventional AOD refining of stainless steel, the reaction between oxygen and carbon in the molten steel is in competition with undesirable reactions between alloying elements (such as chromium) and oxygen to form oxides. Because ferrochrome has a significant carbon content, its addition to the molten steel introduces carbon at the same time as it is being removed. In this respect, the method according to the invention is different from a conventional AOD operation. Accordingly, it is preferred to discontinue the addition of the ferrochrome well before the end of the refining operation. Typically, the ferrochrome is introduced for a period which has a duration of no more than 75% of the total duration of the refining step in the converter 2 . Once the introduction of ferrochrome is discontinued, the carbon levels in the converter 2 will fall relatively rapidly, and it is at this stage important to adjust the mole ratio of oxygen to diluent gases such as argon and nitrogen that are introduced into the molten metal so as to lower the partial pressure of oxygen. So doing helps to favour the oxidation of carbon over the oxidation of chromium. [0039] In order to assess typical operating parameters for the refining step of the method according to the present invention, operation of the converter 2 has been modelled by us using a commercial Metsim software package. Results of the modelling are presented below. These relate to the refining of a batch of 150 tonnes of steel. In performing the modelling work, the following constraints were observed. [0040] Total flow rate through submerged tuyeres was never allowed to exceed 6800 Nm 3 /h. [0041] Maximum temperatures were not allowed significantly to exceed 1708° C. [0042] The lance was assumed to be of a size that can deliver a maximum gas flow rate of 6000 Nm 3 /h. (This flow rate is well within the range of conventional lances.) [0043] Three different operating regimes were modelled. These were as follows with all percentages being by weight unless otherwise stated: Example 1 [0044] Refining of a conventional stainless steel composition (18% by weight of chromium; 8% by weight of nickel and less than 0.1% by weight of carbon) with top blowing of molecular oxygen at a rate of 6000 Nm 3 /h but with minimal ferrochrome introduction and then only in lump form. In this refining operation the carbon concentration is reduced from a starting value of 2.2% by weight to the end value of less than 0.1% by weight. Example 2 [0045] Manufacture of stainless steel in accordance with the invention with introduction of oxygen through the lance 10 at a rate of 6000 Nm 3 /h and addition of 30 tonnes of ferrochrome of the following composition Fe—36%; Cr—53%; C—6.5%; Si—2.7%; balance—minor component and impurities. The starting composition of steel supplied to he converter was taken to be: Fe—82%; Cr—8.2%; Ni—7.9%; C—1.1% and Si-0.18%. Example 3 [0046] As Example 2 but with the introduction of 45 instead of 30 tonnes of ferrochrome. The starting composition of the stainless steel was taken to be Fe—90%; Ni—8.8%; Cr—0.18%; C—0.35% and Si—0.18%. [0047] Whereas in Example 2, some addition of chromium during the melting step of the method according to the invention was needed, no such addition was necessary in Example 3. [0048] The relevant operating parameters are shown in Table 1 below. These operating parameters are also shown in FIGS. 2 to 4 which are graphical representations of Examples 1 to 3, respectively. [0000] TABLE 1 Oxygen Introduction Oxygen Introduction Argon Introduction Nitrogen Introduction Ferrochrome through lance through tuyeres through tuyeres through tuyeres Introduction Duration Start End Start End Start End Start End Total Start End of heat Rate time Time Rate time time Rate time time Rate time time addition time time (min) (Nm 3 /h) (min) (min) (Nm 3 /h) (min) (min) (Nm 3 /h) (min) (min) (Nm 3 /h) (min) (min) (tonne) (min) (min) Example 1 70 6000 4 19 3400 4 39 0 0 39 1700 4 19 2.3 5 5 0 20 70 1750 40 59 5100 41 59 3400 20 40 0 60 70 2500 60 70 0 41 70 Example 2 60 6000 4 33 3400 4 27 0 0 33 3400 4 33 30 5 34 0 34 60 1700 28 50 5100 34 50 0 34 60 0 51 60 2500 51 60 Example 3 59 6000 4 34 3400 4 10 0 0 34 3400 4 10 45 5 34 0 35 59 5100 11 26 5100 35 48 1700 11 26 1700 27 49 2500 50 59 5100 27 34 0 50 59 0 35 59 The final metallurgical compositions obtained in each of Examples 1 to 4 are summarised in Table 2 below. [0000] TABLE 2 Example 1 Example 2 Example 3 % C at 45 mins 0.24 0.17 0.15 Temp C. at 45 mins 1683 1702 1688 Max Temp 1699 1711 1701 Final % C 0.09 0.09 0.1 Final % Cr 18.8 18.3 17.8 Final % Ni 8.4 8.6 8.5 Final % Mn 1.3 1.2 1.2 Final Temp C. 1651 1662 1638 Blow Time 69 60 58 A comparison of the results obtained is set out in Table 3 below. [0000] TABLE 3 Total Total Produc- Blow Tuyere Lance tivity Time % C at Tap O2 O2 O2/t T tonnes Mins Tap % Cr Temp Nm3 Nm3 total N2/t Ar/t max per min Example 1 69 0.09 18.8 1651 2606 1600 27.3 10.3 13.7 1699 2.23 Example 2 60 0.09 18.4 1662 2011 3000 33.4 11.3 12.4 1711 2.5 Example 3 58 0.1 17.8 1638 2380 3100 36.5 10.2 10.7 1701 2.58 [0049] It can be seen from the results set out in the Tables that surprisingly it is possible to reduce the overall blow time as the amount of ferrochrome introduced into the molten steel through the lance 10 is increased. This result is achieved by appropriately balancing the endothermic effect of the particulate ferrochrome with the exothermic reaction between oxygen and carbon. Thus, total rates of addition of molecular oxygen are higher when ferrochrome is being added than when it is not. Relative rates of addition of molecular oxygen, nitrogen and argon are adjusted so as to maintain conditions that favour oxidation of carbon over oxidation of chromium. [0050] Instead of ferrochrome, it is possible to use an ore as the source of chromium for the stainless steel. One such ore is chromite which is a mixed oxide of iron and chromium. Since reduction of chromium oxide is endothermic, the high rates of injection that would be required in order to enable all the chromium to be added to the steel during the refining step make it desirable to add additional fuel and reductant. The additional fuel is preferably in the form of a solid material coinjected with the chromite. The additional fuel may be a particulate carbonaceous material. It is also desirable to introduce one or more deoxidisers such as ferrosilicon and ferroaluminium in order to facilitate the reduction of the chromium oxide to chromium metal. The endothermic reduction of the oxide can be at least partially compensated by increasing the specific oxygen delivery rate to increase the rate of heat generation associated with decarburisation. Accordingly, in such alternative methods according to the invention it remains possible to operate the electric arc furnace mentioned above under conditions which give rise to a slag that can be formed into a foam.
A ferroalloy, particularly stainless steel, is made by melting typically low-carbon steel under foamy slag conditions, and refining the molten steel at least in part by blowing molecular oxygen into the molten steel from a lance positioned above its surface. During the refining step at least one metallurgically acceptable particulate material is introduced into the molten steel. The particulate material is selected from chromium metal, chromium-containing alloys and chromium ores.
2
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the priority benefit of U.S.A. provisional application Ser. No. 60/865,446, filed on Nov. 13, 2006. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a backlight processing system and a method thereof. More particularly, the present invention relates to a backlight processing system and a method that improves the contrast of the frame and adjusts the brightness of the backlight. [0004] 2. Description of Related Art [0005] Typically, the brightness of early electronic devices with liquid crystal display screens is adjusted by the backlight module or the user operating the devices to reduce power consumption. Hence, power saving is made fairly straightforward. However, the display quality is adversely affected when the brightness is adjusted using a conventional backlight module. Further, sometimes the adjusted brightness of the backlight module may be too bright or too dark, causing visual discomfort among the display screen users. [0006] In another prior art, the backlight control is dynamically adjusted according to a frame signal. Please refer to FIG. 1 , which is a schematic view illustrating a conventional backlight processing system. In this prior art, a frame signal is outputted to a display control portion 14 , an average brightness detecting portion 15 , and a peak detecting portion 16 for backlight control processing. Herein, the display control portion 14 converts the outputted frame signal into a data mode that can be displayed by a liquid crystal display screen 11 . The average detecting portion 15 calculates the average brightness based on the frame signal and transmits the calculated average brightness signal AVE as a backlight adjustment parameter to a backlight control portion 13 . Further, the peak detecting portion 16 calculates the peak value for the pixel data of each frame signal to obtain the highest peak signal PEK and transmits the highest peak signal PEK to the backlight control portion 13 to adjust the backlight. Thereafter, the backlight control portion 13 determines whether to adjust the brightness of the backlight according to the average brightness signal AVE and the highest peak signal PEK. Although this prior art adjusts the display frame and reduces power consumption, such combination of the image displayed and the brightness of the backlight causes visual discomfort and eyestrain among display screen users because the image displayed is somewhat dark. SUMMARY OF THE INVENTION [0007] The present invention is directed to a backlight processing system for adjusting the brightness of the backlight and the pixels data in a frame signal. The quality of the adjusted frame is the same as that of the original frame. In addition, the present invention is reduces power consumption. [0008] The present invention is further directed to a method for processing a backlight that improves the contrast of frame pixels and lowers the brightness of the backlight to reduce power consumption. As a result, the outputted frame provides comfortable visual effects to the display screen users. [0009] One embodiment of the present invention is directed to a backlight processing system including a pixel conversion unit, a frame data distribution unit, a frame data determination unit, and a backlight adjustment evaluation unit. Herein, the pixel conversion unit is used to receive a frame data, then adjusts the gray level values of pixels according to the frame signal and outputs the adjusted gray level values of pixels to a liquid crystal display screen. The frame data distribution unit is used to receive a frame signal and compile the statistics on the gray level value versus the number of pixels based on the pixel gray level value distribution of the frame signal in order to output a relational data. The frame data determination unit is coupled to the output of the frame data distribution unit. The frame data determination unit generates a reference signal based on the relational data. This reference signal represents the contrast of the frame. The backlight adjustment evaluation unit is coupled to the output of the frame data determination unit. The backlight adjustment evaluation unit adjusts the backlight according to the reference signal in order to adjust the brightness of a backlight module. Further, the backlight module is used to emit light to the liquid crystal display screen. [0010] In one embodiment, the backlight processing system includes a pixel conversion unit that converts a frame signal according to a look-up table, and a frame data distribution unit that selects the maximum gray level value of each pixel in the frame signal to calculate the number of pixel distribution at each gray level and output a relational data of the gray level values versus the number of pixel distribution. The frame data determination unit accumulates the number of pixel distribution. When the accumulated number is greater than or equal to a ratio of the total number of pixels in a frame signal, a reference signal is outputted. Herein, the reference signal is the gray level value corresponding to the accumulated number. Further, the backlight adjustment evaluation unit outputs a backlight adjustment value according to a first reference value, a second reference value, an upper limit value and a lower limit value, besides the reference signal. Additionally, the backlight adjustment output value is used to adjust the brightness of the backlight module. Herein, when the reference signal is between the first reference value and the lower limit value, the first adjustment value is used as the backlight adjustment value. When, the reference signal is between the first reference value and the second reference value, the second adjustment value is used as the backlight adjustment value. Moreover, when the reference signal is between the second reference value and the upper limit value, the backlight adjustment value is represented by the following equation: [0000] Backdim= APGL/UP. [0011] Herein, Backdim represents the backlight adjustment value, APGL represents the reference signal, and UP represents the upper limit value. [0012] From another point of view, the present invention is directed to a method for processing a backlight that includes the following steps: a frame signal adjustment, an average pixel gray level analysis, and a backlight adjustment evaluation. Herein, the step for adjusting the frame data includes receiving a frame data, converting the pixels in the frame data and transmitting the converted pixels in the frame data to a liquid crystal display screen; the step for analyzing the average pixel gray level includes receiving a frame signal and outputting a reference signal; and the step for evaluating the backlight adjustment includes adjusting the brightness of the backlight source according to the reference signal. [0013] According to one embodiment, the said method for processing backlight further includes the following steps in the step for average pixel gray level analysis: a frame data distribution and a frame data determination. Herein, the step for distributing the frame data includes outputting a relational data of the gray level values versus the number of pixel distribution according to the pixel gray level distribution of the frame signal; and the step for evaluating the frame data includes receiving the relational data to perform evaluation analysis and outputting a reference signal to adjust the backlight. [0014] Since the backlight processing system of the present invention utilizes the pixels in a frame signal and the output of the backlight brightness to adjust the brightness of the backlight accordingly, as different frame data is inputted, the present invention can output display frame that is similar to the original frame which does not cause discomfort among the viewers and is energy-efficient. [0015] In order to make the aforementioned and other objects, features and advantages of the present invention more comprehensible, several embodiments accompanied with figures are described in detail below. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIG. 1 is a schematic view illustrating a conventional backlight processing system. [0017] FIG. 2 is a schematic view illustrating a backlight processing system according to one embodiment of the present invention. [0018] FIG. 3 is a schematic graph illustrating the relationship between the gray level map of the pixels inputted and outputted by the pixel conversion unit 210 of FIG. 2 . [0019] FIG. 4 illustrates a look-up table listing the gray level values of the pixels inputted and outputted by the pixel conversion unit 210 of FIG. 2 . [0020] FIG. 5( a ) is a schematic graph illustrating the relationship between the gray level values versus the number of pixel distribution. [0021] FIG. 5( b ) is a schematic graph illustrating a method for calculating the reference signal based on FIG. 5( a ). [0022] FIG. 6( a ) is a schematic view illustrating a method for processing a backlight according to one embodiment of the present invention. [0023] FIG. 6( b ) is a schematic view illustrating the step S 603 for processing a backlight according to one embodiment of the present invention. DESCRIPTION OF EMBODIMENTS [0024] To overcome the shortcomings encountered by the prior art and achieve a display quality that is the same as that of the original frame with backlight adjustment, the embodiments of the present invention adjust the contrast of the pixels in the original frame signals. Further, to reduce the power consumption of the backlight, the embodiments of the present invention adjust the brightness of the backlight according to the frame signal. [0025] Please refer to FIG. 2 . FIG. 2 is a schematic view illustrating a backlight processing system according to one embodiment of the present invention. A backlight processing system 200 includes a pixel conversion unit 210 , an average pixel gray level analysis unit 220 and a backlight adjustment evaluation unit 230 . Herein, the average pixel gray level analysis unit 220 includes a frame data distribution unit 221 and a frame data determination unit 222 . The aforementioned units are coupled according to the following description. The pixel conversion unit 210 is used to receive frame signals, adjust the gray level value according to the frame signal, and transmits the adjusted gray level value to a liquid crystal display screen 250 for displaying. The frame data distribution unit 221 is used to receive the frame signals and the output of the frame data distribution unit 221 is coupled to the frame data determination unit 222 . The output of the frame data determination unit 222 is coupled to the backlight adjustment evaluation unit 230 . The output of the backlight adjustment evaluation unit 230 is coupled to the backlight module 240 . Next, the embodiments of the present invention are described below. [0026] Please refer to FIG. 3 . FIG. 3 is a schematic graph illustrating the relationship between the gray level map of the pixels inputted and outputted by the pixel conversion unit 210 . Two lines: one solid line and one dotted line are shown in FIG. 3 . The solid line represents no variation in the gray level value, which means the gray level value of the inputted pixel equals to the gray level value of the outputted signal. On the other hand, the dotted line represents the conversion curve adopted by the embodiments of the present invention, which converts the RGB signals to R′G′B′ signals. Through the conversion curve, the gray level values of the pixels in the dark region 301 are reduced. Hence, the display is darker than the frame prior to adjustment. Conversely, the gray level values of the pixels in the bright region 302 are increased. As a result, when outputting a display, the frame is brighter than the frame prior to adjustment, increasing the contrast of the pixels. Nonetheless, since the pixels in the bright state are enhanced and the brightness of the backlight is reduced, the display quality of the liquid crystal display screen 250 retains the vividness of the original colors. [0027] There are various ways to represent the conversion curve shown in FIG. 3 . Three examples are listed below merely for the purpose of illustration. Hence, the present invention is not limited thereto. [0028] (1) f(x)=255, when x>a; and f(x)=[255/(a−x)]*x, when x≦a. [0030] (2) f(x)=0, when x≦a; f(x)=[255/(255−a)]*(x−a), when x≧a. [0032] (3) f(x)=0, when x≦a; and f(x)=255, when x≧b; and f(x)=[255/(b−a)]*(x−a), when a<x<b. [0035] X represents the gray level value of an inputted signal, f(x) represents the gray level value of an outputted signal, while a and b represent two reference gray level values. [0036] To fit the backlight processing system 200 of the present invention into a small and medium-sized electronic display device, the relationship between the gray level values of the signals inputted and outputted by the conversion curve shown in FIG. 3 may be integrated into the look-up table to simplify the design complexity. [0037] Please refer to FIG. 4 . FIG. 4 illustrates a look-up table listing the gray level values of the RGB pixels inputted and the R′G′B′ pixels outputted according to the embodiment of the present invention. Further, all the outputted gray level values can be calculated using interpolation, extrapolation or other algorithms. On the other hand, the conversion curve utilized by the conversion unit 210 of FIG. 2 is not limited to only one. More specifically, a different conversion curve can be utilized depending on whether the images are static or dynamic. [0038] The average pixel gray level analysis unit 220 may identify the frame data accordingly. Please refer to FIG. 5( a ) and FIG. 5( b ), which illustrate the relationship between the gray level values and the number of the pixel distribution of a complete frame. [0039] Each of the gray level values in FIG. 5( a ) and FIG. 5( b ) represents the maximum gray level value in respective pixel. For example, each pixel generally includes three RGB sub-pixels and the gray level values of a pixel (red, green, blue)=(80, 150, 180). In other words, the maximum gray level value for this particular pixel is 180. Additionally, the frame data distribution unit 221 selects all the maximum gray level value of all the pixels in a frame to obtain the number of pixel distribution of each gray level value. For example, as shown in FIG. 5( a ), the number of maximum gray level values for a frame signal, which is an image with a resolution of 320*240, is 320*240. [0040] According to FIG. 5( a ), the frame data determination unit 222 receives the relational data of the gray level values versus the number of pixel distribution from the frame data distribution unit 221 to perform analysis determination. As shown in FIG. 5( b ), the number of the pixel distribution is accumulated starting from the high gray level value to the low gray level value. When the accumulated number is greater than or equal to N % (where N is a positive value) of the total number of pixels in this frame, the corresponding gray level value is used as a reference signal APGL that is outputted. As shown in FIG. 5( b ), when N=25 and APGL is, for example, 180, the average pixel gray level analysis unit 220 provides a reference signal APGL to the backlight adjustment evaluation unit 230 according to the above-mentioned method. Then, the backlight adjustment evaluation unit 230 adjusts the brightness of the backlight according to the reference signal APGL. [0041] Further, according to the method of FIG. 5( b ), the frame data determination unit 222 may also accumulate backwards from the low gray level value to the high gray level value. If the accumulated number is greater than or equal to (100−N) % of the total number of pixels in this frame, the corresponding gray level value is used as a reference signal APGL, and the average pixel gray level analysis unit 220 outputs the reference signal APGL to the backlight adjustment evaluation unit 230 . [0042] The backlight adjustment evaluation unit 230 adjusts the brightness and generates a backlight adjustment value BackDim according to the reference signal APGL in order to control the brightness of the backlight module 240 . For example, when the backlight adjustment value BackDim is 1, the brightness of the backlight module 240 is the brightest. Alternatively, when the backlight adjustment value BackDim is 0, the brightness of the backlight module 240 is the dimmest. [0043] If the backlight adjustment evaluation unit 230 further uses parameters P, Q, Mb and Nb to output a backlight adjustment value BackDim, and 0<Q<P<255 and 0<Mb<Nb<1, the backlight adjustment value BackDim may be represented by the following equations: [0000] BackDim= APGL/ 255 (when P<APGL≦255); [0000] BackDim=Mb (when Q<APGL≦P); [0000] BackDim=Nb (when 0≦APGL≦Q); [0044] For example, Mb=0.7, Nb=0.9, Q=120, and P=180. Further, the lower limit value is 0 and the upper limit value is 255. When the value of the reference signal APGL is between 0 and 120, it means that the inputted frame signal 201 is somewhat dark. Hence, the backlight adjustment value BackDim is set to 0.9 to prevent overly lowering the brightness of the back light and making the image displayed to appear too dark. [0045] Similarly, when the value of the reference signal APGL is between 120 and 180, it means that the brightness of the backlight should be lowered. Hence, the backlight adjustment value BackDim is set to 0.7. Further, when the value of the reference signal APGL is between 180 and 255, the backlight adjustment value BackDim is APGL/255. [0046] It should be noted that, the parameters listed in the above-mentioned embodiment of the present invention are not limited thereto. They can be varied according to the backlight module 240 and the liquid crystal display screen 250 used to provide an optimal combination for the parameter setting. On the other hand, the parameter setting can vary according to different application environment or different image mode to select the appropriate algorithm and parameters for adjusting the brightness of the backlight module. [0047] Please refer to FIG. 6( a ). FIG. 6 ( a ) is a schematic view illustrating a method for processing a backlight according to one embodiment of the present invention. The method for processing the backlight includes the following steps. In step S 601 , a frame signal is received. In step S 602 , the frame signal is adjusted. Further, the conversion in step S 602 adjusts the pixel gray level value of the frame data, for example, according to a look-up table. When the pixels in the frame signal correspond to the pixels in the dark region 301 shown in FIG. 3 , the pixel gray level values are decreased. On the other hand, when the pixels in the frame signal correspond to the pixels in the bright region 302 shown in FIG. 3 , the pixel gray level values are increased. In step S 603 , a reference signal is outputted according to the pixel gray level distribution of the frame signal. In step S 604 , the backlight is adjusted according to the reference signal received. In step S 605 , the converted frame signal is displayed according to the brightness of the backlight source. [0048] Please refer to FIG. 6( b ), which illustrates the step S 603 in details. The aforementioned step S 603 further includes the following steps. As shown in step S 603 a , the maximum gray level value of each pixel in the frame signal is selected and a number of pixel distribution for each gray level value is calculated to obtain the relational data between the gray level value and the pixel distribution quantity (as shown in FIG. 5 a ). As shown in step S 603 b , the pixel distribution quantity of the relational data is accumulated (as shown in FIG. 5 b ). In step S 603 c , when the accumulated number is greater than or equal to a ratio of the total pixel number in the frame signal, the corresponding gray level value is used as a reference signal. [0049] According to the aforementioned embodiment, the backlight processing system of the present embodiment adjusts the pixel brightness, analyzes the frame contrast, and calculates and adjusts the brightness of the backlight according to the pixel gray level value of the inputted frame signal. Different inputted frame signal results in different backlight adjustment to ensure the frame signal is appropriately adjusted to achieve the desired display quality. Therefore, when a viewer is watching the images, the display quality can be maintained and the display contrast can be improved. Further, the present invention is energy-efficient. Additionally, the present embodiment can be implemented in a small and medium-sized electronic display device or embedded into an integrated circuit. [0050] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
A backlight processing system and a method thereof are provided. The gray level values of pixels in an input frame signal are adjusted and the brightness thereof is decreased correspondingly. During gray level value adjustment, the gray level values of the pixels in dark regions are reduced, and the gray level values of the pixels in bright regions are increased. During backlight adjustment, first, statistics information on distribution of the gray level value versus the number of pixels is obtained according to the gray level distribution of the original frame. The number of pixels at each gray level is accumulated. When the accumulation value reaches a certain value, a reference signal is obtained. The brightness of the backlight is then adjusted according to the reference signal.
6
BACKGROUND OF THE INVENTION The present invention relates to a method and apparatus for sensing an image using a solid state image sensor including a plurality of pixels, and more particularly, to a method and apparatus for correcting an image, suitable for use with an X-ray image sensing apparatus. With recent advances in the technology of image sensing apparatus, it has become possible to realize a large-sized image sensing apparatus using a great number of photoelectric conversion elements, and capable of sensing a high-quality large-area image with a high resolution. Such recent advances in the technology also make it possible to acquire radiation image information such as an X-ray image for use in medical examination directly through a high-resolution and large-sized image sensing apparatus instead of using a conventional silver halide film. Such radiation image information may be converted into digital electronic information for further various processing. FIG. 1 is a simplified block diagram illustrating an example of the basic structure of an X-ray image sensing apparatus using a solid state image sensor. In FIG. 1, reference numeral 1 denotes an X-ray generator, 2 denotes a fluorescent plate for converting an X-ray to visible light, 3 denotes an optical system, and 4 denotes a solid state image sensor. The X-ray generated by the X-ray generator 1 passes through an object 15 to be examined, if there is such an object, and incident on the fluorescent plate 2 . If there is no object, the X-ray is directly incident on the fluorescent plate 2 . The fluorescent plate 2 serves as a wavelength converter for converting the X-ray to light with a wavelength sensible by the solid state image sensor 4 . The fluorescent light generated by the fluorescent plate 2 is focused via the optical system 3 onto a two-dimensional solid state image sensor 4 which senses image information using a CCD or a similar device comprising a plurality of photoelectric conversion elements. Reference numeral 8 denotes a clock generator for generating a basic clock signal by which the two-dimensional solid state image sensor 4 and other circuit devices are driven. Reference numeral 9 denotes a control signal generator for generating various control signals on the basis of the clock signal. Reference numeral 5 denotes an analog-to-digital (A/D) converter for converting the signal output by the solid state image sensor 4 to a digital signal, which is supplied over a signal line 12 . Reference numeral 10 denotes a device including a memory (dark output data memory) for storing the data representing the level (dark level) of the signal output by the solid state image sensor 4 when there is no input signal. In normal operation, a subtractor 6 subtracts the dark level from the signal output from the solid state image sensor 4 , and outputs the resultant signal over a signal line 13 . Reference numeral 11 denotes a device including a memory (shading memory) for storing image data obtained when there is no object such as a human body 15 to be examined. This data represents the shading distribution including the variation in the conversion efficiency from one photoelectric conversion element to another of the solid state image sensor 4 . A divider 7 divides actual image data taken in a normal mode by the data stored in the memory 11 so as to make a correction in terms of the shading effect including the variation in the conversion efficiency of the photoelectric conversion elements. The corrected data is output over a signal line 14 . When an actual X-ray image is taken, the solid state image sensor is first driven under the condition that no X-ray is generated, and the obtained dark output signal is stored in the dark output data memory 10 . Then an X-ray is generated under the condition that there is no object such as a human body to be examined, and an image signal is taken via the solid state image sensor 4 . The image data is reduced by an amount corresponding to the dark output data, and the result, which includes the shading effect and the variation in the conversion efficiency of the photoelectric conversion elements, is stored in the shading memory 11 . If it is assumed that an X-ray is incident on the fluorescent plate with uniform energy across the fluorescent plate, and if the X-ray is converted by the fluorescent plate to visible light with uniform conversion efficiency, then it is expected that the solid state image sensor 4 will provide an equal output signal for all pixels. Under the above conditions, if there is a variation in the output signal when there is no object to be examined, the variation in the output signal can be considered to arise from the variation in the conversion efficiency of the photoelectric conversion elements. If this output signal is reduced by an amount corresponding to the output signal which is output from each photoelectric conversion element when there is no incident X-ray, then the result represents the net output of each photoelectric conversion element for the maximum incident energy of the X-ray. From this net output signal, it is possible to obtain shading data, although the data usually includes the variation in the conversion efficiency of the photoelectric conversion elements. In the next step to obtain image information, an image is taken under the condition that there is an object such as a human body to be examined. The subtractor 6 removes the dark output from the image signal, and furthermore the divider 7 corrects the image signal in terms of the shading effect and the variation in the conversion efficiency of the photoelectric conversion elements. The corrected signal is output over the signal line 14 . In the conventional technique described above, it is required to generate an X-ray to obtain correction information about the shading effect and the variation in the conversion efficiency of the photoelectric conversion elements. If the X-ray is generated to obtain correction information each time an image is taken, the life of an X-ray tube is wasted by the nonessential operation. Furthermore, such an operation for obtaining correction information whenever an image is taken results in a great increase in the operation time. Thus it is desirable that the operation of obtaining correction information about the shading effect and the variation in the sensitivity of the photoelectric conversion elements be performed at rather long time intervals, such as once every day. In general, however, the location of the X-ray generator relative to the location of the image sensing apparatus is moved from time to time during a day for convenience of examinations. This can cause a substantial change in the shading condition. FIG. 2 is an one-dimensional illustration of a change in the shading shape due to a change in the position of the X-ray generator. In FIG. 2, the horizontal axis represents the pixel positions, and the vertical axis represents the output of the photoelectric conversion elements. Data 31 represents the initial shading shape, and data 32 represents the shading shape obtained after the X-ray generator is moved from the initial location. As can be seen, variations occur over the entire shading shape. In practice, the distribution of X-ray radiation intensity is not uniform but rather gradually varies such that the intensity becomes maximum near the central position, as represented by curves 31 ′ and 32 ′. Furthermore, small variations in the photoelectric conversion efficiency from pixel to pixel are superimposed on the X-ray radiation distribution 31 ′ or 32 ′, and thus the overall distribution can be represented by an upward convex curve including small fluctuations as is the case in data 31 and 32 shown in FIG. 2 . That is, data 31 and 32 represent the overall shading characteristic at respective locations of the X-ray generator. In FIG. 2, line 33 represents the output obtained by performing the correction process described above. Although small variations due to the variations in the conversion efficiency from one photoelectric conversion element to another are well corrected on the basis of the correction data obtained for the respective locations of the photoelectric conversion elements, the difference between data 31 and 32 due to the shift of the X-ray intensity distribution results in an undesirable slope in the overall characteristic. This can be understood by the fact that when there are two functions both having a similar shape which is smooth and upward convex, if the center of one function is shifted from the center of the other, and if one function is divided by the other, then the relative value inverts at a point where the two functions intersect each other. As described above, the X-ray intensity distribution produces an undesirable effect in the corrected data. This effect can result in an artificial and unnatural modification in the image data. Because the image data taken through the solid state image sensor is used in all the following processes, it is desirable that the image data include no undesirable modification. SUMMARY OF THE INVENTION It is an object of the present invention to provide an image sensing apparatus using photoelectric conversion elements and having the capability of correcting an image signal containing a distribution of radiation from a radiation source and variation distribution of the conversion efficiency of the photoelectric conversion elements in such a manner that only the variation distribution of the conversion efficiency is corrected thereby preventing an artifact from occurring in the corrected image data. It is another object of the present invention to provide an image sensing apparatus provided with a solid state image sensor having a plurality of pixels, wherein the image sensing apparatus has the capability of separating the component of the incident ray intensity distribution from the initial shading data of the apparatus which has been set to arbitrary initial conditions thereby extracting the fluorescent characteristic of a fluorescent plate and the pixel-to-pixel variations in the conversion efficiency of a solid state image sensor. It is still another object of the present invention to provide a method and apparatus for sensing an image, in which a sensed image is corrected in such a manner that only the variations in the fluorescent characteristic of the fluorescent plate and the photoelectric conversion efficiency are corrected on the basis of the data representing the pixel-to-pixel variation distribution of the conversion efficiency without making no correction in terms of the radiation intensity distribution, thereby preventing an artifact from occurring in the corrected image data. It is still another object of the present invention to provide a method and apparatus for sensing an image in which when an image such as an X-ray image is taken through a solid state image sensor including a plurality of photoelectric conversion elements, even if the X-ray intensity distribution varies due to movement in position of an X-ray generator or the solid state image sensor, no artifact such as unnaturally sloped shading occurs because correction is performed only in the terms of the variations in the conversion efficiency of the photoelectric conversion elements. According to an aspect of the present invention, there is provided a method of sensing an image using an image sensing apparatus provided with a solid state image sensor having a plurality of pixels, the method comprising the steps of: separating the component of an electromagnetic wave radiation intensity distribution from distribution data obtained when an electromagnetic wave is incident on the solid state image sensor thereby obtaining a pixel-to-pixel variation distribution of the conversion efficiency of the solid state image sensor; and correcting image data obtained in an image sensing operation, on the basis of the pixel-to-pixel variation distribution of the conversion efficiency. According to another aspect of the present invention, there is provided an image sensing apparatus provided with a solid state image sensor having a plurality of pixels, the apparatus comprising: means for separating the component of an electromagnetic wave radiation intensity distribution from distribution data obtained when an electromagnetic wave is incident on the solid state image sensor thereby obtaining a pixel-to-pixel variation distribution of the conversion efficiency of the solid state image sensor; means for storing the variation distribution of the conversion efficiency; and means for correcting an image obtained in an image sensing operation, on the basis of the variation distribution of the conversion efficiency. In the above method and apparatus, the electromagnetic wave may be an X-ray. In the above method, the step of separating the radiation intensity distribution may be accomplished by determining a function including separate terms approximately representing the radiation distribution and the variation distribution of the conversion efficiency, respectively, thereby separating the radiation distribution. Alternatively, the step of separating the radiation intensity distribution may also be accomplished by passing the distribution data through a two-dimensional low-pass filter thereby achieving the separation. In the above method, the step of separating the radiation intensity distribution may also be accomplished by: measuring the distribution data for a plurality of shifted positions of the solid state image sensor; extracting, from the distribution data obtained for the plurality of shifted positions, a component which remains unchanged regardless of the shift in the position of the solid state image sensor; and employing the obtained component as the variation distribution of the conversion efficiency. The determination of the function may include the step of performing non-linear regression analysis or other regression analysis. In the above apparatus, the means for separating the radiation intensity distribution may include means for determining a function including separate terms approximately representing the radiation distribution and the variation distribution of the conversion efficiency, respectively, thereby separating the radiation distribution. Alternatively, the means for separating the radiation intensity distribution may include a two-dimensional low-pass filter whereby the separation is accomplished by passing the shading distribution data through the two-dimensional low-pass filter. Still alternatively, the means for separating the radiation intensity distribution may include means for measuring the distribution data for a plurality of shifted positions of the solid state image sensor, extracting, from the distribution data obtained for the plurality of shifted positions, a component which remains unchanged regardless of the shift in the position of the solid state image sensor, and employing the obtained component as the variation distribution of the conversion efficiency. Preferably, the apparatus includes a wavelength converting member for converting the wavelength of the electromagnetic wave, wherein the wavelength converting member is disposed at the side of the solid state image sensor on which the electromagnetic wavelength is incident. With the image sensing apparatus provided with a solid state image sensor having a plurality of pixels, according to the present invention, it is possible to separate the component of the incident ray intensity distribution from the initial shading data of the apparatus which has been set to arbitrary initial conditions thereby extracting the fluorescent characteristic of a fluorescent plate and the pixel-to-pixel variations in the conversion efficiency of a solid state image sensor. Thus, when a sensed image is corrected, it is possible to correct only the variations in the photoelectric conversion efficiency on the basis of the data representing the pixel-to-pixel variation distribution of the conversion efficiency without making no correction in terms of the radiation intensity distribution, thereby preventing an artifact from occurring in the corrected image data. In the present invention, it is possible to separate the intensity distribution of radiation such as an X-ray and the pixel-to-pixel variation in the conversion efficiency of the photoelectric conversion elements of the solid state image sensor from a general shading characteristic, and thus it is possible to correct only the variation distribution of the photoelectric conversion elements without correcting the radiation intensity distribution thereby suppressing an artifact such as unnaturally sloped shading due to movement in position of the X-ray tube. In the specific example shown in FIG. 2, 31 ′ and 32 ′ represent the X-ray intensity distributions contained in data 31 and 32 , respectively. In each case, small fluctuations (variations in the conversion efficiency of photoelectric conversion elements) are removed by the correction according to the present invention, and only gradually-varying distribution (radiation intensity distribution) remains as represented by 31 ′ and 32 ′. Gradually-varying radiation intensity distribution is due to movement in position of the X-ray tube and exists also in images obtained by the conventional technique using a silver halide film. The removal of such radiation intensity is not important. However, it is more important to prevent an artifact such as that denoted by reference numeral 33 from occurring in the corrected image signal. In view of the above, the present invention provides a method and apparatus in which no such an artifact occurs. BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1 (prior art), 3 , and 6 are simplified block diagrams illustrating examples of image sensing apparatus; FIG. 2 is a graph illustrating an artifact which occurs when the shading characteristic varies; FIG. 4 is a simplified block diagram illustrating a preferred embodiment of a correction unit A; and FIG. 5 is a simplified block diagram illustrating another preferred embodiment of the correction unit A. DESCRIPTION OF THE PREFERRED EMBODIMENTS First, an example of a method of the calculation performed by the above-described means according to the present invention will be described below. When an X-ray is emitted from a point source, the X-ray radiation intensity varies in inverse proportion to the square of the distance. Thus, the distribution of the X-ray radiation can be represented by the following simple equation: H ( x, y )= K /{( x−x o ) 2 +( y−y 0 ) 2 +L 2 }  (1) where x and y are coordinates taken across the image sensing apparatus, K is the radiation intensity at the point source, L is the distance to the image sensing apparatus, and x 0 and y 0 are the coordinates of the point source measured from the imaging plane. In practice, any X-ray tube cannot be regarded as a point source, and therefore the actual distribution of the X-ray radiation intensity is more complicated. However, the distribution is still smooth in variation. When there is no object such as a human body to be examined, if the X-ray radiation is detected by the solid state image sensor, then the output of the image sensing apparatus will be given by: P ( x i , y j )= H ( x i , y j )× G ( x i , y j ) (1 ≦i≦n, 1 ≦j≦m )  (2) where H(x i , y i ) is the X-ray radiation intensity and the G(x i , y i ) is the sensitivity of the respective photoelectric conversion elements of the solid state image sensor represented as a function of the location (x, y) of the photoelectric conversion elements, n is the number of solid state image sensor elements counted in the x direction, and m is that counted in the y direction. Taking the logarithm of equation (2) yields: log( P ( x i , y j ))=log( H ( x i , y j ))+log( G ( x i , y j ))  (3) The output P(x i , y i ) of the image sensing apparatus represented by equation (3) in the logarithmic form includes a high-frequency component corresponding to small variations arising from the variations in the sensitivity log(G(x i , y j )) of the photoelectric conversion elements, and also includes a gradual variation corresponding to the X-ray intensity distribution log(H(x i , y j )). The term log(G(x i , y j )) representing the variation in the sensitivity of the photoelectric conversion elements and the term log(H(x i , y j )) representing the variation in the X-ray radiation intensity can be isolated form each other in many ways. For example, log(G(x i , y j )) is assumed to be substantially independent of the X-ray radiation intensity distribution, and H(x i , y j ) is assumed to be given by equation (1), then parameters K, x 0 , y 0 , and L can be determined by means of non-linear regression analysis so that the following value is minimized: Σ (i, j) (log (P(x i , y i ))−log(H (x i , y i ))) 2 This calculation is not necessarily required to be performed for all points, but may be performed for representative points (for example for every few points). If it is difficult to apply non-linear regression analysis, regression analysis may be performed, for example, on the assumption that H(x, y) is a polynomial plane in which x and y are independent of each other. More specifically, the following relation (4) is assumed and parameters a k , b k , and c (1≦k≦P) may be determined from linear regression associated with log(P(x i , y i )): log( H ( x i , y i ))=Σ a k x k +Σb k y k +c   (4) where E represents the sum taken from k=0 to p, and p is the degree of the polynomial. When it is difficult to determine the function, the data of log(P(x i , y i )) may be passed through a two-dimensional low-pass filter so as to remove spikes, and resultant data log(H(x i , y i )) including no abrupt changes may be subtracted from log(P(x i , y i )) to obtain log(G(x i , y i )) Alternatively, log(H(x i , y i )) may also be processed as follows. the location of the X-ray tube or the solid state image sensor is moved by an amount corresponding to one pixel in a horizontal or vertical direction, and two different patterns associated with the output signal are taken. If the component included in common in both patterns is extracted, then the result represents the variation in the sensitivity of the photoelectric conversion elements of the solid state image sensor. That is, if the pattern in equation (3) is shifted in the x direction by one pixel, then the original pattern P(x i , y j ) and the shifted pattern P′(x i , y j ) are given as follows: log( P ( x i , y j ))=log( H ( x i, y j ))+log( G ( x i , y j ))  (5) log( P ′( x 1 , y j ))=log( H ( x i+1 , y j ))+log( G ( x i , y j )))  (6) If equation (6) is shifted in the opposite direction, then log( P ′( x i , y j ))=log( H ( x i , y j ))+log( G ( x i−1 ,y j ))  (7) From equations (5) and (7), the following equation can be obtained: log( G ( x i , y j ))=log( P ( x i , y j ))·log( P ′( x i−1 , y j ))  +log( G ( x i−1 , y j )) (2≦i≦n, 1≦j≦m, log(G(x i , y j ))=K j )  (8) where K j is a constant given for each row. The overall gain can vary from row to row depending on the value of K j given for the respective rows. This variation in the gain from row to row may be suppressed to a lower level by determining the values for K j by means of for example linear regression analysis using log(P(x i , y j )) (1≦j≦m). Furthermore, a plurality of sets of data in terms of the shading characteristic which are shifted from each other may be obtained using a similar algorithm thereby determining log(G(x i , y j )) which is equally contained in all sets of data. Now, specific embodiments of the invention will be described below. Although in any embodiment described below, the invention is applied to an X-ray image sensing apparatus, the invention is also applicable to other types of image sens ing apparatus. Embodiment 1 FIG. 3 is a schematic diagram illustrating the construction of an X-ray image sensing apparatus according to the present invention. The construction is similar to that shown in FIG. 1 except that the X-ray image sensing apparatus shown in FIG. 3 includes an additional variation data memory 16 for storing extracted data representing variations G(x, y) in photoelectric conversion efficiency so that in an image sensing operation the variations in the conversion efficiency included in the shading distribution data stored in the memory 11 are corrected by means of dividing operation performed by a divider 7 using the data stored in the memory 16 . Other similar parts to those in FIG. 1 will not be described in further detail. FIG. 4 is a block diagram illustrating the details of the correction unit A surrounded by a broken line in FIG. 3 . In FIG. 4, data whose dark component has been removed is applied to a correction unit A via a signal line 13 . Reference numeral 21 denotes a logarithmic converter which usually operates using a reference table. Reference numeral 22 denotes a memory for temporarily storing an image obtained under the condition that there is no object such as a human body to be examined. Reference numeral 23 denotes a device for detecting the X-ray radiation intensity distribution which usually has a gradually-varying shape. A subtractor 24 determines the variation in the conversion efficiency of the photoelectric conversion elements, which corresponds to the difference from the original data. The resultant data is stored in a memory 28 . When the image of an object such as a human body to be examined is actually sensed, the image signal is supplied to the logarithmic converter (reference table) 21 via the signal line 13 . The logarithmic converter 21 converts the received data into the form of the sum of the X-ray intensity distribution and the variation in the conversion efficiency as represented in equation (3). A subtractor 29 subtracts the logarithm of the conversion efficiency stored in the memory 28 from the image signal so as to correct the conversion efficiency thereof while no correction as to the X-ray intensity distribution is made. The corrected data in the form of logarithm is output over a signal line 27 . To convert the logarithmic data into the original linear form, there is provided an inverse logarithmic converter 21 ′ which operates for example using a reference table. Thus, an image signal which has been corrected in terms of only the variations in the conversion efficiency is output over a signal line 14 . The device 23 for detecting the X-ray radiation intensity distribution can be easily realized using for example a microprocessor programmed to perform function approximation according to any of the methods described above. It is desirable that the approximation method be properly selected so that the overall characteristics of the system (including the X-ray generator) are optimized. Alternatively, the device 23 may also be realized by means of hardware such as a two-dimensional low-pass filter. Note that the data stored in the memory 23 represents not only the variations in the conversion efficiency of the respective photoelectric conversion elements of the solid state sensor but the data represents the overall variations including the variations in the characteristics of other devices such as a fluorescent plate and a plurality of amplifiers disposed at the output stage of the photoelectric conversion elements. Embodiment 2 FIG. 5 is a block diagram illustrating a second embodiment of the invention, wherein, of various components, only a correction unit A surrounded by a broken line is shown in the figure. The differences from FIG. 4 will be described below. Reference numeral 41 denotes a memory for storing first shading distribution data, and reference numeral 42 denotes a memory for storing second shading distribution data. The first shading distribution data corresponds to log(P(x i , y j )) described above in equation (5). The second shading distribution data corresponds to log(P′(x i , y j )) described above in equation (6). A computing unit 43 determines the variations in the conversion efficiency from element to element by performing the calculation described above in equation (8) using the shading distribution data read from the memories 42 and 42 . The resultant data is stored in memory 28 . First, image data is obtained when there is no object such as a human body to be examined, and the obtained image data is converted by the converter 21 to data in the logarithm form. The result is stored via a signal line 45 in the memory 41 serving to store first shading distribution data. Then, the solid state image sensing apparatus is moved by an amount corresponding to one pixel in the x direction, and an image is sensed also under the condition that there is no object such as a human body to be examined. The image data obtained is stored via a signal line 46 in the memory 42 serving to store second shading distribution data. After that, the computing unit 43 sequentially reads data from the memories 41 and 42 and the performs the calculation represented by equation (8). The resultant data representing the variations in the conversion efficiency from one element to another is stored in the memory 28 . In this embodiment, as in the previous embodiment, the above calculations may be performed by a programmed microcomputer consisting of a CPU, a ROM for storing a program, and other devices. The operation of sensing image data of an object such as a human body to be examined may be performed in a similar manner to the first embodiment described above. The present embodiment may be modified such that a plurality of sets of shading data which are shifted in position from each other are measured and the variations in the conversion efficiency are determined by extracting such components which are equally contained in all data sets. The initial values for K j in equation (8) may be determined, as described above, on the basis of an expected distribution in the y direction. In the embodiments described above, the apparatus is assumed to have the structure shown in FIG. 3 . However, the present invention may also be applied to any system including a solid state image sensor having variations in the conversion efficiency. For example, the invention may be applied to such a system shown in FIG. 6 which includes no optical system such as the optical system 3 shown in FIG. 3 but which includes a large-sized solid state image sensor disposed in direct contact with a fluorescent plate. Furthermore, the optical system 3 shown in FIG. 3 is not limited to a lens but it may also be a light guiding element (such as an optical fiber). In the above embodiments, the variations in the conversion efficiency of the photoelectric conversion. elements are extracted on the assumption that the X-ray intensity has a gradually-varying distribution. Instead, the variation in the conversion efficiency may also be extracted from image data obtained by taking an image of an object having a known X-ray transmission characteristic. In particular, this method is useful when it is coupled with the technique disclosed in the second embodiment, because if the X-ray intensity distribution is nearly flat, it is difficult to extract the variations in the conversion efficiency using the technique according to the second embodiment. As can be understood from the above description, the present invention has various advantages. That is, the invention provides a technique of separating the component of the incident ray intensity distribution from the initial shading data of the apparatus which has been set to arbitrary initial conditions thereby extracting the pixel-to-pixel variations in the conversion efficiency of a solid state image sensor. A sensed image is corrected in such a manner that only the variations in the photoelectric conversion efficiency are corrected on the basis of the above-described extracted data without making any correction in terms of the X-ray intensity distribution. This prevents an artifact from occurring in the corrected image data. Furthermore, in the present invention, when an image such as an X-ray image is taken through a solid state image sensing apparatus including a plurality of photoelectric conversion elements, even if the X-ray intensity distribution varies due to movement in position of the X-ray generator or the solid state image sensor, no artifact such as unnaturally sloped shading occurs because correction is performed only in the terms of the variations in the conversion efficiency of the photoelectric conversion elements.
An image sensing apparatus using a solid state image sensor has the capability of correcting an image signal including an intensity variation due to the variation in the intensity of a radiation from a radiation source and also including an intensity variation due to the variation in conversion efficiency of photoelectric conversion elements in such a manner that only the variation in conversion efficiency is corrected thereby suppressing an artifact which would occur in conventional apparatus. A shading distribution (distribution data) is measured by sensing an X-ray through no object to be examined or through an object whose transmittance to the X-ray is well known. The component of the X-ray intensity distribution is separated from the obtained shading distribution data thereby obtaining a pixel-to-pixel variation in conversion efficiency of the solid state image sensor. The image signal is corrected based on the pixel-to-pixel variation in conversion efficiency obtained.
7
BACKGROUND OF THE INVENTION 1. Field of Use This invention relates generally to self-propelled steerable apparatus for removing material from the surface of a confined area and for pumping it to another location for disposition. In particular, it relates to such apparatus which is especially well-adapted, for example, to clean sludge from the bottom of large liquid storage tanks, such as chemical or oil tanks, but could have other applications, such as cleaning any container or confined area having a solid rigid bottom or floor made of metal, concrete, plastic or the like. 2. Description of the Prior Art My U.S. Pat. No. 5,093,949, issued Mar. 10, 1992, discloses self-propelled steerable sludge cleaning apparatus for cleaning sludge from the bottom of large liquid storage tanks. That apparatus, which had motor-driven crawler tracks and was able to move across the bottom of the tank along desired paths in accordance with a computer program, employed a horizontally disposed rotatable motor-driven auger for delivering sludge through a horizontal center-feed pipe to a motor-driven pump for subsequent disposal elsewhere. The auger had oppositely-wound helical auger flights at opposite ends and fed the sludge to the center-feed pipe located near the center of the auger. The motor-driven crawler tracks and associated components were relatively large and heavy and required a separate drive motor and associated controls to effect propulsion and steering. My U.S. Pat. No. 4,574,501, issued Mar. 11, 1986, discloses underwater dredging apparatus of the crater sink type for dredging fluid material such as sand from an underwater area. That apparatus, which was stationary and positioned at a fixed location beneath a body of water by means of a crane, employed a horizontally disposed rotatable motor-driven auger for delivering sand through a vertical pipe to a motor-driven pump for subsequent disposal elsewhere. The auger had oppositely-wound helical auger flights at opposite ends and the vertical pipe was located near the center of the auger. That apparatus was incapable of self-propulsion to other locations. Each of my prior art machines is well-adapted for its intended purpose but it is desirable to provide an improved apparatus for removing material from a confined area and which employs a horizontally-disposed motor-driven auger for supplying material to a motor-driven pump, such improved apparatus being self-propelled, steerable, more compact and less complex than prior art apparatus. Heretofore, it was common practice in tank cleaning operations to decant the liquid in the tank into another container, to de-gas the tank to remove noxious vapors, and admit men into the tank through an access opening, such as a man-way in the side of the tank, with buckets and shovels to remove the sludge or sediment accumulated at the bottom of the tank. However, safety requirements aimed at limiting the exposure of working personnel to noxious vapors and liquids contained the tank are becoming more restrictive and expensive as time goes on. Therefore, it is desirable to eliminate the need for personnel to enter the tank and to limit the time clean-up personnel are exposed to the atmosphere within the tank while installing or removing automated cleaning equipment in the tank. Furthermore, the need to decant the tank to be cleaned, as mentioned above, means that the tank must be taken out of service and this has very expensive consequences. For example, the liquid must be placed in another compatible container and tanks are very expensive. Furthermore, the tank to be cleaned is taken out of service and this is another expense. Also, an out-of-service tank could slow down or even stop an industrial process, resulting in a very expensive production cut-back. SUMMARY OF THE PRESENT INVENTION The present invention provides improved self-propelled, steerable apparatus for removing material from the surface of a confined area for disposition elsewhere. The material may, for example, take the form of sludge which has settled at the bottom of a liquid storage tank such as a chemical or oil tank or the like. The improved apparatus generally comprises a support frame or platform having top and rear walls; a horizontally disposed motor-driven rotatable auger beneath the platform; a motor-driven dredge or sludge pump mounted on the platform; and remotely operable steering means mounted on the platform. The auger provides two functions. First, the auger cooperates with the walls of the support frame to define a passage in which sludge material can collect and be acted upon and moved by the rotating auger to the sludge pump. Second, the auger engages the floor of the confined area and its rotation propels the apparatus across the floor. Forward motion of the apparatus across the floor is restrained by a back-haul cable or tether which is periodically paid out by a remotely controllable winch in small increments to allow the apparatus to move forward a short distance, whereupon the back-haul cable prevents further forward motion while the auger continues to rotate and deliver sludge material to the sludge pump. Means are provided to supply by-pass liquid from a suitable source (and compatible with the sludge) to the aforesaid space to make the sludge more soluble and easier to handle by the auger and pump. The dredge pump has a sludge inlet port communicating with the aforesaid space. The dredge pump also has a sludge discharge port connectable to a sludge discharge hose for disposing of the sludge exteriorly of the tank. The remotely operable steering means comprises an elongated arcuately movable steering arm which extends rearwardly from the platform. One end of the steering arm is pivotally connected to the platform and a rotatable tail wheel is mounted at its other end. An extendible/retractable hydraulic ram is connected between the platform and the steering arm and is operable to pivotally move the steering arm and the tail wheel thereon to effect steering of the apparatus. The afore-mentioned back-haul cable or tether is connected to the tail end of the steering arm. During operation the apparatus is then lowered into a layer of sludge on the floor of a tank to be cleaned so that the edge of the auger and the tail wheel rest on the tank floor. Assuming that there is a small amount of slack in the back-haul cable, rotation of the auger then causes the apparatus to move across the tank floor in a direction transverse to the auger axis until it is stopped by the back-haul cable. With the apparatus at rest, sludge already in the aforesaid space between the platform and auger (and mixed with by-pass fluid to make it more fluid) is moved by the still-rotating auger toward the discharge end of the auger into the dredge pump and from thence through the discharge hose for final disposition. If the sludge is especially fluid, it can continue to flow into the space even though the apparatus is stationary. The back-haul cable, which is attached to the selectively controllable winch, controls the distance the apparatus can move across the tank floor. Paying out or reeling in the back-haul cable can control the position of the apparatus on the tank floor. Counter-torque movement of the platform in response to rotor torque forces the tail wheel firmly against the tank floor to achieve effective steering. The auger can take various forms and the form chosen determines the behavior of the apparatus. If the auger has a single helical spiral, it rotates to feed sludge to an end outlet located at one end of the platform and connected to the sludge pump. In such an arrangement auger action tends to cause the apparatus to move or drift slightly in the axial direction of the auger but such drift is overcome by positioning the tail wheel so that it is at the "dynamic center" of the apparatus. The steering arm can be positioned either by pre-shaping the steering arm or by operating the steering cylinder to overcome the tendency of the apparatus to drift. Furthermore, the steering means enables the apparatus to be steered along arcuate paths across the tank floor. If the auger has oppositely formed helical flights at opposite ends, the auger can feed sludge to a center outlet on the platform and the apparatus has no tendency to drift. Apparatus in accordance with the present invention offers several advantages over the prior art. For example, it is constructed of a minimum number of components. The components of the apparatus are easily assembled and disassembled and can be assembled inside a tank which has a "man way" or access opening smaller than the fully assembled apparatus. It can be quickly assembled and disassembled, thereby reducing the time operating personnel are exposed to toxic or noxious vapors near the man-way. It does not require the tank to be taken completely out of service because it can be lowered into a tank which contains liquid having a layer of sludge at the bottom of the tank. This can result in monetary savings which easily exceed many times over the direct cost of cleaning the tank. It can use the liquid in the tank as by-pass fluid to fluidize the sludge to be removed or can be supplied with by-pass liquid from an external source, if necessary. It relies on the auger to process material, as well as to furnish motive power for the apparatus. It is easily steered along desired paths by remote controls which are manually operable or programmable. Other objects and advantages of the invention will hereinafter appear. DRAWINGS FIG. 1 is schematic view of a tank having apparatus in accordance with the invention disposed therein and associated components disposed thereon; FIGS. 2 and 3 are perspective views of apparatus in accordance with the invention taken from the front side and left end thereof and from the rear side and right end thereof, respectively; FIGS. 2A and 3A are perspective views of the platform of apparatus in accordance with the invention taken from the front side and left end thereof and from the rear side and right end thereof, respectively; FIG. 2B is a bottom plan view of the platform of the apparatus showing details thereof and the auger; FIG. 4 is a top plan view of the apparatus; FIG. 5 is an elevation view of the front side of the apparatus; FIG. 6 is an elevation view of the rear side of the apparatus; FIG. 7 is an elevation view of the left end of the apparatus; FIG. 8 is an elevation view of the right end of the apparatus; FIG. 9 is a cross-section view taken on line 9--9 of FIG. 5; FIG. 10 is an enlarged top plan view of the apparatus with the pump deleted and showing the steering arm, the slide bearing and the steering ram of the apparatus; FIG. 11 is a perspective view of the steering arm and the tail wheel; FIGS. 12 and 12A are schematic views of an elementary control system for the apparatus; FIG. 13 is a schematic top plan view of another embodiment of the invention; and FIG. 14 is a schematic view showing a typical path of movement of apparatus in accordance with the invention. DESCRIPTION OF PREFERRED EMBODIMENTS Referring to FIGS. 1 and 2, the numeral 10 designates a first preferred embodiment of improved self-propelled steerable apparatus in accordance with the present invention for removing material 12 from a confined area, such as the bottom surface or floor 13 of a storage tank 14, for disposition elsewhere. The material 12 may, for example, take the form of sludge which has settled at the bottom of a body of liquid L, such as a liquid chemical or oil, in a liquid storage tank such as a chemical or oil tank or the like. Tank 14, which is not shown in scale, could be on the order of 20 to 60 feet high and 25 to 100 feet in diameter and could be filled to a level about five feet below a man-way 15, for example. Sludge layer 12 is assumed, for purposes of illustration, to be on the order of 10 to 15 inches deep but could be deeper, as hereinafter explained. For example, 10 to 15 inches is typical in petroleum tanks but in chemical processing tanks the depth can reach more than 20 feet. Tank 14 is provided on top with an access opening or man-way 15 (typically 18 to 36 inches in diameter) through which apparatus 10 is lowered and recovered by means of a hoist cable 11 connected to a hoisting winch 17 temporarily mounted on the roof 19 of the tank. Hoist cable 11 is reeved around a pulley 23 supported on an A-frame mast 25 which is releasably bolted to the man-way flange. Preferably, mast 25 is provided with a crane (not shown) for raising the apparatus 10 and related equipment to the top 19 of tank 14. If man-way 15 is too small to accommodate fully-assembled apparatus 10, portions of the apparatus may be suspended on hoist cable 11 just below the man-way while being assembled/disassembled for lowering/raising relative to tank floor 13. As hereinafter explained, apparatus 10 requires a back-haul cable or tether 96 to be attached thereto and this cable is connected to a motor-driven back-haul winch 98 which is also temporarily mounted on the top 19 of tank 14. Back-haul cable 96 is reeved around a rotatable back-haul cable pulley 97 which is swivelably mounted on a gin-pole mast 100 about 5 feet above floor 13 of tank 14. Mast 100 is rigidly secured to tank floor 13 and tank top 19. This arrangement enables apparatus 10 to move about floor 13 while keeping cable 96 taught. Referring now to FIGS. 2 through 9, the improved apparatus generally comprises a support frame or platform 16 having top and rear walls; a horizontally disposed motor-driven reversely rotatable auger 18 beneath the platform; a motor-driven dredge or sludge pump 20 mounted on the platform; and remotely operable steering means 22 mounted on the platform. Platform 16 comprises a top wall or upper deck 24 beneath which auger 18 is rotatably mounted, being supported at one end by a bearing 26 mounted at one end of the platform on a bearing support bracket 39A. Auger 18 is supported at its other end by a reversible hydraulic motor 28 which is mounted on plate 35 at the other end of the platform and connected to said other end of the auger. Platform 16, which in an actual test embodiment was a steel plate about 40" long, 12" wide and 1/4" thick, has a downwardly extending front lip 30 to which a lip extension 32 (portion shown in FIG. 5) is attached. Lip extension 32 serves several purposes, namely: to extend below lip 30 to control the amount of material entering auger 18; to act as a dozer blade to guide material 12 to the auger; to limit penetration of apparatus 10 into the material; and, if extended upwardly above deck 24, as shown in FIG. 9, to as much as 2 or 3 feet, operates to prevent material from flowing over the top of the apparatus. Referring to FIG. 9 and 10, a rear sealing plate or wall 34 extends downwardly from beneath the rear of deck 24 and cooperates with auger 18 to define a space or passage 36 for accumulating the material so it can be moved or transported by the auger to pump 20 as the auger rotates. As FIGS. 2, 2A, 3 and 3A show, end plate 35 closes one end of passage 36 and another removable end plate 39 curves around bearing support bracket 39A and bearing 26 and closes the other end of the passage. Rear sealing plate 34 has a curved portion 34A to allow space for the lower portion of a T-shaped conduit 56 hereinafter described in detail which extends into and communicates with space 36 between auger 18 and rear sealing plate 34. As FIGS. 3 and 4 show, hydraulic motor 28 for auger 18 is rigidly but detachably connected by bolts 29 to plate 35 and has hydraulic fluid inlet/outlet ports 38 and 40 which are connected by hydraulic fluid lines 42 and 44, respectively, to an auger motor control valve 45 shown in FIG. 12. If preferred, auger 18 may be constructed as hollow so that bearing 26 and motor 28 may be mounted internally thereof to make apparatus 10 even more compact. As FIGS. 3A and 7 show, rear plate 34 extends downwardly so that its lower edge edge is about 1 inch above the floor 13 of tank 14. To allow for an uneven floor 13 or projections (not shown) a rubber or neoprene flexible sealing lip 34B engageable with the floor is secured to rear plate 34 by entrapment between rear plate 34 and a rigid mounting strip 34C which is secured to the rear plate by a series of bolts 34D. The sealing lip 34B drags along floor 13 and effectively seals the gap between the plate 34 and the floor against leakage of the sludge material to be removed by auger 18. As FIGS. 2 through 10 show, steering means 22 (hereinafter described in detail) comprises an elongated rigid slide-bearing member 46 which is rigidly mounted on the upper side of deck 24 in spaced apart relationship therefrom and parallel to auger 18. Dredge pump 20, which has a sludge inlet port 48 and a sludge discharge port 50 connectable to a discharge hose 52, is rigidly but detachably mounted on slide-bearing member 46 by brace 21. Dredge pump 20 is driven by a hydraulic dredge pump motor 47 which has hydraulic fluid inlet/outlet ports 49 and 51 which are connected by hydraulic fluid lines 53 and 55 which are connected to a pump control valve 57, as FIG. 12 shows. Pump inlet port 48 is connected by a quick-disconnect coupling 54 to a T-shaped conduit 56. More specifically, T-shaped conduit 56, is rigidly but detachably mounted on platform 16 by bolts 57 extending through a flange 57A (FIG. 9) to enable it to be installed on the platform after the components have been inserted through the man-way 15. Conduit 56 has an upper by-pass liquid inlet port 56A, a lower sludge inlet port 56B and an intermediate sludge outlet port 56C. Sludge inlet port 56B communicates with the aforesaid space or passage 36, as FIGS. 6 and 9 show, and extends downwardly to within about one or two inches of tank floor 13. By-pass liquid inlet port 56A is provided with an adjustable, remotely controllable throttle valve VT (FIG. 3). Valve VT is operable to admit only a desired amount of by-pass liquid to sludge pump 20 to facilitate the desired flow of the sludge. The by-pass fluid must be compatible with the liquid in tank 14. In fact, in most cases the by-pass fluid is the liquid in the tank and it can flow directly into valve VT. In rare cases, by-pass liquid from an external source may be required and the valve VT may be used to detachably connect liquid inlet port 56A to a by-pass liquid supply hose 58 which, as FIG. 12 shows, is connected to a by-pass liquid supply 60. Sludge discharge port 56C is connected by coupling 54 to sludge inlet port 48 of pump 20. The bypass liquid must be compatible or miscible with the sludge being removed and mixes with the sludge to render it more easily transported by pump 20. Referring to FIGS. 2, 3, 4, 5, 6, 7, 8, 10 and 11, remotely operable steering means 22 comprises an elongated rigid L-shaped steering arm or member 62 which extends through a space 64 between upper deck 24 and slide-bearing member 46. One end of steering-arm 62 is pivotally connected to deck 24 by a pivot pin 66. The other end of steering arm 62 is provided with a wheel support bracket 68 which is rigidly connected thereto as by a bolt 70. A tail wheel 72 is rotatably mounted on bracket 68 by an axle 74. Spaced-apart members 76 and 78 are mounted beneath and near opposite ends of slide-bearing member 46 to rigidly support it on deck 24. An extendible/retractable hydraulic ram or steering cylinder 80 is connected between deck 24 and steering arm 62 by pivot pins 82 and 84 and is operable to pivotally move the steering arm and the tail wheel thereon to effect steering of the apparatus. Ram 80 is provided with hydraulic fluid inlet/outlet ports 86 and 88 which are connected by hydraulic fluid lines 90 and 92, respectively. Line 92 is connected to a steering control valve 94 and line 90 is connected to return line 51 of the hydraulic motor 20, as FIGS. 12 and 12A show. Ram 80 is supplied at one end with hydraulic fluid at a constant pressure of 300 psi, for example, and this creates a bias in one direction. The other end of ram 80 is supplied with hydraulic fluid of variable pressure to effect steering. Referring to FIG. 10, if steering arm 62 is swung all the way in the direction of arrow E, apparatus 10 tries to pivot in an arc in the direction of arrow F. Movement of steering arm 62 in the opposite way causes apparatus 10 to pivot oppositely in an arc. If the steering-arm is positioned in its dynamic center as shown broken lines in FIG. 10, apparatus 10 will tend to move straight ahead. It should be noted that tail wheel 72 is straight when steering arm 62 is in its dynamic center so as to off-set the unwanted shift of apparatus 10 caused by auger rotation. Back-haul cable or tether line 96 is connected between winch 98 and a hook 99 on steering arm 62. As FIG. 1 and 2 show, the apparatus is provided with a jet nozzle 67 for supplying a pressurized stream of compatible liquid to assist in fluidizing the material to be dredged, if this becomes necessary, as hereinafter explained. Nozzle 67 is provided with liquid through a supply hose 67A (FIG. 1) from a suitable pump (not shown). The source of liquid may be filtered liquid which is being returned to tank 14 or can be any compatible liquid. Preferably, nozzle 67 is a known type of back-thrust or balanced nozzle located so as not to interfere with the steering or operation of the apparatus. OPERATION It should be understood at the outset that the material 12 to be dredged is similar in its characteristics to sand on an ocean floor in that it is not in itself fluid or fluidized until action is taken to do so. The material can be very fine and packed and needs to be fluidized before it can be handled by pump 20. However, in some cases it may be an organic type material that behaves like a fluidized material without the need to take steps to fluidize it. Note that in the dredging industry material mixed with a liquid to fluidize it is referred to as a slurry and the slurry density is the ratio of material to liquid. Generally considered, the present apparatus fluidizes the material 12 in the following manner: (a) the action of auger 18 stirs up the material while moving the material in the direction of inlet port 56B which is connected to the inlet of pump 20; (b) pump 20 causes fluidization of the material by mixing it with by-pass liquid supplied through throttle valve VT to inlet port 56A; (c) the forward motion of the apparatus across tank floor 13 also helps in fluidizing the material; (d) the apparatus operates at the bottom of the slope of the material which it confronts and the material has a natural tendency under the force of gravity to roll to the bottom of the slope, although in some cases the weight of the material becomes greater than its shear resistance, motion occurs and the motion causes fluidization; (e) in some cases all of the above actions are insufficient to fluidize the material and it is necessary to employ a jet of liquid from jet nozzle 67 which is pointed in the digging direction. Assume that the apparatus 10 is disposed in tank 14 as shown in FIG. 1, that by-pass liquid supply hose 58 is connected, if needed, that throttle valve VT is opened the proper amount, that discharge hose 52 is properly connected, and that the hydraulic fluid control hoses described above are connected to the winches 17 and 98, to hydraulic pump motor 47, to hydraulic auger motor 28 and to hydraulic steering ram 80. Further assume that back-haul cable or tether 96 is connected to hook 99 at the end of steering arm 62. If the layer of material is relatively deep (i.e., more than 10 to 15 inches deep when apparatus of the size disclosed herein is employed) and very viscous, other equipment may be used to excavate a hole in the layer of material so that apparatus 10 can reach floor 13. Such equipment may take the form of a crater sink mechanism (not shown) which is disclosed in my U.S. Pat. No. 4,979,322 issued Dec. 25, 1990. As previously mentioned, the sludge depth in a chemical processing tank can reach more than 20 feet. The apparatus 10 cannot work in mid-material but must be in contact with the floor 13 of the tank and the apparatus disclosed in U.S. Pat. No. 4,979,322 can be lowered through the man-way to excavate a crater in the sludge into which the apparatus can descend to the floor. Now assume that the edge of auger 18 and tail-wheel 72 rest on the tank floor. Rotation of auger 18 then causes apparatus 10 to move in a direction transverse to the auger axis and at the same time moves material toward the discharge end of the auger, through T-shaped conduit 56 and into dredge pump 20 and from thence through discharge hose 52 for final disposition. As FIG. 14 shows, during a cleaning operation the apparatus moving forward first sweeps in an arcuate path to the left. Then, the position of the steering arm 62 is reversed, the apparatus turns around and the apparatus moves forward and sweeps in an arcuate path to the right. This sweep maneuver sequence is repeated as often as necessary to cover the area to be cleaned. While dredging, the auger 18 always rotates in the forward direction and the apparatus always moves in the forward direction. The auger is only operated in reverse to back away from the tank wall and aid the apparatus in turning. The forward progress of the apparatus is dependent on the depth and type of material 12. It is to be understood that the auger rotates at a speed of between 0 and 30 rpm. If auger 18 is 10 inches in diameter and the angular (rotational) velocity is 30 rpm, assuming no slip, then the maximum forward velocity would be about 20 feet per minute or 1,178 feet per hour. It is to be further understood that the back-haul cable 96 is paid out as the apparatus 10 moves forward. The cable 96 is fed out only about one foot at a time. Cable is taken in to pull the apparatus in reverse, as while attempting to move it away from the tank wall during a turn. Care must be taken so as not to allow the apparatus to run over the back-haul cable. Referring to FIG. 9, if auger 18 is rotating clockwise in the direction of arrow A, apparatus 10 tends to move forward in the direction of arrow B and auger action tends to move material to the sludge inlet port 56B of the apparatus and from thence to pump 20. However, such auger rotation also tends to move apparatus 10 slightly in the general direction of arrow C in FIG. 5. Furthermore, the torque of auger 18 turning in the direction of arrow A tends to cause platform 16 to rotate counter-clockwise in the direction of arrow D in FIG. 9, thus causing a downward force to be exerted on tail wheel 72 to stabilize the apparatus and improve steering. As previously mentioned, the auger 18 can take various forms and the form chosen determines the behavior of the apparatus 10. If the auger has a single helical spiral, as is the case with auger 18, it rotates to feed sludge to an outlet 56B located at one end of platform 16. However, in such an arrangement auger action tends to cause the apparatus to move or drift slightly in the axial direction of the auger, but such drift is overcome by positioning the tail wheel 72 so that it is at the "dynamic center" of the apparatus. The steering arm 62 can be positioned either by pre-shaping the steering arm (notice the L-shaped configuration in FIG. 10) or by operating the steering cylinder 80 to overcome the tendency of the apparatus to drift. If, as shown in FIG. 13, the auger 18A has oppositely formed helical flights at opposite ends, the auger can feed sludge to a center outlet 156B on platform 16 and the apparatus has no tendency to drift. As a result, the steering arm 62A for tail wheel 72 can be made straight and centrally located. Referring to FIG. 1, it is apparent that the system disclosed therein requires various motors to drive auger 18, pump 20, steering arm 62, load hoist winch 17 and back-haul winch 98. Such motors are preferably hydraulic rather than electric because some tank cleaning operations take place in a flammable or explosive environment. The valves which control the several motors are solenoid-operated hydraulic control valves which are remotely located exteriorly of tank 14 and operated by a programmable electronic controller EC which can be manually over-ridden when necessary. Such a controller is disclosed in my aforementioned U.S. Pat. No. 5,093,949. Typically, the winch motors M1 and M2 for the winches 17 and 98, respectively, are selectively operable by means of solenoid valves V1 and V2. The solenoid valves 45, 57 and 94 for the auger motor 28, the pump motor 47 and the steering ram 80, respectively, readily lend themselves to programmable sequences of operation. Throttle valve VT is operable to control the flow of by-pass liquid to pump 20. The sludge pump 20 preferably takes the form of a variable displacement pump. Referring to FIGS. 12 and 12A, the sludge pump 20, which is hydraulically driven, is supplied with oil by means of a positive displacement control unit EDC. This type of control easily lends itself to remote control, either manually or by an electronic programmable controller EC. When a cleaning operation is ready to begin, the pump 20 is started and brought up to design speed and the steering arm 62 is centered. Effluent discharge rate and pressure are checked. If all is in accordance with design specifications, auger 18 is slowly speeded up to rated speed for the particular operation. The back-haul cable 96 is fed out about 6 inches and the pump performance is closely monitored. Then, the back-haul cable 96 is slowly paid out and, at some point, the apparatus will stall against the material 12. If it does not stall, three to five more feet of cable 96 is paid out. When the material output diminishes, the steering arm 62 is adjusted to steer the apparatus to the left and the speed of auger 18 is adjusted to maintain the rate of material pumping that is best suited to the particular operation. When the apparatus reaches the left side of the tank 14, the steering arm 62 is turned to the right but no back-haul cable 96 is paid out. When the apparatus reaches the opposite (right) side of the tank 14, the steering arm 62 is turned to the left and, as the apparatus moves to the left, another foot of back-haul cable 96 is paid out. All necessary controls are then adjusted to obtain optimum production for the conditions encountered. When cleaning is finished, the apparatus is turned off and hoist winch 17 is operated to raise the apparatus to man-way 15 whereat it is disassembled, if necessary, withdrawn from the tank and lowered to the ground.
Self-propelled steerable apparatus for removing material, such as sludge, from the bottom surface of a liquid storage tank for disposition elsewhere comprises a support platform and a reversely rotatable motor-driven auger mounted below the support platform and cooperating therewith to define a space for receiving sludge when the rotatable auger is engaged with the surface. A motor-driven pump mounted on the support platform is operable to receive sludge from the auger and deliver it through a discharge hose to a remote location. Rotation of the auger delivers the sludge to the pump and propels the apparatus across the surface. A remotely controllable steering mechanism on the support platform has a tail wheel which engages the surface and steers the apparatus along a desired path. A winch-controlled back-haul cable is connected to the apparatus to periodically stop forward movement of the apparatus while the auger is still rotating so that the sludge can be more efficiently removed.
1
FIELD OF THE INVENTION [0001] The present invention generally relates to a system and method for electronically processing flight plans. More particularly, the present invention pertains to a web-based flight planning service which provides various flight planning and refueling optimizations. BACKGROUND [0002] A flight plan is a document filed by a pilot, dispatcher, or a controller with the Federal Aviation Administration (FAA), or another civil aviation authority, prior to departure. A flight plan generally includes the basic information one would expect, such as departure date, time, and an origin and destination airport. In addition to these necessary details, a flight plan also includes the aircraft identification and aircraft type, an estimated time en route, a listing of alternate airports for use in the event of bad weather, the type of flight (either instrument flight rules (IFR) or visual flight rules (VFR)), pilot's name, and number of people on board. In the United States, flight plans are required for flights under IFR so that air traffic control may initiate tracking and routing services. Under VFR, a flight plan is optional unless the flight's path will cross national borders. Despite this, flight plans are highly recommended in many VFR flights as they provide a way of alerting rescuers if the flight is overdue/missing, and they provide flight following that may warn of other nearby air traffic en route. [0003] The process of producing a flight plan to describe a proposed aircraft flight is well known in the art. Typically, when a flight plan is produced, the pilot (1) calculates the amount of fuel required to complete the trip and (2) checks for compliance with air traffic control requirements, checks for clearance from terrain and structures near takeoff and landing areas, considers potentials for mid-air collisions, avoids restricted or prohibited areas of flight, and the like. In addition to these safety requirements, a pilot or individual making a flight plan may attempt to minimize overall flight costs by selecting the most efficient route, height, and speed for their particular aircraft type and sometimes seek to load the minimum necessary fuel, plus a safety reserve, on board, to maximize flight efficiencies. In flights having a longer duration, fixed base operators having disparate prices for aviation fuel are utilized at airports along the way. [0004] In order to accomplish these goals, flight planning benefits from accurate and up-to-date information. For example, accurate weather forecasts are desired so that fuel consumption calculations can account for the fuel consumption effects of head or tail winds and air temperature. Furthermore, under the supervision of air traffic control, aircraft flying in controlled airspace may be required to follow predetermined routes known as airways, even if such routes are not as economical as a more direct flight. Within these airways, aircraft must maintain flight levels, specified altitudes usually separated vertically by 1000 or 2000 feet (305 or 610 m), depending on the route being flown, the altitude en route, and the direction of travel. Additionally, the performance of each different aircraft types varies based on altitude, air pressure, temperature and weight. When attempting to formulate an efficient flight plan, one quickly discovers that a large number of calculations would be required in order to formulate a flight plan that is even close to optimized. As a result, most flight plans follow one of several common routes at available altitudes which have the most favorable current or forecast weather conditions. However, sometimes these are not the most efficient routes under varying circumstances. The present invention solves a number of these inefficiencies as well as other problems present in the process of flight planning, as are illustrated in the descriptions that follow. SUMMARY [0005] Various technologies and techniques are disclosed for providing optimized flight planning services to a remote user. In one form, the user accesses a service through a series of web pages presented to the user. The user is able to specify an airport or area for arrival/departure for a future flight in a specified airplane type. The service then calculates an optimized route for the flight based upon aircraft performance data, available fuel costs, and up-to-date current or forecast aviation weather. In an alternate form, a flight route is formed from information within stored historical flight plans. By optimizing the path of a flight in this manner, many benefits can be realized. [0006] In another embodiment, the service allows the user to arrange the purchase of aviation fuel at various locations. In a preferred form, the user is able to purchase the fuel at a discount provided by the service. In exchange, the service receives a fee from the affiliated fixed base operator for directing the transaction to them. [0007] This summary is provided to introduce a selection of concepts in a simplified form that are described in further detail in the detailed description and drawings contained herein. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter, as the claims appended thereto serve that function. Still further forms, embodiments, objects, advantages, benefits, features, and aspects of the present invention will become apparent from the detailed description and drawings contained herein. BRIEF DESCRIPTION OF THE DRAWINGS [0008] FIG. 1 is a diagrammatic view of a computer system of one implementation. [0009] FIG. 2 is a flowchart illustrating the process for generating a flight plan based upon previous plans. [0010] FIG. 3 is sample flight plan form as specified by the FAA and utilized by the present system and method. [0011] FIG. 4 is a diagrammatic view of a result displayed to a user in one form of the present system and method illustrated in FIG. 1 . [0012] FIG. 5 is a flowchart illustrating the process for generating an optimized flight plan based upon aviation weather and aircraft performance information. [0013] FIG. 6 is a flowchart illustrating the process for providing fuel transaction scheduling with affiliated FBOs during flight planning. DETAILED DESCRIPTION [0014] For the purposes of understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. [0015] On any given day, more than 87,000 flights take to the skies in the United States. Only 35 percent, or just over 30,000, of those flights are commercial carriers, such as Delta, United, or Southwest. The majority of the remaining flights, roughly 50,000, are general aviation flights (private planes), and air taxi flights (planes for hire), with the remaining being either military or cargo aircraft. While each of these is not required to submit a flight plan, a substantial portion of them do. In addition, the number of daily non-commercial flights is growing and will undoubtedly continue to rise as the need for air transportation increases. [0016] Currently, flight planning is a relatively routine process. However, it is far from optimized and can be quite burdensome. Until applicants' invention, the exact flight plans of others have been difficult to obtain. In addition, a flight plan between two locations may be suitable on one day, but inefficient under the conditions of a subsequent day. Applicants have incorporated many of the features disclosed herein into a fully functioning website at http://flightaware.com/flightplan, the contents of which are incorporated herein by reference. [0017] FIG. 1 is a diagrammatic view of a multi-site computer system 20 of one embodiment of the present invention. In the illustrative embodiment, computer system 20 includes aviation information service 10 , two affiliated fixed base operator servers 40 , and three client computers 30 . In order to preserve clarity, only a small number of the many connected fixed base operator servers and client computers have been shown. Computer system 20 also includes computer network 22 . Computer network 22 couples together a number of computers 21 a - 21 g over network pathways 23 a - 23 g , respectively. More specifically, system 20 includes several servers, namely Web Server 11 and Database Server 12 of aviation information service 10 , and FBO (fixed base operators) Servers 40 a and 40 b , which are operated by affiliated fixed base operators at various geographic locations. System 20 also includes client computers 30 a , 30 b , and 30 c (collectively 30 ). While computers 21 a - 21 g are each illustrated as being a server or client, it should be understood that any of computers 21 a - 21 g may be arranged to include both a client and a server. Furthermore, it should be understood that while seven computers 21 a - 21 g are illustrated, more or fewer may be utilized in alternative embodiments. Preferably, service 10 includes a collection of Web servers 11 for receiving, processing, and responding to user queries. [0018] Computers 21 a - 21 g include one or more processors or CPUs ( 50 a , 50 b , 50 c , 50 d , 50 e , 50 f and 50 g , respectively) and one or more types of memory ( 52 a , 52 b , 52 c , 52 d , 52 e , 52 f and 52 g , respectively). Each memory 52 preferably includes a removable memory device. Each processor 50 may be comprised of one or more components configured as a single unit. When of a multi-component form, a processor 50 may have one or more components located remotely relative to the others. One or more components of each processor 50 may be of the electronic variety defining digital circuitry, analog circuitry, or both. Optical computing could be used as an alternative. In one embodiment, each processor 50 is of a conventional, integrated circuit microprocessor arrangement, such as one or more OPTERON processors supplied by ADVANCED MICRO DEVICES Corporation of One AMD Place, Sunnyvale, Calif. 94088, USA. [0019] Each memory 52 (removable, fixed or both) is one form of a computer-readable device. Each memory may include one or more types of solid-state electronic memory, magnetic memory, or optical memory, just to name a few. By way of non-limiting example, each memory may include solid-state electronic Random Access Memory (RAM), Sequentially Accessible Memory (SAM) (such as the First-In, First-Out (FIFO) variety or the Last-In-First-Out (LIFO) variety), Programmable Read Only Memory (PROM), Electronically Programmable Read Only Memory (EPROM), or Electrically Erasable Programmable Read Only Memory (EEPROM); an optical disc memory (such as a DVD or CD ROM); a magnetically encoded hard disc, floppy disc, tape, or cartridge media; or a combination of any of these memory types, or other types not included in the above list. Also, each memory may be volatile, nonvolatile, or a hybrid combination of volatile and nonvolatile varieties. [0020] Although not shown to preserve clarity, one or more of computers 21 a - 21 g may be coupled to a display and/or may include an integrated display. Computers 21 a - 21 g may be of the same type, or a heterogeneous combination of different computing devices. Likewise, displays may be of the same type, or a heterogeneous combination of different visual devices. Although again not shown to preserve clarity, each computer 21 a - 21 g may also include one or more operator input devices such as a keyboard, mouse, track ball, light pen, and/or microtelecommunicator, to name just a few representative examples. Also, besides a display, one or more other output devices may be included such as a loudspeaker or printer. Various display and input device arrangements are possible. [0021] Computer network 22 can be in the form of a wireless or wired Local Area Network (LAN), Municipal Area Network (MAN), Wide Area Network (WAN), such as the Internet, a combination of these, or such other network arrangement as would occur to those skilled in the art. The operating logic of system 20 can be embodied in signals transmitted over network 22 , in programming instructions, dedicated hardware, or a combination of these. It should be understood that more or fewer computers like computers 21 a - 21 g can be coupled together by computer network 22 , and that Web Server 11 and Database Server 12 may also be connected to one another by a private LAN or similar private connection. [0022] In one embodiment, system 20 operates at several various geographic locations. For example, aviation information service 10 may operate in one state, while FBO Servers 40 a and 40 b and client computers 30 may all be located in other unique states. Web Server 11 of service 10 is configured as a web server that hosts application business logic 33 for an aviation information engine, Database Server 12 is configured as a database server for storing aviation related information, including flight plans, within data store 34 and at least one of client computers 30 is configured for providing a user interface 32 a - 32 c , respectively, for accessing the aviation information service 10 . Preferably, Database Server 12 maintains at least 1 month of historical previously filed flight plans in data store 34 , and most preferably maintains at least six months. In addition, Database Server 12 maintains FBO information, up-to-date aircraft performance information specified by various aircraft manufacturers, and aviation weather information within data store 34 . In a further form, Database Server 12 maintains data store 34 as a memory-resident database to provide more advanced searching functionality and to minimize response times. User interface 32 a - 32 c of client computers 30 a - 30 c can be an installable application such as one that communicates with Web Server 11 , can be browser-based, and/or can be embedded software, to name a few non-limiting examples. [0023] In one embodiment, software installed locally on client computers 30 a - 30 c is used to communicate with Web Server 11 . In another embodiment, Web Server 11 provides HTML pages, data from web services, and/or other Internet standard or company proprietary data formats to one or more client computers 30 a - 30 c when requested. One of ordinary skill in the art will recognize that the term web server is used generically for purposes of illustration and is not meant to imply that network 22 is required to be the Internet. As described previously, network 22 can be one of various types of networks as would occur to one of ordinary skill in the art. It shall be appreciated that data store 34 on Database Server 12 is suitably arranged to store data such as flight plans, fuel prices, historical weather information, and aircraft performance information to name a few representative examples. [0024] In the illustrative embodiment, aviation fuel availability and pricing information is received from each FBO Server 40 . This information may include the price of various types of aviation fuels such as, for purposes of non-limiting example, Jet A and 100LL. This information may be provided to Database Server 12 of service 10 periodically or may be sent through Web Server 11 in response to a request, as is described herein. [0025] Typical applications of system 20 would include more client computers like computers 30 a - 30 c at more physical locations, but only three have been illustrated in FIG. 1 to preserve clarity. Furthermore, although two servers 11 and 12 are shown, it will be appreciated by those of ordinary skill in the art that the one or more features provided by Web Server 11 and Database Server 12 could be provided by the same computer or varying other arrangements of computers at one or more physical locations and still be within the spirit of the invention. Farms of dedicated servers, a single proprietary system, and/or a Storage Area Network (SAN) could also be provided to support the specific features if desired. In the illustrative embodiment, in order to flexibly handle the large quantity of flight information received by service 10 , Database Server 12 includes a relational database, such as SQL, as is known to one of skill in the art. [0026] Turning to FIG. 2 , with continued reference to FIG. 1 , a flowchart illustrating the process for generating a flight route or flight plan based upon previous flight plans is illustrated. The process begins at start point 200 with the service 10 receiving an origin and destination from a remote user (step 202 ) connected to Web Server 11 via one of client computers 30 . The origin and destination may individually be either an airport (specified by name/code) or a geographic area, depending upon the needs of the user. The origin and destination provided by the user is preferably processed by Database Server 12 using data within data store 34 to either confirm the existence of the airport codes or to generate a list of potential airport codes within the specified geographic area. In addition, the service 10 determines the aircraft type which the user plans to use in the current flight (step 204 ). The aircraft type may be input by the user as an aircraft class, model, specific tail number, and/or by other identifying information. In addition, the user may have a user account with service 10 which allows the service to automatically know the aircraft flown by the current user, as would be appreciated in the art, or to allow the user to easily select among several aircraft the user regularly flies. Any special equipment features of the aircraft can be noted, such as extended fuel tanks. [0027] Once the user input is processed, service 10 builds a number of departure airport/destination airport combinations (step 206 ). In the event the origin and destination provided by the user are both specific airports, then only a single combination may be identified. In a preferred form, the service 10 utilizes nearby routes to/from nearby airports to identify routes which may be slightly modified to meet the user's desired flight. However, in most forms, when either one or both of the origin and destination includes a location having more than one available airport then a plurality of potential combinations are set for inclusion, except when only a single suitable airport exists within a specified location. [0028] Given the departure/destination airport combinations, the service 10 preferably performs the following steps for each combination, unless instructed otherwise by the user. First, service 10 selects an available origin/destination airport combination for analysis (step 208 ) from the ones determined in step 206 . For ease of reference, the origin destination airports of the currently selected combination will be referred to, within this section, as airport A and airport B, respectively. In a further form, the various combinations may include suggested airports, either presented to the user for approval or not, based upon availability indicated by weather information. In a still further form, the suggested alternate airports may be screened to ensure proper runway length, hours of operation, weight requirements, and the like for the selected aircraft type. [0029] Once the set of combinations is complete, service 10 queries Database Server 12 to identify relevant flight plans (step 210 ) having a similar aircraft type to that of the current flight. In the preferred form, the query for previously filed plans is further limited to recently filed plans, such as within the last 12, 24, or 36 hours. In an alternate or further form, the query includes current or forecast aviation weather information (i.e. winds aloft, air temperature, icing, etc.) received by Web Server 11 , such as from the National Oceanic and Atmospheric Administration (NOAA), so that only the previous flight plans most closely matching the weather which should be encountered by the current flight would be considered. [0030] Web Server 11 then utilizes business logic 33 to build a set of routes from subsets of the identified flight plans, where each route is comprised of flight path information from at least a portion of one or more flight plans (step 212 ). For instance, one route may be comprised entirely of a flight path from airport A to airport B in a flight plan filed just hours earlier. Another route may be comprised of only a portion of a flight path which went from airport A to airport C, but stopped at airport B for refueling, with the A to B leg being used and the B to C leg being discarded. Additionally, still another route within the set may include a combination of two or more independent flight segments (i.e. “leg”) which collectively begin at airport A and end at airport B. For example, a route may be a combination of a leg from a flight which refuels at airport A and destined for airport X and another leg from a different flight plan which begins at airport X and ends at airport B. With reference to flight plans herein, it should be understood that it may be the flight plans of others as filed are the source of data, but more preferably, preference may be given to data from the flight plans of others in the form approved by the FAA, or alternatively to data from flight plans that have been amended by en route changes from an actual flight taken. It can be further appreciated that a reference to flight plan data herein can also encompass historical data from an actual flight that has been completed, where data is available as to the actual duration of the flight and actual altitudes flown, and actual or forecast weather information for that time period, and the actual route taken and equipment type used. [0031] Upon the completion of the set of routes from one combination in step 212 , the service 10 determines whether more origin/destination airport combinations exist (step 214 ). In the event one does, the process returns to step 208 . Otherwise, the process advances to step 216 . It shall be appreciated that the various iterations of steps 208 , 210 , and 212 may occur in sequence as described herein, for purposes of clarity, or in parallel, such as would be possible in a multi-threaded computing environment. [0032] Once all of the routes are built, as determined by step 214 , they are modified in order to fit the departure time of the current user (step 216 ). This may include updating takeoff, waypoint, and arrival times, as well as many other factors that would be appreciated by one of skill in the art. Following step 216 , the various updated flight routes are presented to the remote user (step 218 ). Preferably, the routes are presented by Web Server 11 to the remote user in the form of a web page, with the routes being sorted according to a set of criteria. The criteria may include, but is in no way limited to, total time, time in flight, distance, overall cost, fuel required, or some other best fit heuristic. The process ends at end point 220 . [0033] In a further form, Web Server 11 receives a selected route from the remote user (not shown) indicating their desired route. Web server 11 then accepts any final flight information required, such as the number of passenger aboard, and may optionally file the completed flight plan electronically (not shown) with the Federal Aviation Administration (FAA). For performing this function, the standard flight plan template provided by the FAA, as shown in FIG. 3 , is completed. Additionally, for purposes of subsequent use, the currently filed flight plan is preferably stored by Database Server 12 for future use. Thereby, the accuracy of the flight routes taken by the flight plans stored in data store 34 increases over time as the recent flight plans evolve. Preferrably, flight plan data is obtained directly from the FAA or air traffic control as it is received and/or approved and/or modified. [0034] Turning to FIG. 4 a representative web page presented by service 10 displaying available flight routes is illustrated. Specifically, FIG. 4 shows a representative web page 400 presented in response to a query concerning a specific origin airport 402 , Indianapolis International (IND), and a specific destination airport 404 , Mc Carran International (LAS), in this example. In addition, the aircraft type 406 and the departure date/time 408 which accompany the query are displayed. The result section 410 within web page 400 is divided into columns which provide information about the available routes. Column 412 indicates the frequency, or number of times, a route has been taken in the selected timeframe. Columns 414 and 416 , respectively, indicate the origin and destination of each route. Column 418 indicates the primary altitude of the flight, while column 420 gives specifics of the full route. The route displayed may be in short form or in decoded form providing the latitude and longitude of each waypoint and an associated altitude and or climb rate. The remote user may select a route by clicking on it or otherwise and be presented with a subsequent web page allowing them to utilize the service to file a flight plan based upon the selected route, as described herein. Additional information on the referenced flight plans, such as the times they were schedule for, or the tail number of the flights, can also be displayed, if desired. [0035] Turning to FIG. 5 , with continued reference to FIG. 1 , a flowchart illustrating a process for calculating an optimized flight plan based upon available aviation weather and aircraft performance information is illustrated. The process of FIG. 5 is comparable in large measure to much of that described as to FIG. 2 . The process begins at start point 500 with the service 10 receiving a desired origin and destination from a remote user (step 502 ) connected to Web Server 11 via one of client computers 30 . The service 10 also must determine the aircraft type which the user plans to use in the current flight (step 504 ), as described herein. Once the user input is complete, the service 10 builds a number of departure airport/destination airport combinations (step 506 ). [0036] Given the departure/destination airport combinations, the service 10 preferably performs the following steps for each combination, unless instructed otherwise by the user. First, service 10 selects an available origin/destination airport combination for analysis (step 508 ) from those determined in step 506 . The service 10 then queries Database Server 12 to identify the aircraft performance information associated with the aircraft type indicated by the remote user (step 510 ). In addition, the service 10 obtains up-to-date current and/or forecast aviation weather information (i.e. winds aloft, air temperature, icing, etc.). In the preferred form, this information is periodically received by Web Server 11 , such as from the NOAA. [0037] Web Server 11 then utilizes business logic 33 to perform mathematical calculations. Parameters that are preferably incorporated include planned altitude(s), fuel consumption, wind speed, temperature, and air pressure or density, known aircraft performance characteristics for the specific type being flown, and other factors including the need for and effect of anti-ice to calculate a total time and cost for each route (step 512 ). In a preferred form, each route also includes any necessary or beneficial refueling stops, and factors in the available cost for the correct type of aviation fuel, as is stored in data store 34 of Database Server 12 . For instance, one route may include refueling at a selected FBO at the departure airport and making the flight entirely along a flight path using one altitude to the destination airport. Another route may include utilizing already available fuel (as specified by the user) to travel to an intermediate refueling destination at one altitude (for refueling by a different selected FBO) and then continue on to the destination airport at a different primary altitude. Additionally, various altitudes may be utilized within any single leg of the trip in order to gain efficiencies from the winds aloft or to avoid the impact of severe weather and/or conditions for icing. [0038] Upon the completion of the set of routes from one combination in step 512 , the service 10 determines whether more origin/destination airport combinations exist (step 514 ). In the event one does, the process returns to step 508 . Otherwise, the process advances to step 516 . It shall be appreciated that the various iterations of steps 508 , 510 , and 512 may occur in parallel or in sequence as described herein. [0039] Once all of the routes are built, as determined by step 514 , the various updated flight routes are presented to the remote user (step 516 ), in a similar fashion to that shown in FIG. 4 . A column for total cost and flight duration may be selectively added. Preferably, the routes are presented by Web Server 11 to the remote user in the form of a web page, with the routes being sorted according to a set of criteria, such as total cost, time en route, or total number of stops. Once presented, the Web Server 11 receives a selected route from the remote user (step 518 ) indicating their desired route. Web Server 11 then accepts any final flight information, such as the number of passengers aboard, and may optionally file the completed flight plan electronically (step 520 ) with the Federal Aviation Administration (FAA) as described herein. The process ends at end point 522 . [0040] Referring now to FIG. 6 , with continued reference to FIG. 1 , a flowchart illustrating the process for providing fuel transaction scheduling with affiliated FBOs during flight planning is illustrated. The process begins at start point 600 with the user submitting an airport or location and fuel type to the aviation information service 10 using a web interface (step 602 ). In an alternate form, the aviation fuel type may be predetermined based upon the type of plane associated with the user or general user settings, as would be appreciate to one of skill in the art. It shall be appreciated that this information may be taken from a flight plan, such as those described herein, and that the steps of this process may be implemented within the steps of the process shown in FIG. 5 to obtain optimal discounted fuel prices. [0041] Once the selected airport is received by service 10 at Web Server 11 , a list of fixed base operators (FBOs) matching the airport location is retrieved from Data Store 34 by Database Server 12 (step 604 ). Using this list, Web Server 11 submits a query over network 22 to the respective FBO Server 40 associated with one or more of the FBOs in the list requesting the current price and availability of the specified fuel (step 606 ). Alternatively, FBO Servers may be configured to transmit any price changes to Web Server 11 , such that current pricing information may be stored within data store 34 by Database Server 12 for subsequent retrieval and use. [0042] In a preferred form, at least one fuel price is discounted over current market rates according to a prior agreement between the service 10 and the specific FBO (step 608 ). In one form, the discount comprises a fixed or graduated percentage or dollar amount based upon some criteria, such as the number of units purchased from the specific FBO, or a related association of FBOs, or the total volume purchased through the service in a specified period. Utilizing these prices, a total price and availability information for a requested amount of fuel at a variety of available FBOs is presented to the user (step 610 .) The user then selects the FBO of their choice (step 612 ), such as by clicking on the FBO presented on a web page. Once selected, the user indicates their acceptance to the terms of the transaction (step 612 ), which preferably do not legally bind the user to complete the transaction. Upon acceptance, a note indicating the price and volume, amongst other necessary details of the scheduled transaction, is sent via Web Server 11 to the appropriate FBO Server 40 (step 614 ). With the transaction scheduled, the user is free to arrive at the FBO and complete the transaction. [0043] Once the transaction is completed, the FBO Server 40 communicates notice to Web Server 11 by sending a confirmation (step 616 ), including the agreed upon price and the total sale amount. In exchange, the FBO associated with the FBO Server 40 remits a fee to the service 10 in accordance with their established agreement (step 618 ). The fee may be in various forms, including a flat or graduated fee, a set, stepped, or graduated percentage of the transaction, or any combination of these, or other alternatives. The fee may be based on other factors including the volume purchased from a specific FBO or common association of FBOs in a specified time period, or the like. The process ends at endpoint 620 . [0044] In an alternate form, the remote user may arrange payment with the service 10 , and the service 10 may remit payment associated with each scheduled transaction to the FBO prior to dispensing the fuel or in response to notification of dispensing the fuel, with the service 10 keeping the portion of the payment from the user attributable to it, according to the terms of the agreement between the respective FBO providing the fuel and the service. [0045] In a further preferred form, the service 10 offers to book rental cars, limousines, hotels, and the like based upon information presented during flight planning. In exchange, the service may also provide a discount for the user while receiving a fee for directing the business to a respective vendor. [0046] In yet another further preferred form, the service 10 provides electronic Digital Terminal Procedures Publications (DTPP) charts for download having either the necessary charts prioritized or the unnecessary charts removed. [0047] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all equivalents, changes, and modifications that come within the spirit of the inventions as described herein and/or by the following claims are desired to be protected. [0048] Hence, the proper scope of the present invention should be determined from the appended claims so as to encompass all such modifications as well as all relationships equivalent to those illustrated in the drawings and described in the specification.
A computer-implemented system and method for the processing and optimization of flight plans is disclosed. Information regarding a plurality of previous flight plans is received over a digital network and is stored in at least a database. The database preferably includes aviation fuel price information, aircraft performance information, and aviation weather information as well. Upon receiving a request, a server generates at least an optimized portion of a flight plan. In one form, historical flight plan data of others is automatically used to aid in the determination of the optimized route offered to the user for review, with the resulting final flight plan being electronically filed with the FAA upon approval. In a further form, the user may arrange fuel transactions at intermediate destinations with the service provider receiving a fee in exchange for facilitating the transaction.
6
TECHNICAL FIELD [0001] The present invention relates to a control apparatus and method for a construction machine. More particularly, the present invention relates to such a control apparatus and method for a construction machine in which when a combined operation of a boom and an arm of an excavator is performed, a loss in the flow rate of the hydraulic fluid discharged from the hydraulic pump can be prevented from occurring. BACKGROUND OF THE INVENTION [0002] A conventional flow control apparatus for a construction machine in accordance with the prior art as shown in FIG. 1 includes: [0003] an engine 1 ; [0004] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to the engine 1 ; [0005] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ; [0006] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 , the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump 2 to be returned to a hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state; [0007] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 , the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump 2 to be returned to the hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state; and [0008] a regeneration flow path 10 configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank T from a large chamber of the first hydraulic cylinder 3 during a retractable drive of the first hydraulic cylinder 3 due to an attachment (including a boom, an arm, or a bucket)'s own weight, and a regeneration valve 13 installed in the regeneration flow path 10 . [0009] As shown in FIG. 1 , when a spool of the first control valve 6 is shifted to the right on the drawing sheet by a pilot signal pressure from a pilot pump (not shown) through the manipulation of a manipulation lever (not shown), hydraulic fluid discharged from the hydraulic pump 2 is supplied to a small chamber of the first hydraulic cylinder 3 via a meter-in flow path 12 of the first control valve 6 . In this case, hydraulic fluid discharged from a large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the first control valve 6 and the return flow path 11 . Thus, the first hydraulic cylinder 3 is driven to be retracted so that the boom can be driven to perform a boom-down operation. [0010] In addition, when the spool of the first control valve 6 is shifted to the left on the drawing sheet through the manipulation of a manipulation lever (not shown), hydraulic fluid discharged from the hydraulic pump 2 is supplied to the large chamber of the first hydraulic cylinder 3 via the first control valve 6 . In this case, hydraulic fluid discharged from the small chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the first control valve 6 and the return flow path 11 a . Thus, the first hydraulic cylinder 3 is driven to be extended so that the boom can be driven to perform a boom-up operation. [0011] Meanwhile, when the hydraulic fluid from the large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T due to the retractable drive of the first hydraulic cylinder 3 , a back pressure is formed in the regeneration flow path 10 by a back pressure check valve 18 installed in the return flow path 11 . For this reason, when a pressure within the small chamber of the first hydraulic cylinder 3 is low, the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T can be supplementarily supplied to the small chamber of the first hydraulic cylinder 3 through the regeneration flow path 10 . [0012] In other words, when there is a shortage in the hydraulic fluid supplied to the small chamber during the retractable drive of the first hydraulic cylinder 3 , the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T can be recycled and supplementarily supplied to the small of the first hydraulic cylinder 3 through the regeneration flow path 10 . [0013] In the meantime, when a combined operation of a boom and an arm is performed by a user, i.e., when the first hydraulic cylinder 3 is driven to be retracted to perform the boom-down operation of the boom and the second hydraulic cylinder 4 is driven to be retracted to perform the arm-out operation of the arm, a load pressure generated in the second hydraulic cylinder 4 is relatively higher than that generated in the first hydraulic cylinder 3 . In this case, the hydraulic fluid discharged from the hydraulic pump 2 is much more supplied to the first hydraulic cylinder 3 whose load pressure is relatively low through the meter-in flow path 12 in terms of the characteristics of the hydraulic fluid. [0014] In other words, the conventional flow control apparatus entails a problem in that since the hydraulic fluid discharged from the hydraulic pump 2 is much more supplied to the first hydraulic cylinder 3 through the meter-in flow path 12 , the efficiency of the recycled hydraulic fluid is degraded. Besides, there is a problem in that the hydraulic fluid from the hydraulic pump 2 is introduced into the small chamber of the first hydraulic cylinder 3 , which causes a loss of the hydraulic fluid, thus leading to a decrease in the energy efficiency of the machine. SUMMARY OF THE INVENTION [0015] Accordingly, the present invention has been made to solve the aforementioned problems occurring in the prior art, and it is an object of the present invention to provide a flow control apparatus and method for a construction machine, which can limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to a boom cylinder whose load pressure is relatively low during a combined operation of a boom and an arm so that an unnecessary loss of the hydraulic fluid can be prevented. Technical Solution [0016] To achieve the above object, in accordance with an embodiment of the present invention, there is provided a flow control apparatus for a construction machine, including: [0017] an engine; [0018] a variable displacement hydraulic pump connected to the engine; [0019] a first hydraulic cylinder and a second hydraulic cylinder, which are connected to the hydraulic pump; [0020] a first control valve installed in a center bypass path of the hydraulic pump, the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump to be returned to a hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder in its shifted state; [0021] a second control valve installed on a downstream side of the center bypass path of the hydraulic pump, the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump to be returned to the hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder in its shifted state; [0022] a regeneration flow path configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank during a retractable drive of the first hydraulic cylinder, and a regeneration valve installed in the regeneration flow path; and [0023] a pressure compensation type flow control valve installed in a meter-in flow path of a spool of the first control valve and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first hydraulic cylinder during a combined operation of the first and second hydraulic cylinders. [0024] The pressure compensation type flow control valve may include a spool having a first position in which the meter-in flow path is opened by a pressure passing through a meter-in orifice installed in the meter-in flow path and an elastic force of a valve spring, and a second position in which the meter-in flow path is closed when the spool is shifted by a pressure in the meter-in flow path. [0025] The pressure compensation type flow control valve may include a spool having a first position in which the meter-in flow path is opened by a pressure passing through a meter-in orifice installed in the meter-in flow path and an elastic force of a valve spring, and a second position in which the flow rate of the hydraulic fluid is limited through the shift of the spool in a direction in which an opening portion of the meter-in orifice is reduced if the pressure in the meter-in flow path is higher than the elastic force of the valve spring. [0026] The first hydraulic cylinder 3 may be a boom cylinder, and the second hydraulic cylinder 4 may be an arm cylinder. [0027] To achieve the above object, in accordance with another embodiment of the present invention, there is provided a flow control apparatus for a construction machine, including: [0028] an engine; a variable displacement hydraulic pump connected to the engine; a first hydraulic cylinder and a second hydraulic cylinder, which are connected to the hydraulic pump; [0031] a first control valve installed in a center bypass path of the hydraulic pump, the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump to be returned to a hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder in its shifted state; [0032] a second control valve installed on a downstream side of the center bypass path of the hydraulic pump, the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump to be returned to the hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder in its shifted state; [0033] a regeneration flow path configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank during a retractable drive of the first hydraulic cylinder, and a regeneration valve installed in the regeneration flow path; [0034] a pressure compensation type flow control valve installed in a meter-in flow path of a spool of the first control valve and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first hydraulic cylinder during a combined operation of the first and second hydraulic cylinders; [0035] at least one pressure detection sensor configured to detect a pilot pressure that is input to the first and second control valves to shift the first and second control valves; [0036] a controller configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor and output a control signal that corresponds to the calculated required flow rate; and [0037] an electronic proportional valve configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller, to a pump regulator that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump. [0038] To achieve the above object, in accordance with still another embodiment of the present invention, there is provided a flow control method for a construction machine which includes: [0039] a variable displacement hydraulic pump connected to an engine; [0040] a first hydraulic cylinder and a second hydraulic cylinder, which are connected to the hydraulic pump; [0041] a first control valve installed in a center bypass path of the hydraulic pump and configured to control a start, a stop, and a direction change of the first hydraulic cylinder in its shifted state; [0042] a second control valve installed on a downstream side of the center bypass path of the hydraulic pump and configured to control a start, a stop, and a direction change of the second hydraulic cylinder in its shifted state; [0043] a regeneration flow path configured to reuse the hydraulic fluid that returns to a hydraulic tank by an attachment's own weight and a regeneration valve; a pressure compensation type flow control valve installed in a meter-in flow path of a spool of the first control valve and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first hydraulic cylinder during a combined operation of the first and second hydraulic cylinders; [0045] at least one pressure detection sensor configured to detect a pilot pressure that is input to the first and second control valves to shift the first and second control valves; [0046] a controller configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor and output a control signal that corresponds to the calculated required flow rate; [0047] an electronic proportional valve configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller, to a pump regulator that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump, the flow control method including: [0048] a first step of allowing the pressure detection sensor to detect the pilot pressure that is input to the first and second control valves to shift the first and second control valves through a manipulation of a manipulation lever; [0049] a second step of calculating the required flow rate of the hydraulic fluid, which corresponds to the detected manipulation amount of the manipulation lever; and [0050] a third step of outputting an electrical control signal that corresponds to the calculated required flow rate to the electronic proportional valve, [0051] wherein the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first and second hydraulic cylinders by the shifting of the first and second control valves is set to be equal to or lower than the flow rate of the hydraulic fluid passing through the pressure compensation type flow control valve. Advantageous Effect [0052] The flow control apparatus and method for a construction machine in accordance with the present invention as constructed above has the following advantages. [0053] The flow control apparatus and method can limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the boom cylinder whose load pressure is relatively low during a combined operation of the boom and the arm so that an unnecessary loss of the hydraulic fluid can be prevented, thereby increasing the energy efficiency and thus the fuel efficiency. BRIEF DESCRIPTION OF THE DRAWINGS [0054] The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which: [0055] FIG. 1 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with the prior art; [0056] FIG. 2 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention; [0057] FIG. 3 is an enlarged view showing a pressure compensation type flow control valve shown in FIG. 2 ; [0058] FIG. 4 is an exemplary view showing a modification of a pressure compensation type flow control valve shown in FIG. 2 ; [0059] FIG. 5 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention; [0060] FIG. 6 is a flowchart showing a process for controlling the flow rate of the hydraulic fluid from the hydraulic pump in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention; and [0061] FIG. 7 is a graph showing the relationship between a manipulation amount and a required flow rate of hydraulic fluid in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention. EXPLANATION ON REFERENCE NUMERALS OF MAIN ELEMENTS IN THE DRAWINGS [0000] 1 : engine 2 : variable displacement hydraulic pump 3 : first hydraulic cylinder 4 : second hydraulic cylinder 5 : center bypass path 6 : first control valve 7 : second control valve 8 : first manipulation lever 9 : second manipulation lever 10 : regeneration flow path 11 , 11 a : return flow path 12 : meter-in flow path 13 : regeneration valve 14 : pressure compensation type flow control valve 15 : valve spring 16 : meter-in orifice 17 : spool DETAILED DESCRIPTION OF THE INVENTION [0079] Now, a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is not limited to the embodiments disclosed hereinafter. [0080] In order to definitely describe the present invention, a portion having no relevant to the description will be omitted, and through the specification, like elements are designated by like reference numerals. [0081] In the specification and the claims, when a portion includes an element, it is meant to include other elements, but not exclude the other elements unless otherwise specifically stated herein. [0082] FIG. 2 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention, FIG. 3 is an enlarged view showing a pressure compensation type flow control valve shown in FIG. 2 , FIG. 4 is an exemplary view showing a modification of a pressure compensation type flow control valve shown in FIG. 2 , FIG. 5 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention, FIG. 6 is a flowchart showing a process for controlling the flow rate of the hydraulic fluid from the hydraulic pump in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention, and FIG. 7 is a graph showing the relationship between a manipulation amount and a required flow rate of hydraulic fluid in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention. [0083] Referring to FIGS. 2 to 4 , the flow control apparatus for a construction machine in accordance with an embodiment of the present invention includes: [0084] an engine 1 ; [0085] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to the engine 1 ; [0086] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ; [0087] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 , the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump 2 to be returned to a hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state; [0088] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 , the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump 2 to be returned to the hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state; [0089] a regeneration flow path 10 configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank T from a large chamber of the first hydraulic cylinder 3 during a retractable drive of the first hydraulic cylinder 3 due to an attachment (including a boom, an arm, or a bucket)'s own weight, and a regeneration valve 13 installed in the regeneration flow path 10 ; and [0090] a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of a spool of the first control valve 6 and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 . [0091] The pressure compensation type flow control valve 14 includes a spool having a first position I in which the meter-in flow path is opened by a pressure passing through a meter-in orifice 16 installed in the meter-in flow path 12 and an elastic force of a valve spring 15 , and a second position II in which the meter-in flow path 12 is closed when the spool is shifted by a pressure in the meter-in flow path 12 . [0092] The pressure compensation type flow control valve 14 includes a spool having a first position I in which the meter-in flow path 12 is opened by a pressure passing through a meter-in orifice 16 installed in the meter-in flow path 12 and an elastic force of a valve spring, and a second position II in which the flow rate of the hydraulic fluid is limited through the shift of the spool in a direction in which an opening portion of the meter-in orifice 16 is reduced if the pressure in the meter-in flow path 12 is higher than the elastic force of the valve spring 15 . [0093] The first hydraulic cylinder 3 is a boom cylinder, and the second hydraulic cylinder 4 is an arm cylinder. [0094] In this case, a configuration of the flow control apparatus for a construction machine in accordance with an embodiment of the present invention is the same as that of the conventional flow control apparatus for a construction machine as shown in FIG. 1 , except the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 in order to limit the supply of a relatively large amount of the hydraulic fluid from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 . Thus, the detailed description of the same configuration and operation thereof will be omitted to avoid redundancy, and the same hydraulic parts are denoted by the same reference numerals. [0095] In accordance with the configuration as described above, when a spool of the first control valve 6 is shifted to the right on the drawing sheet by a pilot signal pressure from a pilot pump (not shown) through the manipulation of a manipulation lever, hydraulic fluid discharged from the hydraulic pump 2 is supplied in a limited amount to a small chamber of the first hydraulic cylinder 3 by a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of the first control valve 6 . In this case, hydraulic fluid discharged from a large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the first control valve 6 , the return flow path 11 and the back pressure check valve 18 . Thus, the first hydraulic cylinder 3 is driven to be refracted so that the boom can be driven to perform a boom-down operation. [0096] Meanwhile, when the hydraulic fluid discharged from the large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T due to the retractable drive of the first hydraulic cylinder 3 , a back pressure is formed in the regeneration flow path 10 by the back pressure check valve 18 installed in the return flow path 11 . For this reason, when a pressure within the small chamber of the first hydraulic cylinder 3 is low, the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T can be supplementarily supplied to the small chamber of the first hydraulic cylinder 3 through the regeneration flow path 10 . [0097] In the meantime, when a combined operation of a boom and an arm is performed by a user, i.e., when the first hydraulic cylinder 3 generating a relatively lower pressure is driven to be retracted to perform the boom-down operation of the boom and the second hydraulic cylinder 4 generating a relatively high load pressure is driven to be retracted to perform the arm-out operation of the arm, the supply of the hydraulic fluid from the hydraulic pump 2 to the small chamber of the first hydraulic cylinder 3 is limited by the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 . Thus, the hydraulic fluid discharged from the hydraulic pump 2 is supplied in a reduced amount to the first hydraulic cylinder 3 after passing through the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 (indicated by a line “b” in the graph of the FIG. 7 ), and the remaining hydraulic fluid discharged from the hydraulic pump 2 is supplied to the second hydraulic cylinder 4 (indicated by a line “a” in the graph of the FIG. 7 ). [0098] For this reason, even during a combined operation in which the boom-down operation of the boom is performed by the retractable drive of the first hydraulic cylinder 3 and the arm-out operation of the boom is performed by the retractable drive of the second hydraulic cylinder 4 , the hydraulic fluid discharged from the hydraulic pump 2 can be prevented from being much more supplied to the first hydraulic cylinder 3 in which a relatively low load pressure is generated than in the second hydraulic cylinder 4 . [0099] Meanwhile, as in the pressure compensation type flow control valve 14 shown in FIG. 4 , if a pressure of the hydraulic fluid which is formed in the meter-in flow path 12 is higher than an elastic force of the valve spring 15 , a spool of the pressure compensation type flow control valve 14 is shifted to the left on the drawing sheet. In other words, the spool of the pressure compensation type flow control valve 14 is shifted to the second position II to further reduce an opening portion of the meter-in orifice 16 so that the supply of the hydraulic fluid from the hydraulic pump 2 to the first hydraulic cylinder 3 can be further limited. [0100] Referring to FIG. 5 , the flow control apparatus for a construction machine in accordance with another embodiment of the present invention includes: [0101] an engine 1 ; [0102] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to the engine 1 ; [0103] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ; [0104] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 , the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump 2 to be returned to a hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state; [0105] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 , the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump 2 to be returned to the hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state; [0106] a regeneration flow path 10 configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank T from a large chamber of the first hydraulic cylinder 3 during a retractable drive of the first hydraulic cylinder 3 , and a regeneration valve 13 installed in the regeneration flow path 10 ; [0107] a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of a spool of the first control valve 6 and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 ; [0108] at least one pressure detection sensor Pa, Pb, Pc, Pd configured to detect a pilot pressure that is input to the first and second control valves 6 an 7 to shift the first and second control valves 6 and 7 ; [0109] a controller 20 configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor Pa, Pb, Pc, Pd and output a control signal that corresponds to the calculated required flow rate; and [0110] an electronic proportional valve 22 configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller 20 , to a pump regulator 21 that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump 2 . [0111] In accordance with still another embodiment of the present invention, there is provided a flow control method for a construction machine which includes: [0112] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to an engine 2 ; [0113] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ; [0114] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state; [0115] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state; [0116] a regeneration flow path 10 configured to reuse the hydraulic fluid that returns to a hydraulic tank T from the first hydraulic cylinder 3 by an attachment's own weight and a regeneration valve installed in the regeneration flow path 10 ; [0117] a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of a spool of the first control valve 6 and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 ; [0118] at least one pressure detection sensor Pa, Pb, Pc, Pd configured to detect a pilot pressure that is input to the first and second control valves 6 an 7 to shift the first and second control valves 6 and 7 ; [0119] a controller 20 configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor Pa, Pb, Pc, Pd and output a control signal that corresponds to the calculated required flow rate; and [0120] an electronic proportional valve 22 configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller, to a pump regulator 21 that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump 2 , the flow control method including: [0121] a first step S 10 of allowing the pressure detection sensor to detect the pilot pressure that is input to the first and second control valves 6 an 7 to shift the first and second control valves 6 and 7 through a manipulation of a manipulation lever; [0122] a second step S 20 of calculating the required flow rate of the hydraulic fluid, which corresponds to the detected manipulation amount of the manipulation lever using a relational expression between the manipulation amount and the required flow rate that is previously stored in the controller 20 ; and [0123] a third step S 30 of outputting an electrical control signal that corresponds to the calculated required flow rate to the electronic proportional valve, [0124] wherein the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first and second hydraulic cylinders 3 and 4 by the shifting of the first and second control valves 6 and 7 is set to be equal to or lower than the flow rate of the hydraulic fluid passing through the pressure compensation type flow control valve 14 using the relational expression between the manipulation amount and the required flow rate. For this reason, in the case where the first hydraulic cylinder 3 or the second hydraulic cylinder 4 is driven alone, an excessive pressure can be prevented from being generated due to an increase in the flow rate of the hydraulic fluid discharged from the hydraulic pump 2 . [0125] According the configuration as described above, the spool of the first control valve 6 is shifted to the right on the drawing sheet by a pilot pressure input upon the manipulation of the manipulation lever in order to perform a single boom-down operation of the boom by the retractable drive of the first hydraulic cylinder 3 . In this case, the pressure detection sensors Pa and Pb detect the pilot pressure that is input to the first control valve 6 to shift the first control valve 6 (see S 10 ), and outputs a detection signal to the controller 20 . The controller 20 calculates the required flow rate (Q 1 ) of the hydraulic fluid relative to the manipulation amount of the manipulation lever to correspond to the detected pilot pressure using a relational expression between the manipulation amount and the required flow rate that is previously stored in the controller 20 (see S 20 ). Then, when the controller 20 outputs a control signal corresponding to the calculated required flow rate of the hydraulic fluid to the electronic proportional valve 22 (see S 30 ), the electronic proportional valve 22 outputs, a secondary pressure generated therefrom to correspond to the control signal input thereto output from the controller 20 , to a pump regulator 21 . [0126] Thus, the hydraulic fluid discharged from the hydraulic pump 2 is reduced in the flow rate when passing through the first control valve 6 by the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 of the first control valve 6 . In other words, the hydraulic fluid from the hydraulic pump 2 whose flow rate is reduced by the pressure compensation type flow control valve 14 is supplied to the small chamber of the first hydraulic cylinder 3 . At this point, the hydraulic fluid discharged from the large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the return flow path 11 and the back pressure check valve 18 . [0127] In this case, when there is a shortage in the hydraulic fluid supplied to the small chamber during the retractable drive of the first hydraulic cylinder 3 , the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T is recycled and supplementarily supplied to the small of the first hydraulic cylinder 3 through the regeneration valve 13 of the regeneration flow path 10 . For this reason, even in the case where the supply of the hydraulic fluid to the small chamber of the first hydraulic cylinder 3 is limited, a phenomenon can be prevented in which the hydraulic fluid is deficient in the small chamber of the first hydraulic cylinder 3 by the regeneration flow path 10 and the regeneration valve 13 . [0128] In the meantime, a spool of the second control valve 7 is shifted to the left or the right on the drawing sheet by the manipulation of the manipulation lever to simultaneously perform the boom-down and arm-out operations. In this case, the pressure detection sensors Pc and Pd detect the manipulation amount of the manipulation lever and output a detection signal to the controller 20 . The controller 20 calculates the required flow rate of the hydraulic fluid, which corresponds to the detected manipulation amount of the manipulation lever using a relational expression between the manipulation amount and the required flow rate that is previously stored in the controller 20 . Then, the controller 20 calculates the required flow rates of the hydraulic fluid of the first control valve 6 and the second control valve 7 , respectively, and outputs a control signal corresponding to the calculated required flow rate of the hydraulic fluid to the pump regulator 21 through the electronic proportional valve 22 . [0129] In this case, when a combined operation of the first and second hydraulic cylinders 3 and 4 is performed, the flow rate of the hydraulic fluid required for the arm-out operation of the second hydraulic cylinder (i.e., the arm cylinder) 4 is higher than that of the hydraulic fluid required for the boom-down operation of the first hydraulic cylinder (i.e., the boom cylinder) 3 , and thus the hydraulic pump 2 discharges a maximum amount of the hydraulic fluid. Thus, even in the case where the combined operation of the first and second hydraulic cylinders 3 and 4 is performed to cause the a large amount of the hydraulic fluid is discharged from the hydraulic pump 2 , the supply of the hydraulic fluid from the hydraulic pump 2 to the small chamber of the first hydraulic cylinder 3 is limited by the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 of the first control valve 6 (indicated by a line “b” in the graph of FIG. 7 ). On the other hand, the remaining hydraulic fluid discharged from the hydraulic pump 2 can be used to drive the second hydraulic cylinder 4 (indicated by a line “a” in the graph of FIG. 7 ). [0130] As described above, in the case where a combined operation of the first and second hydraulic cylinders 3 and 4 is performed, a load pressure generated during the drive of the second hydraulic cylinder 4 (i.e., the arm-out operation) is relatively higher than that generated during the drive of the first hydraulic cylinder 3 (i.e., the boom-down operation). For this reason, the hydraulic fluid discharged from the hydraulic pump 2 can be prevented from being much more supplied to the first hydraulic cylinder 3 in whose load pressure is relatively low, thereby avoiding an unnecessary loss of the hydraulic fluid from the hydraulic pump 2 . INDUSTRIAL APPLICABILITY [0131] In accordance with the flow control apparatus and method for a construction machine of the present invention as constructed above, the supply of the hydraulic fluid from the hydraulic pump to a boom cylinder whose load pressure is relatively low can be limited during a combined operation of a boom and an arm so that an unnecessary loss of the hydraulic fluid can be prevented, thereby improving the energy efficiency. [0132] While the present invention has been described in connection with the specific embodiments illustrated in the drawings, they are merely illustrative, and the invention is not limited to these embodiments. It is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention. Therefore, the true technical scope of the present invention should not be defined by the above-mentioned embodiments but should be defined by the appended claims and equivalents thereof.
Disclosed are a flow control device and a flow control method for a construction machine for preventing the loss of fluid exhausted from a hydraulic pump when a boom and an arm of an excavator are operated in combination. The flow control device for a construction machine according to the present invention includes: an engine; a variable capacity hydraulic pump connected to the engine; a first hydraulic cylinder and a second hydraulic cylinder connected to the hydraulic pump; a first control valve disposed in a center bypass channel of the hydraulic pump, the first control valve, in neutral, returning the fluid exhausted from the hydraulic pump to a hydraulic tank and, when switched, controlling the driving, stopping, and direction change of the first hydraulic cylinder; a second control valve disposed downstream of the center bypass channel of the hydraulic pump, the second control valve, in neutral, returning the fluid exhausted from the hydraulic pump to the hydraulic tank and, when switched, controlling the driving, stopping, and direction change of the second hydraulic cylinder; a regeneration fluid channel for supplementing and reusing fluid returned to the hydraulic tank during a compression stroke of the first hydraulic cylinder, and a regeneration valve disposed in the regeneration fluid channel; and a pressure-compensated flow control valve which is disposed in a meter-in fluid channel of a spool of the first control valve and limits the quantity of working fluid supplied from the hydraulic pump to the first hydraulic cylinder when the first hydraulic cylinder and the second hydraulic cylinder are operated in combination.
5
This is a division of application Ser. No. 440,051, filed Nov. 8,1982. BACKGROUND OF THE INVENTION 1. Field of the Invention: The present invention relates generally to locking devices for releasably fixing two rotating members in a given position with respect to each other, and more particularly to such locking devices as utilize push button release mechanisms. 2. Description of the Prior Art: The use of spring-loaded push buttons as locking devices, to lock a pair of mutually sliding members is well known in the art. In general, such locking pin devices are used with collapsible equipment such as folding walkers and other apparatus specially designed for invalids. Representative appliances utilizing various locking devices are disclosed in the following U.S. patents: U.S. Pat. Nos. 3,783,886 to Thomas; 3,840,034 to Smith; 3,945,389 to Smith; 4,056,115 to Thomas; and 4,180,086 also to Thomas. Of the patents recited, U.S. Pat. No. 4,056,115 recognizes that the prior art locking devices, comprising spring-loaded push buttons and the like, are difficult to manipulate, particularly by individuals with limited manual dexterity who frequently require the aid of such appliances. The '115 patent makes reference to various approaches that attempted to minimize or overcome the problem with spring-loaded locking pins. Thus, U.S. Pat. No. 3,688,789 is noted, in addition to those listed above, that describes the use of an actuating lever that when pressed against the frame of the walker draws the locking pin out of its locking hole, and permits the telescoping tubular members to slide with respect to each other. The '115 seeks to remedy the aforementioned deficiencies by providing a retrofittably adaptor comprising a sleeve with a reciprocable plunger disposed therein, which is adapted to align with the conventional push button assembly, to permit the user to urge the push button inward by simple palm depression. Like the prior art devices discussed within its disclosure, the adaptor of the '115 patent provides an inadequate remedy to the basic problem. The disclosed adaptor, when retrofitted, tends to slip in operation, which the result that it can malfuntion in use and thus render the locking mechanism totally inoperable without repair. Further, whether used in a retrofitting capacity, or as part of original construction, the adaptor of the '115 patent does not confer an economy in manufacture of such devices, which is crucial in most instances to the ultimate purchasers thereof. The adaptor of the '115 patent makes use of the conventional spring loaded locking pin which, by its own design is subject to mechanical failure and jamming in use. One of the above listed patents illustrates a variation on the approach taken by the '115 patent, in which locking is effectuated between two members that rotate with respect to each other. Thus, U.S. Pat. No. 3,945,389 disloses a collapsible walker utilizing a corner brace extending from the gate leg to the connecting cross brace, the corner brace having a longitudinal slot therein that passes along a shaft mounted in the corner brace to permit the gate leg to pivot with respect to the cross brace in conventional fashion. The locking means comprises a spring loaded pin or button that extends outward from the cross brace and is adapted to engage a corresponding opening or detent in the corner brace, to lock the gate leg in the opened position with respect to the cross brace. A depressible tab is pivotally mounted on the corner brace and is adapted to communicate with the opening that receives the pin from the cross brace, with a dimple or other protrusion that, when depressed, drives the pin inward to permit the corner brace to slide with respect to the cross brace. While this latter construction differs from that of the '115 patent, it shares the common element of a push button lock that is constructed and operates in the conventional manner, and therefore with the same limitations. Likewise, the exact alignment of the depressible member may vary, and in use, the dimple may wear, so that depression of the pin may be difficult if possible at all, and the invalid may encounter the same mechanical difficulties as with the walker constructions discussed above. A need therefore exists for a revised lock design, for use with invalid walkers and other apparatus having members rotatable with respect to each other, that is of simple and durable design and operation and is reduced in cost of manufacture. SUMMARY OF THE INVENTION In accordance with the present invention a locking assembly is disclosed for use with structural members adapted to pivot into and out of longitudinal alignment with each other. The locking assembly comprises a spring biased combination plunger and latch, mounted for reciprocation within the first pivoting member, and a catch plate mounted on the second pivoting member adapted to releasably engage the combined plunger and latch, and having a collar therein to releasably retain the latch, and track extending from the collar having a width less than the diameter of the collar, to guide the latch as it enters and escapes from the collar. The combined plunger and latch of the present invention comprises a spring biased locking bolt defining at one end, a frustoconical beveled cam adapted to slide along the track of the catch plate and to guide the locking bolt into the collar. A reduced diameter guide rod extends upward from the cam to maintain the line of travel of the latch, through the track of the catch plate. On its opposite end, locking bolt is attached to its rotating member and adapted for spring biased reciprocation. In the instance where the rotating member is a tubular structure, the latch is mounted traverse to the longitudinal axis of the tube, with both ends protruding from appropriate openings therein. The guide rod at the end opposed from the cam, may be fixed in position by the application of a retaining device such as a threaded nut or the like. A spring biasing means, comprising a reduced diameter connecting rod terminating in a land disposed traverse to the axis of the locking bolt and connected to the locking bolt, is provided. An appropriate coil spring may be placed to rest against the land, and at its opposite end, to urge against the interior surface of the tube. In this way, downward depression of the plunger is counteracted upon release, by upward expansion of the spring. In one embodiment of the invention, the catch plate may be open ended. Thus the track may terminate at a mouth, allowing the latch to fully escape from the catch plate. In such instance, the mouth is positioned at a slight acute angle in the direction of the reduced diameter guide rod, to provide a bearing surface to smoothly engage the beveled cam of the latch. In an alternate embodiment, the catch plate has a closed ended track, and the catch plate is pivotally associated with a support bracket,so that it may pivot about 2 points in operation. Thus, after the locking bolt escapes from the collar, the latch travels along the track, while the catch plate pivots into alignment with the tubular member containing the combined plunger and latch. In the instance where this assembly is utilized with an invalid walker, the bracket and catch plate are so positioned that, when the walker is placed in the folded, storage position, the bracket and catch plate are in substantial alignment with the cross brace of the walker. In this embodiment, the bracket is in the plane containing the gate legs, which comprise the other rotating member. The latch includes in combination, a plunger, as the reduced diameter guide rod extends upward and is adapted to slidably receive a plunger knob thereon. The operation of the locking assembly of the present invention is possible with simple palm pressure and is therefore desirable for use by invalids and others of limited dexterity. The construction of the combined plunger and latch is unitary and integrated, so that the difficulties noted with respect to the prior art are eliminated. Also, the simple construction of the present locking assembly facilitates reduced costs of manufacture which is particularly important in the area of invalid appliances. A reduced number of moving parts are required, and the likelihood of breakdown is accordingly minimized. In addition to the specific utility of the locking assembly with invalid devices, it can be seen that a variety of applications exist, in instances where it is desirable to releasably lock rotating articulated structural members with respect to each other. In a yet further aspect of the present invention, an invalid walker is disclosed which comprises a central cross brace, defining cylindrical bearings, and paired gate legs rotatably journaled within said bearings and adapted to rotate from a closed position of co-planar alignment, to an opened position approximately parallel to each other and transverse to the plane of the cross brace. The walker of the present invention includes a locking assembly comprising catch plates mounted upon said gate legs, and corresponding latches with plungers thereon, mounted on the cross brace, on the upper surfaces thereof adjacent to the bearings. Release of the locking assembly, as mentioned earlier, requires simple palm pressure by the user to cause the latch to recede from the collar, whereupon the user may rotate the gate legs toward the cross brace, to close the walker. The walker may be opened and locked in position simply by rotating the legs outward from each other. No further manipulation of the locking assembly is necessary during this procedure. Accordingly, it is a principal object of the present invention to provide a locking assembly for use with two articulated rotatable members, that facilitates operation by palm pressure. It is a further object of the present invention to provide a locking assembly as aforesaid that is of simple and durable construction and operation. It is a still further object of the present invention to provide an invalid appliance utilizing the present locking assembly, that offers ease of manipulation with reduced effort on the part of the user. Other objects and advantages will become apparent to those skilled in the art from a review of the ensuing description which proceeds with reference to the following illustrative drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary perspective of a locking assembly of the present invention. FIG. 2 is an exploded fragmentary view of the locking assembly of FIG. 1. FIG. 3 is a side sectional view of the plunger and latch component of the locking assembly of the present invention. FIG. 4 is a top view of the locking assembly of FIG. 1 with the plunger knob removed, showing the locking assembly in the engaged position. FIG. 5 is a top view similar to FIG. 4 showing the locking assembly in a disengaged position. FIG. 6 is a side sectional view similar to FIG. 3, showing the locking assembly in the engage position. FIG. 7 is a sectional view taken through Line 7--7, in FIG. 5, showing the locking assembly in the disengaged position. FIG. 8 is a fragmentary perspective view of a locking assembly in accordance with an alternate embodiment of the invention. FIG. 9 is a perspective of an invalid walker in accordance with the present invention. DETAILED DESCRIPTION Referring to FIG. 1, the locking assembly of the present invention is illustrated in perspective and comprises a spring biased reciprocating latch 2, a plunger 4 attached to latch 2, and a catch plate 6 adapted to releasably engage latch 2. The present locking assembly is adapted for use with paired articulated pivoting members, to enable such members to remain fixed with respect to each other at a given point along their respective paths of rotation. The fragmentary illustration in FIG. 1 relates to a specific instance of such articulation, and is drawn from the device illustrated in FIG. 9, which comprises a foldable walker. The first pivoting member 8 in FIG. 1 comprises the adjacent portion of the cross brace of the foldable walker, including its bearing sleeve 10, and the cross bar 12, in which latch 2 is mounted. The second pivoting member utilized in the present illustrations, comprises a sleeve 14 that is fixedly mounted upon one of the connected gate legs 16, that is positioned within bearing sleeve 10 and is adapted for rotation there within. The general environment of this construction is well known in the art, and is illustrated in the U.S. patents listed earlier herein and incorporated herein by reference. In the present invention, and as shown in FIG. 1, sleeve 14 is provided with catch plate 6 that is essentially planar and extends outwardly and generally transverse to the axis of sleeve 14. It can be visualized that as sleeve 14 rotates counter clockwise with gate leg 16, catch 6 will rotate into communication with latch 2. Essentially, then, sleeve 14, gate leg 16 and bearing sleeve 10 correspond in construction to a conventional hinge, so that the applicability of the present invention to alternate constructions wherein rotating articulated members are concerned, can be seen. Referring now to FIG. 2, latch 2 can be seen to comprise a longitudinally extended locking bolt 18 that is adapted to retractably protrude from the first pivoting member comprising cross bar 12. Latch 2 is mounted transverse to the axis of cross bar 12 as shown, and appropriate holes 20 and 22 are provided in cross bar 12 for this purpose. In particular, hole 20 has a diameter sufficient to permit locking bolt 18 to pass freely therethrough. Hole 22, when provided, may be of lesser diameter than hole 20, to receive and engage the anchoring means associated with locking bolt 18, and discussed later on herein. Preferably, locking bolt 18 is essentially cylindrical as shown, though it is to be understood that exact cross sectional shape may vary. Thus, though not illustrated herein, locking bolt 18 may be triangular, square or rectangular in cross section, with an appropriately configured hole 20, permitting passage of locking bolt 18 therethrough. Such variations are contemplated within the scope of the present invention. Referring further to FIG. 2, latch 2 includes a reduced diameter guide rod 24 that extends upward from locking bolt 18, and is positioned externally with respect to cross bar 12. Guide rod 24 serves to position catch 6 with respect to latch 2 during their engagement, in the manner illustrated more particularly in FIGS. 4-8 herein. Particularly and as will be discussed with reference to FIG. 8, guide rod 24 provides one of two pivot axes upon which the catch plate illustrated therein translates into a position of substantial alignment with cross bar 12 when the locking assembly is in its fullest disengagement. Referring further to FIG. 2 a preferably frustoconical cam surface 26 is defined between locking bolt 18 and guide rod 24. Cam surface 26 is adapted to slidably engage catch plate 6 during its travel past latch 2. Thus, as illustrated in FIGS. 5 and 7, catch plate 6 rides along the beveled surface of cam 26 both after and before locking bolt 18 is engaged. Cam 26 also cooperates with the catch plate 6 to assure a smooth initial engagement thereof, in the embodiment illustrated in FIGS. 1-7, as described below. Catch plate 6 defines a collar 28 that is adapted to releasably retain locking bolt 18, as shown clearly in FIG. 4. Collar 28 is preferably sized and configured to correspond to the cross sectional configuration of locking bolt 18, as noted earlier. In particular, collar 28 slidably receives locking bolt 18 and is thus desirably sized to permit slidable reception and firm retention thereof. Catch plate 6 includes a track 30 that communicates with collar 28 as illustrated and defines an access way for latch 2 to enter an escape from collar 28. As shown in FIGS. 5 and 7, guide rod 24, cam 26 and track 30 cooperate during the relative movement of catch plate 6 with respect to latch 2. As shown in FIGS. 4 and 5, the width of track 30 generally corresponds to the diameter of guide rod 24, and is sufficiently larger to permit unobstructed rovement of guide rod 24 through track 30. The exact dimension of track 30 is not critical, so long as it is less than the diameter of collar 28, so.as to permit collar 28 to successfully perform its function. Referring again to FIG. 2, plunger 4 is mounted on guide rod 24 on the free end thereof, and is provided to receive and transmit pressure against locking bolt 18, to urge locking bolt 18 into the retracted position shown in FIGS. 5 and 7, to permit latch 2 to disengage from collar 28. The exact shape and size of plunger 4 may vary depending upon its application. In the instance where the locking assembly is utilized in a device for the physically handicapped and infirm, plunger 4 is preferably rounded and of sufficiently large size to permit comfortable application of palm pressure by the infirm individual, to release latch 2 from catch plate 6 as described. Also, plunger 4 may be prepared from a variety of structural materials, again depending upon its ultimate use, and may, in the instance of collapsible invalid walkers, be prepared from a relatively hard synthetic resinous material. Optionally, plunger 4 may be provided with a relatively soft flexible cover, to add greater comfort to the user. Such modifications are considered within the scope of the present invention. Latch 2 includes a spring biasing means associated with locking bolt 18, as illustrated in FIG. 2 in detail. The spring biasing means may be mounted within the first pivoting member, cross bar 12 for example, and is adapted to resist the retraction of locking bolt 18, that is caused by the exertion of force against plunger 4. The spring biasing means as illustrated comprises a reduced diameter connecting shaft 32 that extends from locking bolt 18 in a direction away from plunger 4, and provides a support and guide for coil spring 34 that is adapted to ride thereover. A transverse surface of locking bolt 18 facing away from cam 26 comprises a land 36 against which one end of coil spring 34 abuts. At its other end, coil spring 34 as illustrated, urges against the stationary inside wall 38 of cross bar 12 adjacent hole 22. The spring biasing means includes an anchoring means that secures spring 34 in position. The anchoring means illustrated herein, comprises a threaded end 40 of connecting shaft 32, and an appropriately threaded nut 42 and associated washer 44. As shown in FIG. 3, nut 42 and washer 44 engage threaded end 40 of connecting shaft 32, to anchor latch 2 within cross bar 12, but to permit latch 2 to reciprocate in response to force applied against plunger 4. The construction of latch 2 can thus be seen to be extremely simple, as few moving parts are involved. This simplicity in construction effects a corresponding economy and manufacture as well as durability and use, because fewer parts must be made which could break down over time. As mentioned earlier, the present invention contemplates alternate embodiments, wherein the catch plate 6 varies in construction. In the embodied illustrated in FIGS. 1-7, the catch plate 6 is open ended and track 30 terminates in a mouth 46 that may be slightly outwardly flared, as illustrated in FIG. 1, or simply a continuation of track 30, as illustrated in FIG. 2. Mouth 46 permits catch plate 6 to completely disengage from latch 2 as shown in FIG. 1. The catch plate 6 as illustrated in this first embodiment is stationary with respect to its supporting pivoting member, sleeve 14. The employment of the catch plate of this embodiment confers an economy in manufacture and operation, as catch plate 6 per se is not a moving part. Referring further to the FIGURES, catch plate 6 as illustrated in this first embodiment, is preferably essentially planar, however mouth 46 is disposed at a slight incline, in the direction of plunger 4. This incline is suggested in FIG. 1 and seen more clearly in the frontal view of catch 6 in FIG. 2, and in the side view thereof in FIG. 7. This incline permits mouth 46 to slide over the beveled surfaces of cam 26 as catch plate 6 engages latch 2, and gradually urges latch 2 downward so that locking bolt 18 assumes the retracted position necessary to permit catch plate 6 to travel there past. The exact angular displacement of the incline of mouth 46 is not critical, and may comprise any generally acute angle. Preferably, however, such angle should probably not exceed 45°, as too sharp an incline may develop resistance during the engagement of mouth 46 with cam 26. An alternate embodiment of the locking assembly is illustrated in perspective in FIG. 8 wherein the catch plate 48 comprises a movable strip defining a collar 50 at one end thereof and a longitudinally extended closed track 52 connected thereto. Catch plate 48 may be attached to sleeve 14 by pivotal mounting upon support bracket 54 that is positioned 180° away from catch plate 6 as illustrated in FIG. 1. Catch plate 48 is pivotally attached to support bracket 54 about pivot axis 56, and is adapted as shown to pivot about a second axis defined by guide rod 24. Thus, when bracket 54 is rotated into axial alignment with cross bar 12, catch plate 48 travels along guide rod 24 and moves into a position of general axial alignment, as well. While this position is not illustrated herein, the movement of catch plate 48 is similar to that shown in FIG. 4 of U.S. Pat. No. 3,945,389, and the relevant disclosure thereof is accordingly incorporated herein by reference. In accordance with a further embodiment of the present invention, a collapsible walker may be constructed as shown in FIG. 9. Walker 60 comprises a cross brace 62 comprising parallel cross bars 64, similar to the cross bar element 12 illustrated in FIG. 1, and transversely extending laterally positioned bearings 66. Substantially U-shaped gate legs 68 are disposed in pairs with connecting U portions 70, conventionally utilized by the invalid for support during walking. The forward most gate legs are seen to be mounted within bearings 66 for rotation therein in conventional manner. As can be visualized, gate legs 68 can rotate from the opened position illustrated in FIG. 9, to the closed position seen regularly in the patents cited of record earlier herein. Walker 60 includes the locking assembly of the present invention generally designated 72. In particular two locking assemblies 72 are shown, positioned at the lateral extermities of the upper cross bar 64. Latches 74 are positioned within cross bar 64, while catch plates 76 are mounted upon sleeves 78 fixedly mounted upon the adjacent portion of gate legs 68. Without further illustration herein, it is apparent that the depression of plungers 80, by palm pressure of the user, permits the user to rotate gate legs 68 toward each other, to thereby collapse walker 60 for storage during non-use. Correspondingly, simple outward rotation of gate legs 68 is all that is necessary to resume the open operable position, as the mouth of catch plate 76 engages the cam surface of the latch 74 as described earlier, depressing the latch until alignment is reached between the latch 74 and the collar 82 of catch plate 76, whereupon latch 74 springs upward into locking engagement. As mentioned earlier, the present locking assembly is useful with a variety of products, wherein articulated rotating members are desirably releasably fixed in position with respect to each other. Thus, the present invention could be utilized with folding furniture and other structural products in addition to the invalid appliances, one of which is illustrated herein. Correspondingly, while the present invention is graphically illustrated as manufactured from metal, it is to be understood that other suitable structural materials may be utilized, depending upon the end use of the products involved. Thus, while light weight materials such as aluminum may be employed, other metals such as steel, copper and the like are also suitable. Additionally, suitable structural plastics having desired hardness, resilience, formability and surface lubricating properties are contemplated herein and may all be used. It is understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are suitable of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within the spirit and scope and defined by the claims.
A locking assembly is disclosed which is suitable for releasably locking two articulated pivoting members in a fixed position with respect to each other. The locking assembly comprises a spring biased reciprocating latch, a plunger attached to the latch, and a catch plate adapted to rotate into locking engagement therewith. The plunger and latch are preferably integral with each other, so that the latch contains a minimum number of moving parts. The latch is designed so that simple palm pressure will cause it to disengage from the catch plate, to permit the pivoting members to move with respect to each other. The present locking assembly is of simple design and inexpensive manufacture, and is durable in use. The locking assembly is particularly applicable for use in invalid appliances such as collapsible walkers, where the users have limited manual dexterity. The simple design of the present locking assembly assures a minimum of mechanical breakdown in use, that is particularly important in the instance where the user of the device is infirm or elderly. The present invention also includes a collapsible walker utilizing the present locking assembly.
5
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to loading and drive mechanisms for cartridge-type tape recorders, and more particularly, such mechanisms for single-drive tape recorders adapted for receiving magnetic tape cartridges having a notch on either side edge. 2. Description of the Prior Art It is desirable in tape recorders adapted for receiving magnetic tape cartridges to have means for firmly and accurately positioning the cartridge three dimensionally. Prior art loading devices are complicated mechanisms and often these devices, such as that disclosed in Anthony Loeschner-Robert A. Wolf U.S. Pat. No. 3,485,500, do not supply a vertical force on the inserted cartridge for three-dimensional alignment. This can cause misalignment of the tape with respect to the playing instrumentalities. It is also desirable that the driving apparatus be mounted in a rigid arrangement. In prior art loading and drive systems, the drive motor is typically brought into contact with the belt capstan of the magnetic tape cartridge. After the cartridge is locked in an aligned position, the capstan drive, which extends from the spring-mounted drive motor, is spring loaded against the belt capstan, exerting against it a predetermined driving force. Such a motor mounting arrangement is complex and risky, and especially prone to jarring during transport of the tape recorder. The jarring may affect the performance of the motor, reducing its reliability as a driving mechanism. A spring loaded motor is also more prone to producing capstan misalignment problems. Therefore, it would be advantageous to have a simple mechanism that can both hold a cartridge accurately in place three dimensionally and engage the cartridge against a stationary capstan drive for proper driving. It is also desirable that the mechanism be rugged and have substantially no movable parts during transport. SUMMARY OF THE INVENTION Accordingly, one object of the present invention is to accurately position a tape cartridge in three-dimensional space. A second inventive object is to load the tape cartridge against the stationary capstan drive with the proper driving force. A third inventive object is to provide a loading and drive mechanism which is simple, yet reliable and accurate. A fourth inventive object is to provide a loading and drive mechanism which is rugged and has substantially no movable parts during transport. The foregoing objects and others are achieved by the utilization of two simple overcenter loading cams which urge the tape cartridge vertically against reference surfaces and horizontally against a stationary capstan drive with the proper driving force, thereby reliably positioning the cartridge in the tape recorder. Alignment of the tape cartridge with respect to the capstan drive simultaneously positions the cartridge with respect to the other playing instrumentalities in the tape recorder. The loading and drive mechanism is quite simple yet rugged. The proper driving force is maintained by the cams pressing the cartridge against the drive roller of the stationary capstan drive. As the capstan drive is a stationary hardstop for the inserted cartridge, the drive motor is no longer spring-mounted. Hence, it is more rugged, and there is less chance of shaft deformation or jarring of the mounting arrangement from handling. The stationary positioning of the capstan drive also assures greater alignment of the magnetic tape cartridge with respect to the tape head, which is advantageously aligned with respect to the stationary capstan drive. The overcenter loading cams are not subject to jarring during transport. A substantial force must be exerted against the cams before they can be operated, hence, any normal movement during transportation will not affect their loading and drive performance. The invention and its further objects, features, and advantages will be readily discerned from a reading of the description to follow of illustrative embodiments. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of the mechanism partially in section constructed in accordance with the present invention with the magnetic tape cartridge partially inserted; FIG. 2 is a sectional view of the mechanism along line 2--2 of FIG. 1 during initial insertion of the magnetic tape cartridge; FIG. 3 is the sectional view of mechanism shown in FIG. 2 when the cartridge is partially engaged in the tape recorder; FIG. 4 is the sectional view shown in FIG. 2 of the mechanism when the cartridge is in final engagement in the tape recorder; and FIG. 5 is a sectional view of a second embodiment of the cam means constructed in accordance with this invention. DETAILED DESCRIPTION Shown in FIG. 1 is a baseplate-mounted cartridge 10, similar to the structure described in Robert A. Von Behren U.S. Pat. No. 3,692,255, issued Sept. 19, 1972, in which cartridge 10 comprises two tape reels (not shown) and a belt capstan 14 mounted on a baseplate 16; the shell and other parts of cartridge 10, not material to the present invention, have been omitted from FIG. 1 for the sake of clarity. Baseplate 16 of cartridge 10 is substantially rectilinear, having a forward edge 18 and a notch 20 on either side edge 22. Belt capstan 14, which drives the tape reels with a drive belt (not shown), and the tape reels are advantageously aligned with respect to baseplate 16. In the preferred embodiment of the invention, the baseplate surfaces are used to position cartridge 10 in tape recorder 30; the baseplate side edges 22 protrude beyond the cartridge shell on either side of the cartride (the cartridge shell is not shown). While the invention is advantageously disclosed for loading a base-plate mounted cartridge, it is appreciated that the loading and drive mechanism, constructed in accordance with this invention, is suitable for any rectilinear magnetic tape cartridge having a forward edge and a notch on either side edge. It may sometimes be advantageous to utilize the surfaces of the cartridge shell along with the cartridge base as the cartridge positioning surfaces for alignment in the tape recorder. It is also appreciated that cartridge 10 may consist of a pinch roller (not shown) rather than a belt capstan 14, by which the cartridge magnetic tape is then directly driven. Also shown in FIG. 1 is a simplified version of a typical single-drive tape recorder 30, illustrating only so much of the tape recorder as is necessary to orient and explain the invention. Rigidly mounted to a mainplate 32 is a drive motor 34. A capstan drive 36 which comprises a drive roller 37 and a drive shaft 38 extends from drive motor 34. Capstan drive 36, while capable of rotation about its shaft's axis, is traversely fixed in position, forming a hardstop against further movement of cartridge 10 in tape recorder 30 as constructed in accordance with this invention. To guide cartridge 10 towards capstan drive 36 is a bed 40 which forms a cartridge receiving path depicted by arrow 41. Bed 40 comprises mainplate 32, which forms a platform, with sidewalls 44 mounted near either side edge of mainplate 32. At the cartridge receiving end of bed 40, the sidewalls 44 advantageously have tapered surfaces 43 to facilitate cartridge insertion into path 41. The surfaces of sidewalls 44 and mainplate 32 guide cartridge 10 to assure ease of entry of cartridge 10 during insertion. The sidewalls 44 are advantageously made of a low-friction material which has good dimensional stability; such materials are conventionally known in the art. It is appreciated that sidewalls 44 may be flanged at their base to form guiding surfaces in place of the guiding surface provided by mainplate 32. Extending from each side wall 44 is a projection 46 which hangs over mainplate 32. The bottom surface of each projection 46, which substantially faces mainplate 32, is accurately aligned with respect to capstan drive 36 to form a vertical reference surface 47, against which baseplate 16 is lodged upon final engagement of cartridge belt capstan 14 to drive roller 37. Advantageously, there is substantial leeway for baseplate 16 between reference surfaces 47 and mainplate 32. This is desirable in easing cartridge entry and reducing potential wearing of the guiding surfaces from repeated insertion of cartridge 10. Also, the projections 46 advantageously have tapered surfaces 45 to further facilitate cartridge insertion. While the cartridge receiving path 41 in the preferred embodiment is not enclosed, it is appreciated that in some circumstances, an enclosed cartridge receiving cavity is desirable in which the ceiling is advantageously used as vertical reference surface 47'. This is preferable where the cartridge shell surfaces are used to position the cartridge 10' in tape recorder 30'. Near each side wall 44 is a cam means constructed in accordance with this invention. Each cam means comprises an overcenter loading cam 50 pivotally mounted to mainplate 32 with a pin 52, as shown in FIG. 1. Cams 50 rotate about an axis substantially parallel to cartridge forward edge 18 upon cartridge insertion in bed 40. To permit access of cams 50 into cartridge receiving path 41 are openings 55 in mainplate 32 near the side walls 44, also illustrated in FIG. 1. In the preferred embodiment of the loading and drive mechanism, each overcenter loading cam 50 has a first finger 54 that protrudes into cartridge receiving path 41 prior to substantial insertion of tape cartridge 10, and a second finger 56 that protrudes into cartridge receiving path 41 against the corresponding cartridge notch 20 on either side edge of baseplate 16 during final engagement of cartridge 10 with capstan drive 36. Each cam 50 has a slot 58 substantially along the length of first finger 54. In each cam means a coil spring 59 is attached to the corresponding cam 50 in slot 58 at one end and fixed at the other, advantageously to mainplate 32 with pin 62 as depicted in FIG. 2. Preferably, each coil spring 59 is supported on a spring slide 64, or equivalent, to permit easy movement of coil spring 59 along the length of the corresponding cam slot 58. Each spring 59 has a first and second stable position at either slot end, 60 and 61 respectively, toward which the spring end, which is attached to cam slot 58, moves. In turn, each spring 59 biases the corresponding cam 50 toward a first and second stable state. During final engagement between cartridge 10 and capstan drive 36, a means for urging cartridge 10 against the vertical reference surfaces 47 to supplement the upward forces of the cams 59 is desirable. In the preferred embodiment, a low-friction roller 48 supplies a gentle upward pressure near the entrance of bed 40 against cartridge 10 upon cartridge insertion. As shown in FIG. 2, roller 48 is mounted on holder 49 in a recess 42 of mainplate 32. Holder 49 is supported by a leaf spring 51 that is attached to mainplate 32 with pin 53; holder 49 may be formed as an integral part of leaf spring 51. Roller 48 protrudes into cartridge receiving path 41. To provide a more complete understanding of the invention, the operation of the locking and drive mechanism of the preferred embodiment is explained in further detail. Only one of the cam means is illustrated. Referring to FIG. 2 of the drawing, cartridge 10 has been manually inserted into bed 40. The side edges 22 of cartridge baseplate 16 are laterally positioned during cartridge insertion by the guiding surfaces of bed 40 to prevent twisting and turning of cartridge 10. As cartridge 10 is moved toward capstan drive 36 by manual force exerted in the direction depicted by arrow 66; forward edge 18 of cartridge baseplate 16 contacts the first finger 54 of each cam 50 at either side of bed 40. Further manual insertion causes the rotation of cams 50 in the clockwise direction as viewed in FIG. 3 about their pivotal axes. The cams 50 tend to resist the insertion of cartridge 10 at this point due to the biased force of the coil springs 59 towards their first stable position 60, as depicted in FIG. 2. As the cams 50 rotate clockwise, the second fingers 56 of cams 50 enter cartridge receiving path 41, engaging the corresponding cartridge notches 20. At the same time, the coil springs 59 move upward along the corresponding cam slots 58. After substantial rotation of cams 50, spring 59 of each cam means has moved into an overcenter position along cam slot 58 whereby spring 59 no longer resists the clockwise rotation of the corresponding cam 50 as illustrated in FIG. 3. Each spring 59 then seeks its second stable position 61. Shown in FIG. 4 each spring 59 in biasing towards position 61, urges the corresponding cam 50 to rotate further in the clockwise direction. Each cam 50, in turn, pulls cartridge 10 further into cartridge receiving path 41 with its second finger 56; this pull can be felt by the hand manually inserting cartridge 10 and is a reliable indication that cartridge 10 is being placed in full engagement with drive roller 37. The cams 50 rotate further until the second fingers 56 urge, through their contact with corresponding cartridge notches 20, cartridge belt capstan 14 horizontally against drive roller 37 as illustrated in FIG. 4, advantageously with a predetermined driving force. Simultaneously through the same points of contact therewith, the second fingers 56 also urge cartridge 10 against the vertical reference surfaces 47. Near the entrance of bed 40 roller 48 urges cartridge 10 to lodge against the vertical reference surfaces 47 thereby ensuring that cartridge baseplate 16 is completely normal to capstan drive shaft 38, as shown in FIG. 4. To eject cartridge 10 a manual force must be applied to pull cartridge 10 out of bed 40, during which there is resistance by the cam means initially, as the springs 59 are biased toward their second stable position 61. Similar to the cartridge insertion operation, as manual force is exerted to remove cartridge 10, the cams 50 rotate to gradually cause the springs 59 to move past an overcenter point along the corresponding cam slots 58. Accordingly, the springs 59 move toward their first stable positions 60, rotating the cams even further to create a "pushing out" force against cartridge 10 which can be felt by hand, thereby ensuring that ejection has occurred. FIG. 5 shows another embodiment of the loading and drive mechanism constructed in accordance with this invention. Each cam means comprises an overcenter loading cam 68 having a first finger 69 to be contacted by cartridge forward edge 18 during cartridge insertion, and a second finger 70 for engaging cartridge 10 through the corresponding cartridge notch 20 in response to substantial cartridge insertion. A cam pin 71 is mounted to the surface of cam 68, the surface of said cam being substantially perpendicular to the cam's pivotal axis; cam pin 71 is preferably made of low friction material. A leaf spring 72 is fixedly mounted at one end, preferably to mainplate 32 at point 75, and in slidable contact along its length with cam 68 through pin 71. Cam 68 is biased toward a first state 73 by spring 72 prior to substantial insertion of cartridge 10, as shown in FIG. 5. Also, illustrated in FIG. 5 is a dotted outline of cam 68 being biased towards a second state 74 by spring 72 during engagement of cartridge 10 against drive roller 37. Upon rotation of cam 68 in response to contact by cartridge foward edge 18 during manual insertion of cartridge 10, cam pin 71 rotates also in the clockwise direction as viewed in FIG. 5. At the same time, pin 71 moves along the length of spring 72 to the right and displaces spring 72 vertically in the upward direction as pin 71 rotates. As spring 72 seeks its original undisplaced position, it resists the rotation of cam 68, biasing cam 68 toward first stable state 73. As cam 68 rotates further, pin 71 reaches an overcenter point along the length of spring 72 where the clockwise rotation is no longer resisted by spring 72. Instead, spring 72, in seeking its original undisplaced position, urges pin 71 further along its length, biasing cam 68 toward second stable state 74. Also, as cam 68 rotates, cam second finger 70 enters path 41 to engage the corresponding cartridge notch 20 and to cause further insertion of cartridge 10. Upon engagement of belt capstan 14 against drive roller 37, cam rotation ceases, as does further movement of pin 71 along spring 72. During final engagement, second finger 70 urges cartridge 10 vertically against vertical reference surfaces 47, as well as horizontally against drive roller 37. 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.
Positioning a magnetic tape cartridge with respect to a stationary capstan drive is achieved with great accuracy in this invention by simple overcenter loading cams which bias the cartridge horizontally against the capstan drive, as well as vertically against reference surfaces. The cartridge is thus reliably positioned with precision in the tape recorder.
6
FIELD OF THE INVENTION [0001] This invention relates in general to wellbore completion and hydrocarbon production and, in particular, to a novel method of completing and producing long lateral wellbores. BACKGROUND OF THE INVENTION [0002] When a well is drilled, production casing is set so that the well can be properly cemented and the production zone(s) do not have fluid communication with other geological strata. The production zone is logged and then the production casing is perforated so that oil and/or gas can be drained from the production zone into the production casing of the well. Traditionally, hydrocarbon wells were drilled vertically down to and through one or more hydrocarbon production zone(s). As shown in FIG. 1 , a vertical wellbore 10 having a production casing 12 passes through a hydrocarbon production zone 14 . A plurality of perforations (not shown) formed in the production casing 12 using methods well known in the art permit hydrocarbons 16 to flow into the production casing 12 . The casing perforations also permit the production zone 14 to be treated to stimulate production by creating a plurality of fractures 18 in the production zone 12 using, for example, hydraulic fracturing techniques that are well known in the art. A production tubing 20 is used to deliver the hydrocarbons 16 to the surface. A packer 22 seals the annulus between the production tubing 20 and the production casing 12 . [0003] Vertical wellbores have now been substantially abandoned in favor of more productive lateral wellbores that provide more exposure to the production zone. Although the first recorded true lateral well was drilled near Texon, Tex. in 1929, new technology developed over the last decade has permitted lateral drilling techniques to rapidly evolve. Hydrocarbon wells are now drilled vertically to a point above the production zone and then curved so that the wellbore enters the production zone at an angle and continues laterally within the production zone for more in-zone exposure to the hydrocarbon bearing formation. Some production zones are up to 300 feet (91.5 meters) thick, or more, and with lateral drilling techniques casing can be run up to 8,000 ft. (2.44 kilometers) into the production zone, thus providing significantly more area for hydrocarbons to drain into the production casing. [0004] FIG. 2 is a schematic cross-sectional diagram of an exemplary prior art hydrocarbon well 30 with a lateral wellbore. Well know features such as the conductor and surface casing are not shown. A vertical section 32 of the hydrocarbon well 30 is drilled down into proximity of a production zone 14 , cased and cemented in a manner well known in the art. In many areas, the vertical section of the well may be 10,000 feet (3.05 kilometers) in length. In some areas the vertical section may exceed 10,000 feet (3.05 kilometers) in length. A curved section 34 of the hydrocarbon well 30 is then drilled into the production zone 14 . Once it is established that the curved section 34 is in the production zone 14 , a lateral wellbore 36 is drilled in a desired direction in as straight a path as possible within the production zone 14 . Recent innovations in work strings for completing lateral wellbores described in applicant's co-pending U.S. patent application Ser. No. 14/735,846 filed Jun. 10, 2015, the specification of which is incorporated herein by reference, permit lateral wellbores of at least 12,000 feet (3.66 kilometers) to be successfully completed. After the lateral wellbore 36 is drilled, a production casing 38 is run into the lateral wellbore 36 . The production casing 38 is generally “cemented in” before it is perforated for production. In any event, sections of the production casing 38 are perforated and stimulated using methods known in the art until an entire length of the production casing 38 has been perforated and the surrounding production zone 14 has been stimulated. A production tubing 42 is then run into the well and a packer 44 is set to seal the annulus. In a very long lateral bore, stimulation of the production 14 surrounding the lateral well bore 36 is a major undertaking and now costs more than drilling, casing and cementing the bore. Once stimulation and flow-back of stimulation fluids are completed, production of hydrocarbons from the wellbore 30 begins. In a shale basin such as found in the Bakken play, production is generally commercially viable for about 2 years, and may be extended by reworking the well using methods known in the art. [0005] While the lateral wellbore method has been commercially successful, the potential for innovative production strategies has yet to be realized. [0006] There therefore exists a need for a novel method of completing and producing long lateral wellbores. SUMMARY OF THE INVENTION [0007] It is therefore an object of the invention to provide a novel method of completing and producing long lateral wellbores. [0008] The invention therefore provides a method of producing hydrocarbons from a cased and cemented long lateral wellbore, comprising: preparing a first production section of the long lateral wellbore for production, the first production section having a length of less than a total length of the long lateral wellbore; producing hydrocarbons from the first production section until production from the first production section is uneconomic; setting a plug to plug off the first production section of the long lateral wellbore; preparing a next production section of the long lateral wellbore for production, the next production section having a length of less than a total length of the long lateral wellbore; producing hydrocarbons from the next production section until production from the next production section is uneconomic; if hydrocarbons have not been produced from the entire long lateral wellbore, plugging off the next production section of the long lateral wellbore; and repeating the steps of preparing a next production section and producing from the next production section until an entire length of the long lateral wellbore has been prepared for production and produced until production from the long lateral wellbore is uneconomic. [0009] The invention further provides a method of producing hydrocarbons from a cased and cemented long lateral wellbore, comprising: preparing a first production section of the long lateral wellbore for production, the first production section having a length of less than a total length of the long lateral wellbore; producing hydrocarbons from the first production section until production from the first production section is uneconomic; pulling production equipment from the long lateral wellbore; setting a plug to plug off the first production section of the long lateral wellbore; preparing a next production section of the long lateral wellbore for production, the next production section having a length of less than a total length of the long lateral wellbore; running the production equipment back into the long lateral wellbore; producing hydrocarbons from the next production section until production from the next production section is uneconomic; pulling the production equipment from the long lateral wellbore; pulling the plug from the long lateral wellbore; running the production equipment back into the long lateral wellbore until a packer is in an unperforated region between the first and next production sections of the long lateral wellbore; setting the packer in the unperforated region; installing a tubing at a wellhead of the long lateral well bore; pumping enhanced oil recovery flood fluid through the tubing into an annulus of a production casing of the long lateral wellbore, and hence down the annulus and through perforations in the production casing of the next production section; and producing hydrocarbons through a production tubing associated with the packer until the production of hydrocarbons is uneconomic. [0010] The invention yet further provides a method of producing hydrocarbons from a cased and cemented long lateral wellbore, comprising: drilling a plurality of long lateral wellbores from a single well pad; preparing a first production section of each of the long lateral wellbores for production, the first sections having a length of less than a total length of the respective long lateral wellbores; producing hydrocarbons from the first production sections of the respective long lateral wellbores until production from the respective first production sections becomes uneconomic; setting a plug to plug off the first production section of each of the respective long lateral wellbores; preparing a next production section of the respective long lateral wellbores for production, the respective next sections having a length of less than a total length of the respective long lateral wellbores; producing hydrocarbons from the respective next production sections until production from the respective next production sections becomes uneconomic; if hydrocarbons have not been produced from an entire length of the respective long lateral wellbores, plugging off the next production section of the respective long lateral wellbores; and repeating the steps of preparing a next production section and producing from the next production section until an entire length of the respective long lateral wellbores have been prepared for production and produced until production from the respective long lateral wellbores becomes uneconomic. BRIEF DESCRIPTION OF THE DRAWINGS [0011] Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, in which: [0012] FIG. 1 is a schematic cross-sectional diagram of an exemplary prior art vertical hydrocarbon well; [0013] FIG. 2 is a schematic cross-sectional diagram of an exemplary prior art lateral hydrocarbon well; [0014] FIG. 3 is a schematic-cross sectional diagram of a lateral hydrocarbon well with a first section completed for production using the method in accordance with the invention; [0015] FIG. 4 is a schematic-cross sectional diagram of the lateral hydrocarbon well shown in FIG. 3 with a second section completed using the method in accordance with the invention; [0016] FIG. 5 is a schematic cross-sectional diagram of a portion of a lateral wellbore completed using a method in accordance with the invention. [0017] FIG. 6 is a schematic cross-sectional diagram of the lateral hydrocarbon well shown in FIG. 4 configured for enhanced oil recovery using the method in accordance with the invention; [0018] FIG. 7 is a schematic cross-sectional diagram of the lateral hydrocarbon well shown in FIG. 4 configured in another way for enhanced oil recovery using the method in accordance with the invention; [0019] FIG. 8 is a schematic cross-sectional diagram of a detail of a lateral hydrocarbon well configured for enhanced oil recovery in accordance with the invention; and [0020] FIG. 9 is a schematic diagram of lateral hydrocarbon wells drilled using methods in accordance with the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0021] The invention provides a method of completing lateral wellbores that leverages the potential of long lateral wellbores enabled by current lateral boring and completion equipment and techniques. Lateral wellbores in excess of 12,000 linear feet (3.66 kilometers) may now be drilled and completed. In accordance with the invention, such wellbores are completed in two or more production sections, and hydrocarbon is produced from each production section until production from that production section is exhausted or no longer commercially viable. In accordance with a further aspect of the invention, 2 or more lateral wellbores are drilled from the same drill pad and each wellbore is produced in production sections until all the wellbores in each pad have been produced. In accordance with a yet a further aspect of the invention, perforation and stimulation of each production section is carefully planned to permit the respective production sections to be re-stimulated if desired. In accordance with yet a further aspect of the invention, enhanced oil recovery (EOR) is practiced within a lateral wellbore by pumping EOR flood fluids down a work string into a first production section and producing hydrocarbons up the annulus of the production casing from a second production section, or pumping EOR flood fluids down the annulus of the production casing into the second production section and producing hydrocarbons up the work string from the first production section. [0022] FIG. 3 is a schematic-cross sectional diagram of a lateral hydrocarbon well 100 having a production casing 101 , with a first production section 102 completed for production using the method in accordance with the invention. Modern drilling techniques permit very long lateral wellbores to be drilled and completed. This permits hydrocarbon deposits under natural bodies of water such as rivers 104 and/or cities 106 to be exploited without inconvenience or disturbance to surface features. In accordance with the method, after the long lateral wellbore is drilled, cased and cemented, only the first production section 102 at the farthest reach of the production casing 101 is perforated and stimulated for production. A length the first production section 102 is a matter of design choice and may depend on any one or more of a number of factors including; a production potential of the production zone 14 ; current or projected price for hydrocarbon products to be produced from the production section; current investment funds available for production stimulation treatments; availability of stimulation service providers; desired lifetime of the entire well; etc. In general each production section 102 has a recommended length of 2,000′-4,000′ (600-1,200 meters), or at most less than the entire length of the lateral wellbore of the hydrocarbon well 100 . Keeping production section 102 at a length of 4,000′ (1,200 meters) or less permits service providers to achieve a more focused stimulation treatment, which results in better production per linear foot of wellbore. Each production section 102 may also have a different length, as described below in more detail. An operator may decide to have 3 production sections in a 12,000 ft. lateral wellbore. The furthest production section out from the vertical wellbore may be 3,000′ in length. The second production section may be 4,000′ in length, and the last section would therefore be about 5,000′ in length. [0023] After the first production section 102 of production casing 101 has been prepared for production using production casing perforation and formation stimulation techniques well known in the art, flow-back of stimulation fluids is performed in accordance with methods that are also known in the art. After flow-back, production from the hydrocarbon well 100 may commence. Depending on the production formation 14 , hydrocarbon may be initially produced up the production casing 101 . After production up the production casing 101 is not viable, a production tubing 108 is then run into the well. A packer 110 is set to seal the annulus around the production tubing 108 and production from the hydrocarbon well 100 continues or commences. A pump assisted lift may be required to produce hydrocarbons from the production section 102 , as understood by those skilled in the art. Production from the production section 102 continues until production from that production section is no longer commercially viable. [0024] FIG. 4 is a schematic-cross sectional diagram of the lateral hydrocarbon well 100 shown in FIG. 3 with a second production section 112 of the production casing 101 completed using the method in accordance with the invention. Once production from production section 102 is no longer viable, the production tubing 108 and packer 110 are pulled from the well and a re-stimulation of section 102 may be performed to prolong production. Alternatively, a plug 114 is set in the unperforated interval “u” of the production casing 101 , where the packer 110 had been set. Perforating equipment (not shown) is then run into the production casing 101 and the production second section 112 is perforated and stimulated until an entire length of the second section 112 of the production casing 101 is prepared for production. A length of the unperforated section “u” left between the sections 102 and 112 is preferably at least one production casing joint (40′-12.2 m) in length and may be up to two casing joints in length. A length of the new production section 112 may be determined using production information collected during production from production section 102 . Consequently, new production section 112 may be longer, shorter, or the same length as production section 102 depending on production targets and any other factor relevant to operation of the hydrocarbon well 100 . An operator may also consider changing the stimulation treatment or service provider when stimulating the second production section 112 to determine the efficacy of a different treatment/service provider because production yields from the production sections 102 and 112 provide a direct comparison of stimulation efficacy since production from each section is from the same wellbore in the same production zone. Once stimulation and flow-back of stimulation fluids are completed, the production tubing 108 and the packer 110 are then run back into the wellbore and the packer 110 is reset. Production from the second production section 112 then commences and continues until the production from production section 112 is no longer economically viable, at which time the production section 112 may be plugged off, and the process of preparing another production section may be repeated until the entire lateral wellbore has been produced. Alternatively, enhanced oil recovery (EOR) may be performed, as described below with reference to FIGS. 6-8 , or re-stimulation of production sections 102 and 112 , or production section 112 alone, may be performed as described below with reference to FIG. 5 . [0025] FIG. 5 is a schematic cross-sectional diagram of a portion of one of the lateral wellbores 100 with a production casing 101 in the production zone 14 completed using a method in accordance with a further aspect of the invention. In accordance with the invention, initial perforation and stimulation of each production section 102 , 112 (see FIG. 4 ) of the lateral wellbore 100 is carefully planned with consideration to the potential of re-stimulation the respective production sections 102 , 112 at a later date when a second stimulation procedure may be used to extend a life of the production section(s) 102 , 112 . Since re-stimulation must be done down a work string, which limits the flow rate of stimulation fluids, careful consideration must be given to the length of perforations that can be re-stimulated taking into account the distance of the production section 102 , 112 from the wellhead, the diameter of the production casing 101 , which determines a diameter of the work string that may be used, pressure loss in the work string, etc. Consequently, unperforated intervals “uu” are left between perforated runs 140 where fractures 150 are created by stimulation fluids. The unperforated intervals “uu” are long enough to ensure that stimulation fluids are unlikely to migrate down a backside of the production casing 101 during the re-stimulation procedure as this could have detrimental effects that would require expensive remediation. [0026] FIG. 6 is a schematic-cross sectional diagram of the lateral hydrocarbon well 100 shown in FIG. 4 configured for enhanced oil recovery (EOR) using the method in accordance with the invention. After section 112 has been produced, or substantially produced, EOR may be considered to extract remaining hydrocarbon from the production zone 14 in production sections 102 , 112 . In accordance with one aspect of the invention EOR may be performed by removing the production tubing 108 and the packer 110 shown in FIG. 4 . The plug 114 is also removed (see FIG. 4 ). A work string 200 and packer 202 are then run into the well 100 until the packer 202 can be set in the unperforated interval “u” between production sections 102 and 112 where the plug 114 had been set. In one embodiment the work string 200 is the work string described in applicant's above-referenced U.S. patent application Ser. No. 14/735,846, though if the run through the lateral bore is not too long coil tubing or jointed tubing such as Hydril® PH6® may be used as the work string 200 . Once the packer 102 is set, an EOR flood fluid 210 such as, for example, carbon dioxide (CO 2 ), liquid nitrogen (LN 2 ), compressed natural gas (CNG), water (H 2 O), or brine is pumped from the surface down the work string 200 . The pressurized flood fluid enters the production zone 14 through the perforations in the production casing 101 of production section 102 . As the pressurized EOR flood fluid enters the production formation 14 , remaining hydrocarbon 220 is urged along a path of least resistance through the perforations in section 112 and up the annulus of the production casing 101 to the surface where it is produced through a production tubing 230 installed at the wellhead 240 . Using this method, EOR fluids are pumped into section 102 until the EOR flood fluid flows up the annulus of the production casing 101 to the wellhead 240 . [0027] FIG. 7 is a schematic-cross sectional diagram of the lateral hydrocarbon well 100 shown in FIG. 4 configured in another way for EOR using the method in accordance with the invention. In this configuration, the production tubing 108 and the packer 110 are left in the well and EOR flood fluid 210 is pumped down the annulus through tubing 232 installed at the wellhead 240 . Since the production casing 101 is unperforated above production section 112 , the EOR flood fluid 210 is forced through the perforations in production section 112 into the production zone 14 . Hydrocarbons 220 in the production zone 14 are urged by the EOR flood fluid 210 along the path of least resistance through the perforations in production section 102 , where they enter the production casing 101 . The hydrocarbons 220 are contained by the packer 106 and are forced up the production tubing 108 to the surface. Generally after an initial production period, there is no longer enough downhole pressure to force hydrocarbons 220 to the surface whether under normal production conditions or under EOR. Consequently, a pump is required to move the hydrocarbons 220 to the surface, an example of which is explained below in more detail with reference to FIG. 8 . [0028] FIG. 8 is a schematic cross-sectional diagram of a more detailed example of a lateral hydrocarbon well 100 configured for EOR in accordance with the invention. FIG. 8 is not drawn to scale. As shown in FIG. 8 , a lateral wellbore 100 with four production sections 102 , 112 , 133 and 144 . Each of the production sections 102 , 112 , 133 and 144 are separated by an unperforated region “u”. Each unperforated region “u” being at least one casing joint in length, as described above with reference to FIG. 3 . In this example, all four production sections 102 , 112 , 133 and 144 have been perforated, stimulated and produced. The production tubing 108 and packer 106 are then pushed down the production casing 101 past production section 144 and the packer 106 is set in the unperforated region “u” between production sections 144 and 133 . As explained above with reference to FIG. 7 , EOR flood 210 fluid is then pumped down the annulus from the wellhead 240 (see FIG. 7 ). The EOR flood fluid 210 is forced through perforations in the production section 144 and into the production zone 14 . Hydrocarbons remaining in the production zone 14 are urged along a path of least resistance through the perforations in production sections 133 , 112 and 102 and into the production casing 101 . The hydrocarbons 220 are lifted to the surface through the production tubing 108 by a plunger pump 260 . A sucker rod string 250 drives the plunger pump 260 , which is connected to the end of the production tubing 108 . The plunger pump 260 lifts the hydrocarbons 220 to the surface in a manner well known in the art. The sucker rod string is reciprocated by a balanced beam pump jack, commonly referred to as a “nodding donkey”, (not shown) in a manner well known in the art. [0029] FIG. 9 is a schematic diagram of lateral hydrocarbon wells drilled using methods in accordance with a further aspect of the invention. In accordance with this aspect of the invention hydrocarbon wells are concentrated on well pads 300 a - c , which are located in convenient and unobtrusive locations, such as public road allowances off main rural roads, or the like, to minimize environmental impact while maximizing year round access. Each pad accommodates at least 2 hydrocarbon wells. In this example, each well pad 300 accommodates 4 lateral wells 301 , though the number of wells 301 on a well pad 300 is a matter of design choice dependent on at least: location, formation boundaries, lease holder rights and investment funds. Each of the wells 301 on each well pad 300 may be drilled in succession or at different times. Each well 301 has a lateral wellbore 302 that is drilled as long as possible given the limitations of: lease holder rights, production zone boundaries, and lateral wellbore completion equipment and technology. Lateral wellbores 302 cross paths but do not directly intersect, to provide a “network” of drainage within the production zone. Since current completion technology permits the completion of very long lateral wellbores 300 , they may be used to extract hydrocarbons underlying surface features such as a lake or reservoir 320 ; a river 330 ; a city, town or village 340 ; farm land 350 ; forest or recreational land 360 ; wet land (not shown) or the like. The network of drainage provided by the lateral wellbores is also suitable for EOR, since once produced some of the lateral wellbores 102 can be used as EOR flood fluid wellbores while others are used as EOR production bores. [0030] The methods in accordance with the invention also permit an operator to close in a well when oil prices make production uneconomical. Once a currently producing section is depleted, it can be plugged and the well closed in until prices recover. Since the cased wellbore above the plug is not perforated, the well can be brought back online without any difficulty when oil prices recover to economic production levels. [0031] The invention has been described with specific reference to wellbores in excess of 8,000′. However, the invention is equally applicable to lateral wellbores that are less than 8,000′ long. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
Long lateral wellbores are prepared for the production of hydrocarbons by preparing only a portion of the wellbore for production at a time, starting at a remote end of the long lateral wellbore. The prepared production section is produced until production becomes uneconomic before a further production section is prepared and produced.
4
FIELD OF THE INVENTION DISCLOSURE [0001] The present invention disclosure generally relates to a spring assembly for a plow mechanism and, more particularly, to a plow mechanism spring assembly having two axially arranged springs with an alignment guide disposed therebetween for aligning adjacent ends of the springs relative to each other and relative to an elongated axis of the spring assembly BACKGROUND [0002] Spring assemblies are used in myriad of different environments. In one form, spring assemblies are used in connection with plows on railcars. In another form, spring assemblies are known to be used in combination with snow plows on light and medium trucks. The business of manufacturing plows for trucks is highly competitive, with manufacturers differentiating themselves based on features and enhanced technology they design into their products. [0003] When plowing a street or parking lot, it is not infrequent for a lower edge of the plow to strike an object which is concealed beneath the snow. This occurs particularly often when a displaced manhole/sewer cover is forcibly struck or engaged during a plowing operation. Alternatively, the plow blade can strike various objects while plowing a road which is not paved, for example, gravel or dirt roads. Since the roads being plowed are typically frozen, it is common for an object of significant size to become frozen into the road. As an example, medium size rocks which would normally not pose a problem when laying loose on the road, can and often do present a problem, when they are frozen into the surface of the road and concealed beneath a layer of snow. Additionally, when the snow fall accumulates, it tends to hide or otherwise conceal obstacles such a curbs, dividers and the like, which an operator may not see or can misconstrue the significance thereof resulting in the snow plow being mistakenly driven thereinto sometimes with considerable force. [0004] Accordingly, snow plow blades have been manufactured with a blade trip mechanism. Such a mechanism allows the plow blade to pivot or otherwise rotate so as to allow the plow blade to yield upon substantial impact with an object. That is, and upon striking an object and/or obstruction, such a mechanism permits a bottom of the snow plow blade to pivot rearwardly from a normal plowing position. Simultaneously, and as the bottom of the snow plow blade pivots rearwardly, the top of the snow plow blade moves forward from the normal plowing position. [0005] Movement between the normal plowing position of the snow plow blade to a position in which the bottom of the snow plow blade pivots rearwardly or backward is commonly referred to as blade tripping. Movements of the snow plow blade from a normal plowing position to a “blade tripped” position is resisted by two or more trip springs mounted behind the snow plow blade. Each spring extends from a position wherein the spring is connected toward a top of the snow plow blade to frame structure used to connect the plow blade to a vehicle. When the bottom of the snow plow blade is forced backward, the springs provide a strong resistance to the movement while tending to absorb some of the impact forces of the of the snow plow blade with the object which has been engaged and struck. [0006] When the force causing the snow plow blade to trip are removed, i.e, after the object being struck has been overcome, the springs forcibly urge the snow blade to return to the normal plowing position, also referred to as the “blade return” position. Since it is not desirable for the snow plow blade to be easily moved from the normal plowing position when plowing snow, the springs are quite strong. Moreover, and depending upon the size or height of the snow blade and the location on the frame wherein the springs are connected thereto, the springs often have an extended length. Although necessary for proper operation of the plow assembly, their extended length coupled with the strength required thereof makes such springs expensive. [0007] Thus, there is a continuing need and desire for an elongated spring assembly which provides both the necessary strength and durability and yet is economical to produce and replace whereby reducing maintenance costs associated with such plows. SUMMARY [0008] In view of the above, and in accordance with one aspect of this invention disclosure, there is provided an axially elongated spring assembly for releasably maintaining a plow blade in a predetermined position about a generally horizontal axis. The spring assembly includes an elongated retractable/extendable connector arranged in general coaxial alignment with an elongated axis of the spring assembly. A first end of the connector is operably connected to the plow blade at a location disposed above the generally horizontal axis; with a second end being operably connected to a plow blade frame. Two springs, arranged in axial relation relative to each other, are disposed between the first and second ends of and along the connector. An alignment member is disposed between adjacent ends of the two springs. The alignment member defines a generally centralized opening so as to permit the guide to slidably move along and relative to the connector while maintaining alignment of adjacent ends of the two springs relative to each other and relative to the elongated axis defined by the spring assembly. [0009] Preferably, each spring of the spring assembly is formed from an axially elongated one-piece elastomeric material defining an elongated bore opening to opposed ends thereof. The elongated bore defined by each spring preferably has a closed margin about a diameter thereof. In one form, the each spring has a plurality of axially spaced flange sections along a length thereof, with any two axially adjacent flange sections on each spring being axially separated by an axially elongated energy absorption section for allowing each spring to react to energy imparted thereto during operation of said spring assembly. [0010] In one embodiment, the alignment member defines an opening extending therethrough, with a marginal edge of the opening having a cross-sectional configuration which proximates a cross-sectional configuration of the elongated connector. Each spring of the spring assembly has interior and exterior surfaces In this form, the alignment member has a body portion with projections axially extending away from opposed and generally parallel surfaces on the body portion and arranged in generally concentric relation with the elongated axis defined by said spring assembly. Each projection on the alignment member preferably defines an exterior surface sized to axially extend within and operably engage the interior surface of a respective spring to affect alignment between the adjacent ends of the two springs relative to each other and relative to the elongated axis defined by the spring assembly [0011] According to another aspect of this invention disclosure, there is provided biasing structure arranged in combination with a plow blade assembly having a frame defining a longitudinal axis. The frame mounts a plow blade for pivotal movement about a generally horizontal axis between a blade return position and a blade tripped position. The biasing structure urges the plow blade from the blade tripped position toward the blade return position and includes a pair of laterally spaced spring assemblies disposed to opposed lateral sides of the longitudinal axis defined by the plow blade frame. Each spring assembly includes an extendable/retractable connector defining an elongated axis. A first end of the connector is operably joined to the plow blade above the axis about which the plow blade pivots and a second end of the connector is operably joined to the frame. First and second end-to-end springs are arranged in operable combination with and along a lengthwise portion of each connector for biasing the plow blade from the blade tripped position toward the blade return position. An alignment member is disposed between the first and second springs of each spring assembly for aligning adjacent ends of the springs relative to each other and relative to the elongated axis of the connector. The alignment member defines a generally centralized opening adapted to slidably move along and relative to the connector. [0012] In one form, the springs of each spring assembly are formed from an axially elongated one-piece elastomer defining an elongated bore opening to opposed ends thereof. The elongated bore defined by each compression spring preferably has a closed margin. In the illustrated embodiment, each spring has a plurality of axially spaced flange sections along a length thereof, with any two axially adjacent flange sections on each spring being axially separated by an axially elongated energy absorption section for allowing each spring to react to energy imparted thereto during operation of the spring assembly. [0013] The opening in the alignment member of each spring assembly preferably has a marginal edge with a cross-sectional configuration which proximates a cross-sectional configuration of the respective elongated connector. Also, the spring of each spring assembly has interior and exterior surfaces. Moreover, in one form, the alignment member of each spring assembly has a body portion with projections axially extending away from opposed and generally parallel surfaces on the body portion and arranged in generally concentric relation with the elongated axis defined by the respective spring assembly. In one form, the projections on the alignment member of each spring assembly each define an exterior surface sized to axially extend within the interior surface of a respective spring to effect alignment between the opposed ends of the two springs of the respective spring assembly relative to each other and relative to the elongated axis defined by the spring assembly [0014] According to yet another aspect, there is provided an axially elongated spring assembly defining an elongated axis and includes an elongated multipiece connector whose first end is articulately joined to a first member and articulately joined toward a second end to a second member to permit pivotal movements between the first and second members. Two springs are arranged axially relative to each other along and about the connector between the first and second ends thereof. An alignment member is disposed between the two springs to effect alignment of adjacent ends of the two springs relative to each other and relative to an elongated axis of the spring assembly. The alignment member defines a generally centralized opening adapted to slidably move along and relative to the elongated connector. [0015] In one form, each spring is formed from an axially elongated one-piece hollow elastomer opening to opposed ends. The elongated bore defined by each spring preferably has a closed margin about a diameter thereof. In a preferred form, each spring has a plurality of axially spaced flange sections along a length thereof, with any two axially adjacent flange sections on each spring being axially separated by an axially elongated energy absorption section for allowing each spring to react to energy imparted thereto during operation of said spring assembly. [0016] Preferably, a marginal edge of the opening in the alignment member of each spring assembly has a cross-sectional configuration which proximates a cross-sectional configuration of the elongated connector. Moreover, each spring has interior and exterior surfaces In one embodiment, the alignment member has a body portion with projections axially extending away from opposed and generally parallel surfaces on the body portion and arranged in generally concentric relation with the elongated axis defined by the spring assembly. The projections on the alignment member preferably defines an exterior surface sized to axially project within the interior surface of a respective spring to affect alignment between the opposed ends of the two springs relative to each other and relative to the elongated axis defined by the spring assembly DESCRIPTION OF THE DRAWINGS [0017] FIG. 1 is a side elevatonal view of a spring assembly in accordance embodying principals and teachings of this invention disclosure forming part of a plow assembly mounted to a light duty vehicle such as a pick-up truck; [0018] FIG. 2 is a fragmentary top plan view of the plow assembly shown in FIG. 1 ; [0019] FIG. 3 is a schematic and enlarged side elevational view showing a plow blade in a lower operating position; [0020] FIG. 4 is a schematic view similar to FIG. 3 showing the plow blade in a raised and deflected position; [0021] FIG. 5 is a plan view of an alignment guide forming part of the present invention disclosure; and [0022] FIG. 6 is a cross-sectional view taken along line 6 - 6 of FIG. 5 . DETAILED DESCRIPTION [0023] While this invention disclosure is susceptible of embodiment in multiple forms, there is shown in the drawings and will hereinafter be described a preferred embodiment, with the understanding the present disclosure sets forth an exemplification of the disclosure which is not intended to limit the disclosure to the specific embodiment illustrated and described. [0024] Referring now to the drawings, wherein like reference numerals indicate like parts throughout the several views, there is shown in FIGS. 1 and 2 a plow assembly, generally indicated by reference numeral 10 , which includes a universal mounting or frame assembly 20 having a plow blade 40 connected toward a forward end thereof. Although the present invention disclosure is shown for illustrative purposes as part of a plow assembly which, in turn, is mounted or otherwise connected to a front end of a vehicle, generally identified by reference numeral 12 ( FIG. 1 ), it should be appreciated the principals and teachings of the present invention disclosure can find utility in applications and uses other than that shown. [0025] Frame assembly 20 is of a conventional design. In the embodiment illustrated for exemplary purposes, and as shown in FIG. 2 , the frame assembly 20 for operably connecting the plow blade 40 to the vehicle 12 ( FIG. 1 ) defines a longitudinal axis 22 and includes a pair of arms 23 , 24 arranged in a generally V-shape relative to each other and which permit the plow blade 30 to be raised and lowered, when required or desired. To affect such ends, and as shown in FIG. 1 , frame assembly 20 includes a conventional lift mechanism 26 including a distendable/retractable driver 27 attached to a pivotal lever 28 . In one form, one end of a chain 30 is operably connected toward a free or distal end of the lever 28 . The other end of the chain 30 is connected to the frame arms 23 , 24 . Selective operation of the driver 27 causes the arms 23 , 24 to pivot whereby raising and lowering the plow blade 40 to a desired position. [0026] The plow blade 40 has a front clearing surface 42 , concave in the direction of movement, a lower scrapper edge 44 , an upper edge 46 , and a rear side or surface 48 . The blade 40 is attached toward a front of the frame assembly 20 in a conventional and well known manner so as to permit the plow blade 40 to pivot about a generally horizontal axis 50 located to the rear side 48 of the plow blade 40 . Suffice it to say, the plow blade 40 is mounted to the frame assembly 20 such that it may pivot between a blade trip return position, shown in FIG. 3 , and a blade tripped position, shown in FIG. 4 . [0027] It will be appreciated by those skilled in the art, and during operation of the plow assembly 10 , when the edge 44 of the plow blade 40 strikes or hits an object on the ground sufficiently hard, it will be driven from the blade return position shown in FIG. 3 to the blade tripped position shown in FIG. 4 . That is, in the event the blade 40 strikes an obstruction sufficiently hard, the lower edge 44 moves upward and pivots rearward about axis 50 while the upper edge 46 will pivot or rotate forward about axis 50 as the plow 40 is driven from the blade return position shown in FIG. 3 to the blade tripped position shown in FIG. 4 . This forward tilt allows blade 40 to slide up and over the obstruction. [0028] To bias plow blade 40 toward the blade return position ( FIG. 3 ) and to resist movement of the plow blade into the blade tripped position ( FIG. 4 ), biasing structure 60 is arranged in operable combination with blade 40 . In the embodiment shown in FIG. 2 , biasing structure 60 includes first and second spring assemblies 62 and 62 ′ preferably arranged generally parallel to each other and to opposed lateral sides of the longitudinal axis 22 of frame assembly 20 . It will be appreciated, more than two spring assemblies can be utilized to form the biasing structure 60 if so desired without detracting or departing from the spirit and scope of this invention disclosure. Preferably, the spring assemblies 62 , 62 ′ are substantially similar relative to each other and, thus, only spring assembly 62 will be described in detail. [0029] In the embodiment shown in FIG. 3 , each spring assembly defines an elongated axis 64 and includes an elongated retractable/extendable connector 66 preferably arranged in general coaxial alignment with the elongated axis 64 of the spring assembly. Suffice it to say, connector 66 is designed and constructed to permit movement of the blade 40 between the blade return position ( FIG. 3 ) and the blade tripped position ( FIG. 4 ). Preferably, and as shown in FIG. 2 , the axis 64 of each spring assembly 62 , 62 ′ is disposed generally parallel to the longitudinal axis 22 of frame assembly 20 . As such, the spring assemblies 62 , 62 ′ preferably do not pull in a direction which is at an angle relative to the longitudinal axis 22 of the frame assembly 20 . Such a design offers a major advantage over previously known spring arrangements which are disposed at an angle relative to the longitudinal axis 22 of the frame assembly. By arranging the spring assemblies generally parallel to the longitudinal axis 22 of frame assembly 20 substantially all the spring force of the spring assemblies is utilized for the blade trip operation. Such a design provides more consistent blade trip operation. Moreover, such design eliminates almost all lateral trip spring force from being exerted on the frame assembly 20 of the plow assembly. [0030] In the illustrated embodiment, connector 66 is of multipiece construction and includes a first axially elongated member or piece 68 which is operably joined or otherwise attached to a second axially elongated piece 70 . The connector pieces 68 , 70 are operably interconnected to each other so as to permit extension/retraction of each spring assembly during operation of the plow assembly 10 . [0031] As illustrated in FIGS. 3 and 4 , a first end 76 of connector 66 is operably and articulately joined or attached to the plow blade 40 at a location disposed above the horizontal axis 50 about which the blade 40 pivots. A second end 78 of connector 66 is operably and articulately connected to the frame assembly rearward of the rear side 48 of plow blade 40 . [0032] As shown in FIG. 3 , and spaced axially away from that end 76 articulately connected to blade 40 , connector piece 68 is provided with a first fixed radial flange or stop 80 . Similarly, and spaced axially away from that end 78 articulately connected to frame assembly 20 , connector piece 70 is provided with a second fixed radial flange or stop 84 disposed in axially spaced relation from stop 80 . The axial distance between flanges 80 and 84 on connector 66 can vary depending upon any of a number of factors. That is, the axial distance between flanges 80 and 84 on connector 66 can vary depending upon the particular plow design. Moreover, the axial distance between the connector flanges 80 and 84 can vary depending upon the obstruction being struck and the disposition of the plow blade when it reaches the blade tripped position. Suffice it to say, the axial distance separating the flanges 80 and 84 on connector 66 can range between about 24 inches and about 40 inches during operation of the plow blade assembly 10 . [0033] In one form, the radial flange or stop 80 is arranged generally coaxial with the longitudinal axis 64 of the respective spring assembly and defines a projection 81 extending axially inward toward a longitudinal center of the respective spring assembly. In the illustrated embodiment, the projection 81 defines a radial shoulder 82 having an outside diameter which is smaller than an outer diameter of stop 80 so as to allow the projection 81 to axially extend within an interior of a spring 90 and provides the stop 80 with a step 83 . [0034] In one form, the radial flange or stop 84 is arranged generally coaxial with the longitudinal axis 64 of the respective spring assembly and defines a projection 85 extending axially inward toward a longitudinal center of the respective spring assembly. In the illustrated embodiment, the projection 85 defines a radial shoulder 86 having an outside diameter which is smaller than an outer diameter of stop 84 so as to allow the projection 85 to axially extend within the interior of the interior of a spring 90 ′ and provides the stop 84 with a step 87 . [0035] As shown in FIG. 3 , operably disposed between the opposed ends of connector 66 , each spring assembly 62 includes first and second axially aligned springs 90 and 90 ′. It should be appreciated, however, if and when required, each spring assembly can include more than two springs arranged in end-to-end relationship without detracting or departing from the spirit and scope of this invention disclosure. In the illustrated embodiment, springs 90 , 90 ′ are designed as compression springs that are axially arranged in operable combination with and between the stops 80 and 84 on connector 66 such that springs 90 , 90 ′ extend along and about a lengthwise portion of the connector 66 and bias the plow blade 40 from the blade tripped position ( FIG. 4 ) toward the blade return position ( FIG. 3 ). [0036] As shown, springs 90 , 90 ′ are substantially similar in design relative to each other and, thus, only spring 90 will be described in detail. Preferably, each spring has an axially elongated body 92 with a generally cylindrical configuration between opposed ends. Moreover, each spring is generally hollow and defines an elongated bore 94 opening to opposed ends of the respective spring whereby providing each spring with interior 95 and exterior surfaces 97 . As shown, the bore 94 defined by each spring has a closed margin about a diameter thereof. Although not specifically shown, it should be appreciated, the principals and teachings of the present invention disclosure equally apply to metal coil springs. [0037] In the preferred form, each spring 90 , 90 ′ is formed from an axially elongated one-piece thermoplastic ether ester elastomer. In the illustrated embodiment, each spring 90 , 90 ′ is provided with a plurality of axially spaced flange sections 96 along a length thereof. Preferably, the flange sections 96 of each spring 90 , 90 ′ has a generally constant outside diameter. As shown in FIG. 3 , any two flange sections 96 on each spring 90 , 90 ′ are axially separated by an energy absorbing section 98 for allowing the spring to react to energy imparted thereto during operation. Each energy absorbing section or convolute 98 of each spring 30 preferably has the form of a ring whose lateral outer face is curved toward an exterior of the respective spring. [0038] The thermoplastic ether ester elastomer used to form springs 90 , 90 ′ is initially created as a preform. An elastomer having tensile characteristics such that the ratio of plastic strain to elastic strain is greater than 1.5 to 1 has proven particularly beneficial. The preferred elastomer is one manufactured and sold by E.I. duPont de Nemoirs under the trademark Hytrel®. Notably, however, suitable elastomer materials other than Hytrel® would equally suffice without detracting or departing from the spirit and scope of this disclosure. Notably, the elastomer material forming the elastomer is free of spring-like characteristics. For a more complete description of transmuting such elastomer material into a spring, attention is directed to U.S. Pat. No. 4,198,037 to D. G. Anderson and/or U.S. Pat. No. 5,141,697 to N. E. Wydra; with applicable portions of either and/or both references being incorporated herein by reference. [0039] Preferably, the elastomer used to form springs 90 , 90 ′ has a molecular structure and a Shore D durometer hardness ranging between about 40 and 60. In the preferred embodiment, the elastomer used to form springs 90 , 90 ′ has a Shore D durometer of about 55. Significantly, such elastomer is quite durable and has an excellent flex life. Moreover, such elastomer is not subject to tearing or to crack propagation even in relatively thin cross-sections. Additionally, such an elastomer is known to work well in a wide range of temperature variants [0040] Preferably, and after being arranged in operable combination with spring 90 , the step 83 on stop 80 operably engages and acts as a seat for an outer end of spring 90 . Moreover, and after being arranged in operable combination with spring 90 , projection 81 on stop 80 will axially extend into the interior of spring 90 such that the outer diameter of the projection 81 generally aligns one end of spring 90 relative to the elongated axis 64 of the respective spring assembly. Similarly, and after being arranged in operable combination with spring 90 ′, the step 87 on stop 84 operably engages and acts as a seat for an outer end of spring 90 ′. Moreover, and after being arranged in operable combination with spring 90 ′, projection 85 on stop 84 axially extends into the interior of spring 90 ′ such that the outer diameter of the projection 84 generally aligns one end of spring 90 ′ relative to the elongated axis 64 of the respective spring assembly. Notably, an outer diameter of each stop 80 , 87 is larger than the outer diameter of each spring 90 , 90 , respectively. [0041] After being arranged about and along the respective connector 66 , and to advantageously align axially adjacent inner ends of the springs 90 , 90 ′ relative to each other and relative to the elongated axis 64 of each spring assembly whereby optimizing performance of the biasing structure 60 , each spring assembly furthermore includes an alignment member 100 . In the embodiment shown in FIGS. 5 and 6 , alignment member 100 includes a body portion 102 having an outer diameter generally equal to or somewhat larger than the outer diameter of each spring 90 , 90 ′. [0042] Alignment member 100 further includes projections 108 and 118 axially extending away from opposed and generally parallel surfaces 104 and 106 of the body portion 102 . The generally parallel surfaces 104 and 106 on alignment member 100 preferably engage and acts as seats for an inner end of springs 90 , 90 ′, respectively. Notably, in a preferred form, the body portion 102 defines a centralized axis 107 with the projections 108 and 118 being arranged in generally concentric relation relative to the centralized axis 107 . Projection 108 has a diameter smaller than an outside diameter of member 100 . As such, projection 108 defines a radial shoulder 110 with a diameter equal to or slightly smaller than the interior surface 95 of spring 90 . Similarly, projection 118 has a diameter smaller than an outside diameter of member 100 . As such, projection 118 defines a radial shoulder 120 having a diameter equal to or slightly smaller than the interior surface 95 of spring 90 ′. [0043] As shown in FIGS. 5 and 6 , alignment member 100 further define a generally centralized opening 124 extending through the body portion 102 , through the projections 108 and 118 , and opening to opposed sides of member 100 . The opening 124 has a predetermined marginal configuration which preferably proximates the cross-sectional configuration of the connector 66 ( FIGS. 3 and 4 ) extending axially therethrough. As such, and when mounted in operable combination with the respective spring assembly of biasing structure 60 ( FIGS. 3 and 4 ), the alignment member 100 is permitted to slide along the length of the connector 66 while maintaining a predetermined rotational orientation with respect to the connector 66 . In FIGS. 5 and 6 , the marginal configuration of opening 124 is illustrated as being generally square. It should be appreciated, however, the marginal configuration of opening 124 can be other than square i.e. triangular, rectangular, oval and etc without detracting or departing from the spirit and scope of this invention disclosure. [0044] As shown in FIGS. 3 and 4 , when arranged in operable combination with springs 90 , 90 ′ of each spring assembly, projection 108 on alignment member 100 axially extends into the interior surface 94 of spring 90 ′ so as to allow surface 104 to engage with the abutting end of spring 90 while the radial shoulder 110 on projection 108 effects alignment of spring 90 relative to the elongated axis 64 of the respective spring assembly. Similarly, projection 118 on member 100 will axially extend into the interior surface 94 of spring 90 ′ so as to allow surface 106 to engage with the abutting end of spring 90 ′ while the radial shoulder 120 on projection 118 effects alignment of spring 90 ′ relative to the elongated axis 64 of the respective spring assembly. [0045] During operation of the plow assembly 10 , and in the event the plow blade 40 strikes an obstruction, forward rotation or roll of the upper portion of the blade 40 about axis 50 temporarily lengthens the connector 66 and blade 40 is moved toward the blade tripped position schematically represented in FIG. 4 . As such, and as schematically shown in a comparison of FIGS. 3 and 4 , the axial distance between the first and second stops 80 and 84 is shortened resulting in compression of the springs 90 , 90 ′ of each spring assembly 62 of the biasing structure 60 . Notably, however, and to optimize spring performance and operation, although the springs 90 , 90 ′ are compressed, the alignment member 100 slides along the length of the connector whereby maintaining the inner ends of the springs 90 , 90 ′ in generally axial alignment with each other and relative to the elongated axis 64 of the respective spring assembly 62 . After the obstruction is overcome, the forces acting to displace the blade to the tripped position are overcome by the spring assemblies comprising biasing structure 60 . That is, the forces applied by the spring assemblies of the biasing structure 60 tend to forcibly return or restore blade 40 to the blade return position ( FIG. 3 ). [0046] It may therefore be appreciated from the above detailed description of the preferred embodiment of the present invention disclosure that it teaches a biasing structure having two axially arranged spring assemblies each of which includes a plurality of axially disposed springs and an alignment guide for maintaining adjacent inner ends of the springs 90 , 90 ′ in generally aligned relation relative to each other and relative to an elongated axis of the spring assembly. In one form, the biasing structure is used to return a plow blade from a blade tripped position to a blade return position with consistency and regularity. The use of two springs arranged in end-to-end relation relative to each other economizes on the cost to manufacture the spring assembly without detracting from its performance. In most applications, Applicants have advantageously discovered it is more economical to use two shorter length springs in end-to-end combination relative to each other rather than having to manufacture a one-piece spring having the same effective length. Moreover, constructing such spring assemblies with two elastomeric end-to-end springs renders a design which is both durable and long lasting while requiring minimal maintenance in a myriad of different ambient weather conditions. Additionally, the ability to change the force required to move or roll the plow blade to a blade tripped position can be adjusted both readily and inexpensively by simply changing one or both of the elastomeric springs comprising the biasing structure. [0047] From the foregoing, it will be observed that numerous modifications and variations can be made and effected without departing or detracting from the true spirit and novel concept of this invention disclosure. Moreover, it will be appreciated, the present disclosure is intended to set forth an exemplification which is not intended to limit the disclosure to the specific embodiment illustrated. Rather, this disclosure is intended to cover by the appended claims all such modifications and variations as fall within the spirit and scope of the claims.
A spring assembly defining an elongated axis and includes an axially elongated connector articulately connected toward a first end to a first member and articulately connected toward a second end to a second member for joining and permitting pivotal movements between the first and second members. Two springs are arranged axially relative to each other along and about the connector between the first and second ends thereof. An alignment member is disposed between the two springs for aligning adjacent ends of the two springs relative to each other and relative to an elongated axis of the spring assembly. The alignment member defines a generally centralized opening adapted to slidably move along and relative to the connector.
5
FIELD OF THE INVENTION This invention relates to an improved format for recording data on a magnetic storage medium and the like and more particularly to a format that affords identification and correction of recording errors. DESCRIPTION OF THE PRIOR ART Data stored on magnetic disks is typically organized in sectors each of which has a unique address followed by a stream of data. The address permits the sector to be identified so that the desired data can be recovered or read. Because the weakest links in a magnetic storage system are the magnetic medium and the medium/head interface, erroneous recording and recovering of data usually arises from magnetic deficiencies rather than from electronic deficiencies. If the stored data is incorrect due to inaccuracies in recording or recovering the data, it is desirable to know that an error has occurred and to be able to correct the error. One technique for affording an indication whether an error in data recording and/or recovering has occurred is known as a Cyclic Redundancy Check as described in Signetics "BiPolar/MOS Microprocessor Data Manual," Copyright 1977, at page 112. Cyclic Redundancy Check is referred to hereinafter as CRC. In a CRC system selected data bits are combined in accordance with a prescribed equation to produce a CRC signal which is recorded in a sector after the data is recorded in the sector. If on recovering the data and the CRC and subjecting the data to the same equation to derive a new CRC, the new CRC is different from the recorded CRC, such difference is an indication of erroneous recording and/or reading. The CRC system merely indicates the existence of an error but does not permit correction of the erroneous data recording. SUMMARY OF THE INVENTION In accordance with the present invention a sector of data composed of a plurality of data bits in binary or other form is converted into a group of data segments wherein each data segment is of uniform length and is smaller than a sector. If each sector is grouped or formed into n data segments, then each data segment has 1/n times the number of bits as in the entire sector so that all bits are recorded. Each data segment is recorded with a timing pattern and a CRC field that is related only to the data segment, and in addition the data in each data segment is combined with the data in all other data segments in a unique manner to produce a check segment which is recorded after all data segments are recorded. The check segment, which can be created by combining all data segments in an exclusive OR circuit, is a function of the contents of all data segments so that if one data segment is in error, its true value can be recovered by properly combining the correctly recorded data segments and the check segment. The identity of the supposed erroneous data segment is established in accordance with the prior art by comparing each CRC field with the data in its associated data segment. Accordingly, the present invention not only provides for an indication of erroneous recording but also a procedure for reconstructing the erroneously recorded data into correct data. The above-mentioned timing signal is used in conjunction with each segment and is prevented from changing until the completion of recording of all segments in a sector. Accordingly, only if the timing signals associated with all segments in a sector are the same does the circuit attempt to recover the data. An object of the invention is to so format data before its recordation onto a magnetic disk or like medium that any errors in recording or reading are made known and certain types of errors can be corrected. Another object of the invention is to provide a circuit for achieving the last-mentioned object which can be introduced into existing equipment without substantial modification thereto. This object is achieved because the circuit of the invention is adapted for installation between an existing central processing unit and an existing disk drive unit and is adapted to operate on the data without adversely affecting data flow between such existing units. The foregoing, together with other objects, features and advantages, will be more apparent after referring to the following specification and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of a data transmission system in accordance with the present invention. FIG. 2 is a block diagram of a portion of FIG. 1 in more detail. FIGS. 3A-3D are block diagrams of a portion of FIG. 2 in alternate positions and in still more detail. FIG. 4 is a pictorial diagram of a sector of data recorded in accordance with the invention. FIG. 5 is a pictorial diagram of the header of the data format of FIG. 4. FIG. 6 is a pictorial diagram of the data segment of the data format shown in FIG. 4. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring more particularly to the drawings, reference numeral 12 indicates formatting apparatus according to the invention which is shown in association with a peripheral processing unit (PPU) 13 coupled to a main bus 14 to which a central processing unit (CPU) 15 is also connected. Formatting apparatus 12 is connected between PPU 13 and a disk storage system or disk drive 16. Peripheral processing unit 13 is a part of an existing computer and is controlled by the computer for effecting writing of data into disk drive 16 and reading the data therefrom. As is typical of systems of this nature there is a data bus 18 extending from peripheral processing unit 13 and a command/status bus 20. The data is supplied to and from the peripheral processing unit over the data bus, and command and other related control signals are supplied to and from the processing unit on command/status bus 20. There are circuit paths between formatting apparatus 12 and disk drive 16; they will be described in more detail herinafter. Formatting apparatus 12 includes a nanoprocessor 26, which controls data flowing between peripheral processing unit 13 and disk drive 16, and a microprocessor 28, which is connected to command/status bus 20 and disk drive 16. Microprocessor 28 controls nanoprocessor 26. FIG. 2 shows in more detail the construction of nanoprocessor 26. Data is coupled on bus 18 to an input/output FIFO shift register 30 which has its output coupled by a circuit path 32 to a switch 34. The functions of switch 34 will be described subsequently. Among other things, switch 34 couples data via a circuit path 35 to disk drive 16. Switch 34 also couples data to a first buffer 36 via a path 38 and to a second buffer 40 via a path 42. Buffers 36 and 40 function to store data temporarily during transfer of data between PPU 13 and disk drive 16 for purposes that are explained below; the buffers can be embodied in RAMs. Switch 34 also couples data to a CRC generator 44 via a path 46 and to input/output shift register 30 via a path 48. Additionally, switch 34 receives data inputs from first buffer 36 on a path 50, from second buffer 40 on a path 52 and from CRC generator 44 on a path 54. Finally, switch 34 has a flag output path 55 on which appears a state signal indicative of accurate (or inaccurate) recordation or recovery of data. The circuits enumerated in the preceding paragraph respond to command signals supplied over bus 20. Such signals are processed by microprocessor 28 to cause nanoprocessor 26 to convert data received by it on bus 18 into a format according to the invention. The specific nature of the format is dictated by a control and timing circuit shown schematically at 56. Because the elements that constitute control and timing circuit 56 are not per se novel, a description of the various functions performed by the control and timing circuit suffices to afford an understanding of the circuit. There are signal paths between the control and timing circuit 56 and each of the elements previously specified. More specifically, there is a control path 60 extending from the control and timing circuit to input/output shift register 30, a control path 62 extending to CRC generator 44, a control path 64 extending to second buffer 40, a control path 66 extending to first buffer 36, a control path 68 extending to switch 34 and a control path 70 extending to disk drive 16. There is a pattern store 72 which has an input 74 from control and timing circuit 56 and an input 76 from microprocessor 28. Pattern store 72 has an output 78 coupled to the input of switch 34. The pattern store is loaded from microprocessor 28 with a time signal for recordation in disk drive 16 which time pattern is prevented from changing during recordation of a given sector. Additionally, there is a control path 80 extending from microprocessor 28 to disk drive 16 for providing timing signals during recording and recovery of the data. A data path 81 extends from disk drive 16 to switch 34; data is transmitted over path 81 upon readout of the data from disk drive 16. A circuit path 82 from disk drive 16 to control and timing circuit 56 and a circuit path 83 from the disk drive to microprocessor 28 convey signals indicative of the status of the disk drive to the control and timing circuit and the microprocessor. Although switch 34 can be embodied in a variety of forms, a suitable form, seen in FIGS. 3A-3D includes a read only memory (ROM) 84. At the upper left are the data inputs to the ROM which correspond to those seen in FIG. 2. At the right hand side are outputs of the switch corresponding to those shown in FIG. 2. At the lower left, control path 68 is seen to be composed of a plurality of lines, and the digital signal pattern on the lines dictates the interconnections established between the data inputs and the data outputs of the ROM. ROM 84 also is capable of generating an exclusive OR (XOR) function, such function being pictorially and schematically indicated at 85 and being described more fully hereinbelow. As will appear subsequently, the above-described apparatus produces a data format schematically depicted in FIGS. 4, 5 and 6. Shown in those figures is a portion of a single data track on a magnetic medium in disk drive 16, the portion at the left hand extremity of each figure leading the portion at the right hand figure as the magnetic medium moves relative to a conventional read/write head (not shown). Referring to FIG. 4, each sector 86 begins with a header gap 87 which identifies the beginning of a sector and synchronizes the clock in disk drive 16. Next is a header 88 which uniquely identifies the sector so that the sector can be addressed. Gap 87 and header 88 are permanently written on the magnetic medium. As seen in FIG. 5 header 88 includes a sync portion 90, which can be composed of a bit pattern suitable for preparing system logic for receipt of further data. Next, the header has a location or address field 92. Location field 92 can include a plurality of bits, e.g., 32 bits, that provide a unique address for each sector 86 within a given disk drive system. Finally, the header includes a CRC portion 94 which contains a prescribed number of bits, e.g., 15, and has a value derived from the specific signal recorded in location field 92 so that on readout of the data a comparison of a CRC signal generated from the data stored in location field 92 and the CRC signal stored in portion 94 indicates whether an error exits in the reading process. Following header 88 is a gap 96 which produces a signal indicating termination of the header segment and commencement of a first data segment 98. The composition of the information written in first data segment 98 is seen in greater detail in FIG. 6. Data segment 98 commences with a sync field identified at 100. The sync field defines the beginning of a data segment and is composed of a binary signal, e.g., a series of eight ones, for preparing system logic for ensuing data. Next is a data field 102 in which is recorded a segment of data, i.e., a portion of the data in the entire sector. In one system designed in accordance with the invention there are nine data segments exemplified by data segment 98, and the data field in each contains 115 32-bit words or a total of 3,680 bits. Next, data segment 98 contains a time code portion 104 which can be a series of 32 bits indicative of the time of writing the data. As has been indicated and will be recapitulated subsequently, microprocessor 28 in cooperation with pattern store 72 assures that the time code recorded in each segment will be uniform throughout all segments in a given sector. Finally, data segment 98 includes a CRC portion 106 which includes a signal having a value that is a function of the information recorded in data field 102 and time code portion 104 so that upon readout, comparison of the recorded CRC signal with a CRC signal generated from the data field and time code portion as they are read from the medium in disk drive 16 provides an indication of errors or the lack thereof in writing or reading of the data. The remaining data segments which are identified in FIG. 4 by the legends SEG 2-SEG 9 are equivalent to data segment 98 and are recorded in sequence on the magnetic medium. After data SEG 9 is recorded a check segment 108 is generated and recorded. Check segment 108 is identical in format to data segment 98 and the information recorded in data field 102 of check segment 108 is a prescribed function of the data recorded in the data fields of the preceding nine data segments. Such function is exemplified in the apparatus shown in FIGS. 3A-3D as an exclusive OR (XOR) function. Thus, if the data field in one of the data segments is erroneously written or read, the content of such data segment can be reconstructed from the function recorded in the data field of check segment 108 and the data recorded in the remaining correctly recorded and read data segments. The procedure for producing the check segment data field will be explained in connection with FIGS. 2 and 3A-3D. Referring to FIG. 2, data coupled over bus 18 to shift register 30 is applied to switch 34 over path 32. Under the control of control and timing circuit 56 acting on paths 60 and 68, the data field of the first data segment is recorded on disk drive 16 over path 35. The connections effected by switch 34 for recording the data in the first data segment are shown in FIG. 3A. Simultaneous with application of the data over path 35 to the disk drive, the data is also applied to second buffer 40 over path 42 for temporary storage and to CRC register 44 over path 46. Data in the second data segment (see FIG. 3B) is similarly transmitted by switch 34 from circuit path 32 to circuit path 35. The data is also applied to CRC generator 44 over path 46. Additionally, the incoming data field for data segment 2 is combined with the data previously stored in the second buffer (applied over circuit path 52) to produce an XOR function at 85. The XOR function is applied to first buffer 36 over path 38 for temporary storage in that buffer. During recordation of data in the third data segment (see FIG. 3C) switch 34 couples the data from path 32 to path 35 and to path 46. In addition, the data is combined with the contents of the first buffer (applied over circuit path 50) to produce an XOR function of the data contained in data segments 1, 2 and 3. Such XOR function, produced at 85, is supplied to the second buffer on path 42 for storage in that buffer. The above procedure is alternated for succeeding data segments, switch 34 directing data as depicted in FIG. 3B during even segments and as depicted in FIG. 3C during odd segments. When the data fields in all data segments have been recorded, the data field in check segment 108 is recorded, and switch 34 controls data flow in the manner seen in FIG. 3D. The content of the second buffer, after recordation of the data field for the ninth data segment, is the XOR function of all preceding data segments and such is directly connected to path 35 for recordation in disk drive 16 and to path 46 for transmission to CRC generator 44. The connections effected by switch 34 as seen in FIG. 3D are for the case where the final data segment is an odd data segment. Obviously, if the final data segment were an even segment then circuit path 50 from the first buffer would be applied to circuit path 35. Operation of the formatting apparatus of the present invention is typically commenced when CPU 15 sends data on main bus 14 to peripheral processing unit 13 with a command to store the data. Referring to FIG. 2, the data is conveyed over path 18 to shift register 30 and the command signals are conveyed over path 20 to microprocessor 28. The microprocessor loads pattern store 72 on path 76 with the signals for time code portion 104 (see FIGS. 4-6). When the appropriate header 88 is read by the read/write head in disk drive 16, a signal is applied on path 55 to control and timing circuit 56. The latter circuit applies a signal on path 68 which forces switch 34 to write over path 35 a series of zeros to form gap 96 on the medium in disk drive 16. Next, the control and timing circuit 56, acting over path 68, forces switch 34 to write a series of ones which constitute sync portion 100 of the first data segment 100. Then one segment of data from shift register 30 is coupled by switch 34 from circuit path 32 to circuit path 35 to effect recordation of data field 102 in disk drive 16. During such recordation of the data field of data segment 1 (see FIG. 3A), such data field is coupled over circuit path 42 to second buffer 40 in which the data is temporarily stored. At the same time, the data is coupled over path 46 to CRC generator 44. Upon completion of the recordation of the data field, a time code signal is coupled from pattern store 72 on path 78, and under the influence of the control signal on circuit path 68, the time code is transmitted over circuit path 35 for recordation in the disk drive and over circuit path 46 to CRC generator. Upon completion of recordation of the time code, CRC generator 44 generates a CRC signal that is a function of both the data recorded in data field 102 and the time code recorded in time code portion 104. Such CRC signal is connected by switch 34 from circuit path 64 to circuit path 35 for recordation in disk drive 16. Thereafter, a gap equivalent to gap 96 is recorded under control of the signal on circuit path 68 which causes switch 34 to force a series of zeros on path 35. Data segment 2 is recorded next and commences with a sync signal 100. Then data from register 30 is connected over path 32 through switch 34 to circuit path 35 to establish data field 102 for data segment 2. The data is also coupled to CRC generator 44 on path 46. See FIG. 3B. Simultaneously with recording the data field for data segment 2, the content of second buffer 40 is applied to switch 34 on path 52 and is XORed with the data entering on path 32 by means of XOR function 85. The XORed data is conducted on path 38 for temporary storage in first buffer 36. The XORed data is stored in first buffer 36 during completion of recording of data segment number 2 which includes a time code portion 104, a CRC portion 106 and a gap 96. Recordation of the third data signal then proceeds with recordation of a sync portion 100. During recordation of the data field in data segment 3, switch 34 is supplied with an appropriate control signal over circuit path 68 to effect the connections shown in FIG. 3C. As seen in FIG. 3C, data from register 30 is connected from input circuit path 34 to output circuit path 35 for transmittal to disk drive 16 and to path 46 for transmittal to CRC generator 44. The data is also XORed with the data stored in first buffer 36, the output of the XOR function being connected via path 42 to second buffer 40. After the data field for segment 3 is stored in disk drive 16, a time code, CRC signal and gap are recorded. The data fields for subsequent even numbered segments are handled as seen in FIG. 3B which shows that as the data field is conveyed to disk drive 16 and to CRC generator, the data is XORed with the contents of second buffer 40. The data fields in subsequent odd segments are handled as shown in FIG. 3C in which as data is recorded in disk drive 16 the data is XORed with the contents of first buffer 36. The final segment in sector 86, as explained previously in connection with FIG. 4, is a check segment 108. After a sync portion 100 of the check segment is recorded in disk drive 16 the output of second buffer 40 is connected to circuit path 35 for recordation in the disk drive and to circuit path 46 for transmittal to CRC generator 44. At this time, the second buffer contains the XOR function of the data fields in data segments 1-9, inclusive. When the data field for check segment 108 has been written, a time code and CRC signal are recorded and storage of the data sector is complete. Read out of the data occurs when a unit, such as CPU 15, on main bus 14 calls for the data sector recorded as described next above. PPU 13 and the circuit of the invention cause the data in the addressed sector to be delivered from disk drive 16 to the main bus. After the desired sector is located by identification of its header 88, the data is conveyed from disk drive 16 to switch 34 on path 81. Switch 34 connects the data to register 30 on path 48 and to CRC generator 44 on path 46. The output of register 30 is coupled to PPU 13 on data bus 18 to effect delivery of the data to main bus 14. When the data from data field 102 of the first data segment has been read, the time code is applied by switch 34 to CRC generator 44 and to first buffer 36 so that the time codes in subsequent segments can be compared with the temporarily stored time code. After the time code has been read, CRC generator 44 contains a newly generated CRC signal that is a function of the data field and time code in the first data segment. Such newly generated CRC signal is applied to switch 34 on path 54 for comparison with the CRC signal 106 as read from the medium in disk drive 16 and as applied to switch 34 on path 81. The result of the comparison is manifested on flag output path 55, one state indicating equality of the two CRC signals and an opposite state indicating inequality. The flag is applied to microprocessor 28 through control and timing circuit 56 for transmission with status information over main bus 14 to the CPU. Read out of subsequent data segments is as described in the immediately preceding paragraph except that the time code in each succeeding data segment is compared with the time code stored in buffer 36 from the first data segment. A flag signal indicating equality or inequality of the time codes is applied to flag output path 55 and to the main bus. When check segment 108 is applied over path 81 to switch 34, it is coupled over path 42 for temporary storage in buffer 40. The flag signals produced on flag output path 55 are conveyed to microprocessor 28 through control and timing circuit 56. Microprocessor 28 determines whether the time code for the segments match and whether the CRC signal for each segment is correct. If only one segment has a CRC error and all other segments have matching time codes, the microprocessor produces a status signal that indicates that the data can be recovered. The status signal is made available to the CPU on main bus 14. If the circuit of the invention is so instructed by the CPU, the check segment temporarily stored in buffer 40 is applied to switch 34 on path 52 and then to register 30 on path 48 for delivery to the main bus. Thus, it will be seen that the present invention provides a data format for recordation in a disk drive which permits both detection of occurrence of an error and reconstruction of the data when only one segment has been erroneously recorded. This mode of operation is made possible because, as the data field and time code in each segment are recorded, a CRC signal for that individual data segment and time code is produced and recorded and because the data in each data field are accumulated and combined according to a prescribed function with data in all other data fields to produce a check signal from which data in one segment can be reconstructed if the data in such segment are erroneously recorded or read out and if the time code in every segment is identical. In the specific embodiment described above and shown in the drawings, the prescribed function employed in combining all data fields to produce the check segment is an XOR function; such function is exemplary, not limiting. Because the formatting apparatus of the invention can be introduced between an existing peripheral processing unit and an existing disk drive, the advantages of the invention can be achieved without significant equipment replacement or redesign. Although one embodiment of the invention has been shown and described, it will be obvious that other adaptations and modifications can be made without departing from the true spirit and scope of the invention.
A sector of data to be recorded on a magnetic medium is formatted by dividing the data sector into a plurality of data segments. Recorded with each segment is a time code which is identical for all segments in a given sector. During recordation of the data and time code for each segment, a cyclic redundancy check (CRC) signal is generated and the CRC signal is recorded after the data and the time code. As data in a segment is recorded, it is also temporarily stored. The temporarily stored data is combined according to a prescribed function with data in the succeeding segment and that function is temporarily stored for combination with the data in the next succeeding segment so that after all segments of data have been recorded there is a function that uniquely represents the data in all data segments. The function is recorded as a check segment. On recovery of the data, an error in any given segment can be detected by employment of the CRC signal associated with the segment containing an error. Reconstruction of the data in the erroneously recorded or read segment can be achieved by combining the contents of the correctly recorded and read data segments and the check segment, provided that the time codes read in these segments are identical.
6
CROSS REFERENCE TO RELATED APPLICATIONS This is a continuation-in-part of application Ser. No. 08/362,078 filed Dec. 22, 1994, abandoned. BACKGROUND OF THE INVENTION This invention concerns non-stick coated cookware, with a decorative pattern visible through a light transmitting topcoat. More specifically, it concerns such cookware with a textured surface. U.S. Pat. No. 4,259,375--Vassiliou (1981) discloses an article of cookware with a 3-layer coating having a discontinuous speckled or spattered pattern in a partial layer directly beneath the topcoat. The spattered coating is deliberately sprayed directly on the layer under it while the under layer is still wet and soft so that the spattered layer sinks into the under layer and does not provide roughness that could telegraph through the surface. It was said that roughness would provide a place for a fork or other utensil to catch in the coating and tear the coating. The spattered layer dots were also sprayed on directly, such as at 90 degrees from the substrate, so as to form more or less round dots. This patent is incorporated by reference herein for its disclosure of materials, processes and equivalents suitable for the present invention. U.S. Pat. No. 3,961,993--Palisin (1976) discloses spraying multilayer polymer coatings on a substrate, one layer being sprayed on top of the layer under it after the under layer has become tacky. A tacky underlayer permits the successive layer to adhere better without completely merging indistinguishably with the underlayer. Still, any roughness in the upper layer would tend to smooth out as the two layers interact. U.S. Pat. No. 3,655,421--Long (1972) describes means of keeping globules of an intermittent coating from flowing out to make a uniform layer, by controlling surface tension relations. It is desirable to have a superior non-stick, decorative coating for cookware with a raised or textured surface and with greater flexibility for aesthetic design than just to make smooth round dots. SUMMARY OF THE INVENTION The present invention provides an article of cookware having a cooking surface which comprises a multi-layer, non-stick coating which minimizes sticking by food residues and which is heat resisting by being stable at temperatures above 300° C. on a substrate, wherein the coating comprises a primer adhered to the substrate, a non-stick, heat-resisting, light-transmitting topcoat, and optionally one or more intermediate coats, with the topcoat adhered to any such intermediate coats which are adhered to the primer or, in the absence of intermediate coats, the topcoat being adhered directly to the primer, with the coating under the topcoat having a first color or darkness, wherein a discontinuous layer of raised globules is present on and covers no more than 80% of the area of the coating under the topcoat, said globules having at least one color or darkness which is visibly different than said first color or darkness as seen through said topcoat, said discontinuous layer creating a texture or roughness in said topcoat. Included in the invention are a method of making an article in which the coatings are applied by spraying coating compositions successively on the substrate and ultimately heating the article to cure the coating, wherein the coating under the discontinuous coating is dried enough before applying the discontinuous coating so that substantial portions of the spattered coating remains on top of said under coating to create the roughness telegraphing through the topcoat. DETAILED DESCRIPTION An important part of the process for obtaining the present invention is the drying or "flashing" the primer or intermediate coat before applying the discontinuous coat, adequately so the spattered dots do not sink into the primer or the intermediate coat. In normal application, air flow for 30 seconds or longer, or preheating the substrate or the air with a shorter time of air flow, will suffice. Those skilled in the an know how to select the ingredients of each coating to avoid wetting which might cause the globules to run together. Wetting is generally not a problem with most heat resistant materials useful for cookware coatings, especially perfluoropolymers such as polytetrafluoroethylene and (PTFE) and copolymers of TFE and fluorovinyl ethers (PFA). Preferably the coatings contain oxide-coated mica, and preferably the oxide in TiO 2 , as described in U.S. Pat. Nos. 3,087,827--Klenke et al., 3,087,828 and 3,087,829--both to Linton, and granted 1963. In the examples which follow, parts, percentages and proportions are given by weight except where stated otherwise. EXAMPLE 1 A primer having the composition of Table 1 is sprayed on a clean, lightly etched aluminum substrate to a dry film thickness (DFT) of 7.5 to 10 microns, the primer is dried at 66° C. for 3 minutes and a black midcoat of Table 2 is applied to a DFT of 17.5 to 20 microns. The midcoat is allowed to dry at ambient temperature for 45 seconds and three separate inks or spatter coatings are applied using a DeVilbiss spatter gun to provide a discontinuous coming. The inks of Table 3 or 4 are colored to be significantly different than the black midcoat background and are sprayed at a 45° angle (or at an angle of from 30° to 75°) to provide irregular shapes on the spinning substrate. The effect is to provide an appearance of natural stone. The inks are not limited to solid color pigments but also include color achieved by reflectance with coated mica. Furthermore, mixtures of solid pigments, different colored coated mica, and all of these can be used for unusual optical effects. A topcoat of Table 5 is then applied wet-on-wet over the spattered particles. The topcoat, in this example, contains mica particles in a 1-15 micron particle size range so as not to interfere with the aesthetics of the spatter coat. The entire system is sintered at 427° to 435° C. for 5 minutes. The temperature being controlled is that of the substrate metal rather than that of the oven, which will vary with the speed of product through the oven and the length of the oven. TABLE 1______________________________________ Coating Solids Content Composi- in Finished tion ArticlePrimer (Wt. %) (Wt %)______________________________________Furfuryl Alcohol 1.82 --Polyamic acid salt in N-Methyl Pyrrolidone 18.10 24.48Water 48.33 --Mica coated with TiO.sub.2 0.05 0.24PTFE Dispersion 7.93 22.19FEP Dispersion 5.88 15.08Colloidal Silica Dispersion 3.58 5.00Ultramarine blue dispersion 13.74 32.06Aluminum silicate dispersion 0.58 0.94______________________________________ TABLE 2______________________________________ Solids Content Coating in Finished Composition ArticleIntermediate (Wt. %) (Wt %)______________________________________PTFE Dispersion 56.34 77.43PFA Dispersion 10.21 14.22Water 4.62 --Carbon black dispersion 2.71 3.79Ultramarine blue dispersion 0.49 3.22Mica coated with TiO.sub.2 0.75 1.73Surfactant catalyst soln. 12.63 --Acrylic dispersion 12.23 --______________________________________ TABLE 3______________________________________Typical spatter ink formulation composition (parts by weight) A (white) B (gray) C (brown)______________________________________PTFE Dispersion 542.0 542.0 542.0PFA Dispersion 96.0 96.0 96.0Ceramic Dispersion 50.0 50.0 --TiO.sub.2 Dispersion 100.0 100.0 20.0Iron Oxide Dispersion -- -- 80.0Channel Black Dispersion -- 8.0 2.0Solvent Surfactant Blend 110.00 110.00 110.00Acrylic Dispersion 120.00 120.00 120.00Solvent-Surfactant Blend 30.00 30.00 30.00Hydroxylpropyl 30.00 15.00 20.00cellulose soln.Viscosity in centipoise as 682 608 682measured by Brookfleld#2 spindle, @20 rpm______________________________________ TABLE 4__________________________________________________________________________ White Gray Solids Content Solids Content Coating in Finished Coating in Finishes Composition Article Composition ArticleSpatter Coats (Wt. %) (Wt. %) (Wt. %) (Wt. %)__________________________________________________________________________PTFB Dispersion 50.29 71.04 50.61 70.63PFA Dispersion 8.91 12.58 8.96 12.52Al.sub.2 O.sub.3 Ceramic Dispersion 4.64 5.46 4.67 5.43TiO.sub.2 Dispersion 9.28 10.92 9.34 10.86Carbon black Dispersion -- -- 0.75 0.52Surfactant-Catalyst Solution 12.99 -- 13.07 --Acrylic Dispersion 11.13 -- 11.20 --Hydroxyl propyl 2.78 -- 1.40 --cellulose soln.Viscosity in centipoise as 682 608measured by Brookfield#2 spindle, @20 rpm__________________________________________________________________________ TABLE 5______________________________________ Solids Content Coating in Finished Composition ArticleTopcoat (Wt. %) (Wt %)______________________________________PTFB Dispersion 66.73 94.04PFA Dispersion 3.51 4.95Water 3.77 --Mica coated with TiO.sub.2 0.43 1.01Surfactant catalyst soln. 12.52 --Acrylic dispersion 13.04 --______________________________________ COMPARISON 1 The same process is carried out except the discontinuous coat is applied immediately after midcoat application (wet-on-wet) without flash drying. Accelerated abuse cooking results, using 6 pans of each, gave the results of Table 6. The rating of 5 is a standard judged by an experienced tester, based on damage to the coating from a number of standardized cooking tests, using weighted ball point pens to abuse the coatings. This shows the superior durability of the invention. TABLE 6______________________________________ # of cooks to 5 rating______________________________________Ex. 1 97 AvgComparison 1 78 Avg______________________________________
Cookware with a multi-layer, non-stick coating on its cooking surface has a random spattered pattern of raised dots or globules in an inner coat, telegraphing roughness through an outer coating to create texture.
8
This application is a continuation of application Ser. No. 043,372, filed on Apr. 28, 1987, now U.S. Pat. No. 4,788,556. BACKGROUND OF THE INVENTION This invention relates to methods and apparatus for the elimination of dissolved air from ink used in an ink jet apparatus and, more particularly, to a new and improved method and apparatus for deaerating ink in a highly effective manner. In many ink jet systems, ink is supplied to a chamber or passage connected to an orifice from which the ink is ejected drop-by-drop as a result of successive cycles of decreased and increased pressure applied to the ink in the passage, usually by a piezoelectric crystal having a pressure-generating surface communicating with the passage. If the ink introduced into the passage contains dissolved air, decompression of the ink during the reduced pressure portions of the pressure cycle may cause the dissolved air to form small bubbles in the ink within the passage. Repeated decompression of the ink in the chamber causes these bubbles to grow and such bubbles can produce malfunctions of the ink jet apparatus. Heretofore, it has been proposed to supply deaerated ink to an ink jet apparatus and maintain the ink in a deaerated condition by keeping the entire supply system hermetically sealed using, for example, flexible plastic bags or pouches as a deaerated ink supply. Such arrangements are not entirely satisfactory, however, because the flexible plastic pouches are at least partially air-permeable and, in hot melt ink systems, this problem is aggravated because the plastic pouch material becomes more permeable to air at elevated temperatures at which the heated ink is capable of dissolving large amounts of air, e.g., up to 20 percent by volume. Moreover, air may dissolve into the ink at the ink jet orifice during periods of non-jetting. Such dissolved air may diffuse through the ink into the jet pressure chamber, and thereby cause malfunction of the jet. Consequently, air bubble formation in the ink jet head of a hot melt jet apparatus is a primary cause of hot melt ink jet failure. Accordingly, it is an object of the present invention to provide a new and improved method and apparatus for eliminating dissolved air from ink in an ink jet system which overcomes the above-mentioned disadvantages of the prior art. Another object of the invention is to provide a system for deaerating ink in an ink jet system and for purging any air bubbles which have been formed in the ink jet head. SUMMARY OF THE INVENTION These and other objects of the invention are attained by subjecting ink in an ink jet system to reduced pressure applied through a membrane which is permeable to air but not to ink. In one form of the invention, ink is conveyed to an ink jet head through a passage which communicates through a permeable membrane with a plenum maintained at a reduced air pressure. To eject any air bubbles which may have been formed prior to removal of dissolved air, the permeable membrane may be flexible and an increased air pressure may be applied to the membrane which raises the pressure on the ink in the jet, causing expression of such ink and thus purging the jet of air bubbles. In a particular embodiment, the ink supply leading to the ink jet head includes a deaerating passage in which the ink is formed into an elongated thin layer between two opposite wall portions and at least one of the wall portions comprises a flexible, air-permeable membrane covering a plenum in which the air pressure may be reduced or increased. In addition, a check valve is provided upstream from the deaerating passage so that increased pressure in the plenum will eject ink and any trapped air bubbles from the ink jet head. Within the ink jet head, ink is circulated by convection from the orifice to the deaerating passage. BRIEF DESCRIPTIONS OF THE DRAWINGS Further objects and advantages of the invention will be apparent from reading of the following description in conjunction with accompanying drawings, in which: FIG. 1 is a block diagram, partly in section, schematically illustrating a representative embodiment of an ink jet ink supply including an ink deaerator in accordance with invention; and FIG. 2 is an en cross-sectional view of the ink deaerator used in the ink supply system of FIG. 1. DESCRIPTION OF PREFERRED EMBODIMENT In the typical embodiment of the invention illustrated in the drawings, an ink jet apparatus includes an ink supply reservoir 10 holding liquid ink for use in an ink jet head 11 from which ink is ejected to produce a desired pattern on a sheet or web 12 of paper or other image support material in the usual manner. The ink jet head 11 is supported by conventional means for reciprocal motion transverse to the web 12, i.e., perpendicular to the plane of FIG. 1, and the web is transported by two sets of drive rolls 13 and 14 in the direction indicated by the arrow past the ink jet head. The ink supply system includes an ink pump 15 for transferring ink from the ink supply 10 through a flexible supply line 16 to a reservoir 17 which is supported for motion with the ink jet head 11. If hot melt ink is used in the ink jet apparatus, the ink supply system may be of the type described in the Hine et al. U.S. Pat. application Ser. No. 043,369, filed Apr. 28, 1982, for "Hot Melt Ink Supply System", now U.S. Pat. No. 4,814,786 assigned to the same assignee as the present application. In that ink supply system ink is transferred from the ink supply 10 to the reservoir 17 only when the level of the ink 18 in the reservoir is low. To maintain the ink in the reservoir 17 at atmospheric pressure, a vent 19 is provided. Accordingly, the ink 18 standing in the reservoir 17 contains air even if the ink was protected from air in the ink supply 10. Moreover, when hot melt inks are used, as much as 20 percent by volume of air may be dissolved in the ink. If ink containing such dissolved air is subjected to the periodic decompression which takes place in the ink jet head 11, air bubbles can form in the ink, causing failures in the operation of the ink jet head. To overcome this problem in accordance with the present invention, an ink deaerator 20 is provided in the ink supply path between the reservoir 17 and the ink jet head 11. An air pump 21 is connected through a flexible air line 22 to provide increased or reduced air pressure to the ink deaerator. The ink deaerator 20 is mounted for reciprocal motion with the ink jet head 11 and the reservoir 17, and, in the illustrated embodiment, the air pump 21 is operated by engagement of a projectable pump lever 23 with a projecting lug 24 on the deaerator 20 during the reciprocal motion of the deaerator. The pump lever 23 is connected to a piston 25 within the pump arranged so that, if negative pressure is to be provided to the deaerator, the pump lever will be engaged during motion of the deaerator in one direction, causing the piston to move in a direction to apply reduced pressure through the line 22, after which the piston may be locked in position. If increased pressure is to be applied to the deaerator, the lever 23, together with the piston 25, is moved in the opposite direction by the lug 24. The internal structure of the deaerator 20 and the ink jet head 11 is shown in the sectional view of FIG. 2. At the lower end of the reservoir 17 a check valve 26 is arranged to permit ink to pass from the reservoir to a narrow elongated deaerating passage 27 which leads to two passages 28 and 29 in the ink jet head 11 through which ink is supplied to the head. In a particular embodiment, the passage 27 is about 0.04 inch thick, 0.6 inch wide and 31/2 inches long and is bounded by parallel walls 30 and 31 which are made from a flexible sheet material which is permeable to air but not to ink. The material may, for example, be a 0.01 inch thick layer of medical grade silcone sheeting such as Dow Corning SSF MEXD-174. On the other side of the membranes 30 and 31 from the passage 27, air plenums 32 and 33, connected to the air line 22, are provided. Each plenum contains a membrane support 34 consisting, in the illustrated example, of a corrugated porous sheet or screen, to support the membrane when the pressure within the plenum is reduced. The air pump 21 is arranged to normally maintain pressure within each plenum at less than about 0.75 atmosphere and, preferably at about 0.4 to 0.6 atmosphere. In addition, the length and width of the passage 27 are selected so that, during operation of the ink jet head, the ink being supplied thereto is subjected to a reduced pressure within the passage for at least about one half minute and, preferably for at least one minute. With this arrangement, enough dissolved air is extracted through the membranes 30 and 31 from the ink within the passage to reduce the dissolved air content of the ink below the level at which bubbles can be formed in the ink jet head. The membranes 30 and 31 and the plenums 32 and 33 are also arranged to expel ink which may contain air bubbles through the orifice 35 in the ink jet head 11 when operation of the system is started after a shut-down. For this purpose the air pump 21 is arranged as described above to supply increased pressure through the line 22 to the deaerator 20. This causes the flexible membranes 30 and 31 to move toward each other. Since the check valve 26 prevents ink from moving back into the reservoir 17, the ink in the passage 27 is forced into the ink jet head 11, expelling any ink therein which may contain air bubbles through the ink jet orifice 35. In order to deaerate ink in the ink jet head 11 which may have dissolved air received through the orifice 35, a heater 36 is mounted on the rear wall 37 of an ink jet passage 38 which leads from the passages 28 and 29 to the orifice 35. When the heater 36 is energized, ink in the passage 38 which may contain dissolved air received through the orifice 35 during inactive periods in the operation of the jet is circulated continuously by convection upwardly through the passage 38 and then through the passage 29 to the deaerating passage 27. In the deaerating passage 27 the ink is deaerated as it moves downwardly to the passage 28, and it then returns through the passage 28 to the passage 38. In operation, ink from the reservoir 17, which contains dissolved air, is transferred to the ink jet head 11 through the passage 27 as the ink jet head operates. The reduced pressure in the plenums 32 and 33 causes dissolved air in the ink to be extracted from the ink through the membranes 30 and 31. As the deaerator 20 moves in its reciprocal motion, the air pump 21 is operated by the lug 24 and lever 23 to maintain reduced pressure in the plenums. When it is necessary to expel ink from the ink jet head on start-up of the system, the air pump 21 is arranged to supply increased pressure to the plenums 32 and 33. During nonjetting periods of the ink jet head, the ink circulates convectively through the passages 38, 29, 27 and 28, transporting ink which may contain air from the orifice 35 to the deaerator. Although the invention has been described herein with reference to a specific embodiment, many modifications and variations therein will readily occur to those skilled in the art. For example, the permeable membrane and air plenum may form one wall of an ink reservoir. Accordingly, all such variations and modifications are included within the intended scope of the invention as defined by the following claims.
In the particular embodiment of an ink deaerator described in the specification, an elongated ink path leading to an ink jet head is formed between two permeable membranes. The membranes are backed by air plenums which contain support members to hold the membranes in position. Reduced pressure is applied to the plenums to extract dissolved air from the ink in the ink path. Increased pressure can also be applied to the plenums to eject ink from the ink jet head for purging. Within the ink jet head ink is circulated convectively from the orifice to the deaerating path even when the jet is not jetting ink.
1
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/434,881, filed Dec. 18, 2002, and which is hereby incorporated by reference in its entirety. BACKGROUND INFORMATION [0002] Every year, a great number of drivers mount a bicycle, boat, or cargo container on a car top rack, and later drive into a garage or other low clearance area, causing an impact or collision that can damage thousands of dollars of equipment, accessories, rack components, and the roof of the vehicle itself. The devices and methods disclosed herein can be used to detect overhead obstacles as the vehicle approaches them, and can signal the driver to stop when the approach is fast enough or close enough to result in an impact or collision. SUMMARY [0003] A device for and method of detecting the presence of and evaluating the approach to obstacles situated in the path of articles attached to the roof of a vehicle and alerting the driver of the vehicle when an impact or collision between the articles and the obstacles is likely to occur. An example device includes an ultrasonic transducer and circuitry to measure the distance to obstacles, an audible warning device, a microprocessor to perform such tasks as controlling the generation of ultrasonic pulses, measuring the echo delay, calculating the risk of collision, and signaling the warning device, and a housing which protects the components of the device and can be quickly and easily attached to and detached from the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS [0004] [0004]FIG. 1 is a diagram showing a vehicle fitted with an example device approaching a garage. [0005] [0005]FIG. 2 is a top view of an example device. [0006] [0006]FIG. 3 is a bottom view of an example device. [0007] [0007]FIG. 4 is a cutaway view of an example device. [0008] [0008]FIG. 5 is a view of an example remote warning component using a radio receiver. [0009] [0009]FIG. 6 is a an example block diagram of electronic components of an example device. [0010] [0010]FIG. 7 is an example of the ultrasonic transceiver circuit diagram. [0011] [0011]FIG. 8 is a flow diagram of an example main microprocessor program. [0012] [0012]FIG. 9 is a flow diagram of an example ping subroutine of the program depicted in FIG. 7. [0013] [0013]FIG. 10 is a flow diagram of an example risk calculation subroutine of the program depicted in FIG. 7. [0014] [0014]FIG. 11 is a flow diagram of an example test subroutine of the program depicted in FIG. 7. [0015] [0015]FIG. 12 is a diagram related to FIG. 1 showing the vehicle closer to the garage, and representing the point of echo fall-off. [0016] [0016]FIG. 13 is an example plot of echo delay vs. forward travel showing the echo fall-off condition. DETAILED DESCRIPTION [0017] The devices and methods disclosed herein provide a new and practical way to prevent damage to articles carried on the roof of a vehicle. Examples of the devices and methods include electronic components for periodically measuring the distance between a point on the vehicle and an obstacle located in the path of travel of articles carried on the roof of the vehicle, an algorithm for evaluating the measurements to determine the risk of a collision between the articles and the obstacle, and a device for warning the driver of the vehicle to stop when the risk exceeds a predetermined value. [0018] An overview of the operation of the example overhead obstacle detector and methods is shown in FIG. 1. Vehicle 1 carrying bicycle 2 on roof-top rack 3 approaches garage 4 or a similar overhead obstruction. Overhead obstacle detector device 5 is mounted on the forward portion of the roof of vehicle 1 , and generates periodic bursts of ultrasonic waves 6 along the path of angle θ, which is substantially in the direction of forward travel of vehicle 1 . When vehicle 1 moves sufficiently close to garage 4 , ultrasonic waves 6 are reflected by substantially vertical portions 8 and 9 of garage 4 and return to device 5 , where they are detected and amplified by an ultrasonic receiver circuit described later. A microprocessor in device 5 measures the elapsed time between transmission and reception of ultrasonic waves 6 , and the elapsed time represents the distance 10 between device 5 and reflecting surfaces 8 or 9 . [0019] If no echo is received from an obstacle in the path of ultrasonic waves 6 , such as when vehicle 1 is driving on the road and has not yet approached garage 4 , the microcontroller of device 5 is programmed to go into a low power idle mode for approximately one second before generating the next burst of ultrasonic waves 6 . Once an echo return signal from an obstacle is received, and is sufficiently strong to be detected by the receiver circuit, the microprocessor in device 5 begins sending bursts of pulses at a higher rate, for example every 250 ms, and begins calculating the risk of a collision between roof-top articles, represented by bicycle 2 , and obstacles, represented by garage 4 , using an evaluation technique described later. When the calculated risk exceeds a predetermined level, the microprocessor signals an audible and/or visual alarm contained in device 5 , warning the driver of the vehicle to stop immediately. [0020] [0020]FIG. 2 shows an example overhead obstacle detector 5 as it may appear when mounted on a vehicle. The measuring and evaluating components may instead be installed in the roof of the vehicle, and the warning component might instead be installed in the driver compartment. The visible features of the device can include housing 11 , ultrasonic transducer 12 , and magnetic base 13 . Magnetic base 13 is sufficiently powerful to hold the device on the roof of the vehicle under the conditions of road speed and wind speed encountered in typical highway driving. The magnetic base allows the driver to rapidly attach the device to the vehicle whenever articles are carried on the roof, and rapidly detach the device when removing the articles or leaving the vehicle unattended. [0021] In an alternate overhead obstacle detector, the magnetic base 13 is removed and replaced instead by one portion of a two piece quick-release clamping mechanism, the second portion of which may be clamped to some portion of the carrier or rack mounted on the roof of the vehicle. Thus the device may still be rapidly attached and detached from the vehicle by separating the two pieces of the quick-release mechanism. This device could be used on vehicles with a non-ferrous roof, and may also include the use of a remote warning device attached to a warning signal connector on housing 11 . To accommodate hearing-impaired drivers, an alternate example of the warning device includes a visual warning indicator connected to the external warning connection of the housing, and fixed to the vehicle windshield or mounted inside the driver compartment. [0022] Another example of the overhead obstacle detector is possible where the measuring, evaluating, and warning components are built permanently into the vehicle, and make use of the vehicle's battery for power. [0023] [0023]FIG. 3 is a bottom view of an overhead obstacle detector as it may appear when removed from the vehicle and turned over. Speaker 14 can provide the audible warning component of the example device, and has sufficient amplitude to be clearly heard by the driver through the roof of the vehicle and under normal driving conditions. Bottom cover 15 corresponds to magnetic base 13 described above, and may be constructed of magnetic material, or may contain an embedded magnet or magnets, or may be covered by an adhesive-backed magnetic sheet. Switch 16 can turn the device off and on when it is removed and replaced from the vehicle, and may be located in bottom cover 15 to protect it from inadvertent operation. In an alternate example of an overhead obstacle detector, switch 16 is a magnetic switch integrated into bottom cover 15 that is automatically closed when the device is attached to the vehicle roof, and automatically opened when the device is removed. [0024] [0024]FIG. 4 shows a cutaway view of overhead obstacle detector 5 , and illustrates the internal components. Ultrasonic transducer 17 may be attached to housing 18 , and could be sealed to prevent water from entering housing 18 . In this example, transducer 17 may be situated at angle 7 in FIG. 1 with respect to the longitudinal axis of housing 18 . In an alternate example of the overhead obstacle detector, the attachment method of transducer 17 may allow this angle to be adjusted by the driver when the nominal value of angle 7 is not suitable for typical operating conditions, such as when the vehicle has a roof plane that deviates substantially from horizontal. In another example of an overhead obstacle detector, adjustment of angle 7 could be accomplished with a mechanism for changing the angle of bottom cover 19 with respect to housing 18 , for example a wedge-shaped shim. [0025] In the example overhead obstacle detector, circuit board 20 contains the ultrasonic transmitter and receiver circuitry, microprocessor, and additional supporting electronic components. Transducer 17 , speaker 21 , external alarm connector 22 , external power connector 23 , and batteries 24 are connected to circuit board 20 . [0026] An alternate example of the warning component is shown in FIG. 5, and consists of a radio receiver 25 , microprocessor 26 , a warning speaker or buzzer 27 , and an accessory adapter plug 28 , or alternately a battery. This example of the warning component may be fitted inside the vehicle driver compartment, and receives signals from a low-power radio transmitter embedded on circuit board 20 . In this example, a signal could be transmitted from device 11 to warning component 29 when the alarm condition is met, and the warning speaker or buzzer 27 could be activated. The warning component may alternately include one or more LEDs or other visual status indicators 30 to signal the driver if the device 11 is not operating properly, for example when the battery is low, or the device 11 is not turned on, or the radio transmitter or receiver is not working. To provide status information about operating conditions, device 11 could transmit a periodic signal to warning component 29 , and microprocessor 26 could activate indicator or indicators 30 according to the presence or state of the periodic signal. [0027] In another example overhead obstacle detector, radio receiver 25 may be replaced with an infra-red optical receiver, and a remote infra-red optical transmitter may be attached to external alarm connector 22 . [0028] [0028]FIG. 6 is a block diagram showing an example of the circuit board, transducer, and speaker. Microcontroller 31 outputs a square wave signal on output line 32 , which is amplified by transmitter 33 and sent to the ultrasonic transducer 34 . Echo signals received by transducer 34 , which is used in this example for both transmitting and receiving, are detected and amplified by receiver 35 , which outputs a reference voltage and comparator signal on lines 36 and 37 , respectively. Alternate examples of the overhead obstacle detector may include a separate transmitting and receiving transducer. After sending the pulse signal on line 32 , microcontroller 31 starts an internal timer, waits for a time period corresponding to the ringing period of the transducer, and then monitors comparator line 37 . When the signal voltage on comparator line 37 exceeds the voltage on reference line 36 , the value of the internal timer is captured, and a risk evaluation calculation described below is initiated. When the risk exceeds a predetermined maximum value, the microcontroller outputs to speaker 38 a signal corresponding to a collision warning. In alternate examples of the overhead obstacle detector, the microcontroller periodically tests for low battery voltage and/or the presence of dirt or other contaminants on transducer 34 according to procedures described below, and outputs signals corresponding to these conditions on speaker 38 . [0029] The ultrasonic transceiver circuit of the example device is show in FIG. 7. The transmit pulse generated by the microcontroller is input on line 39 , and controls the gate of enhancement MOSFET 40 . This causes current to flow through the primary winding of transformer 41 and generates a high voltage signal driving ultrasonic transducer 42 . When an echo is received by transducer 42 , it generates a voltage on the input of operational amplifier 43 , which amplifies the signal and inputs it to operational amplifier 44 . Operational amplifier 44 outputs the comparator voltage which is sent to the microprocessor on line 45 . The reference voltage is output on line 46 . The detection sensitivity can be adjusted via resistor 47 . In an alternate example of the ultrasonic transceiver, the receiver circuit can be replaced by an integrated sonar ranging chip such as the Texas Instruments TL852. [0030] [0030]FIG. 8 is a flow diagram of an example of the main program of the microprocessor. Upon startup at 48 , such as when the device is switched on or power is connected, the microcontroller can immediately execute the ping subroutine 49 , which is described in detail below. Ping subroutine 49 returns a value representing the time delay D between sending and receiving the burst of ultrasonic pulses, and hence the distance to the closest object which returns an echo loud enough to trigger the comparator as described above. If there are no detectable echoes within a predetermined time out period, the ping subroutine returns 0. If a time value is returned, the program proceeds to step 50 , which tests for the presence of a stored time value from the previous ping. If a previous time value exists, the program proceeds to the calculation subroutine 51 , which is described below. The current and previous time values are used by calculation subroutine 51 to calculate the value of the risk parameter. Next, the program compares the risk parameter returned by the calculation subroutine to a predetermined maximum value. If the risk is greater than the predetermined maximum, the collision alarm routine 52 is called to signal the alarm device and thus warn the driver of a collision. The program then proceeds to 53 , where the stored time value is replaced by the current time value. Next, the program waits for an interval representing the desired sample rate between successful pings of approximately 250 ms. If the ping subroutine 49 times out instead of returning a value, the program proceeds to block 54 , where the stored time value is cleared. The program then proceeds to 55 , where the microprocessor is put to sleep for a period of approximately one second. The processor then wakes up and proceeds again to the ping subroutine 49 . In an alternate example, the program may proceed from block 54 to the test subroutine 56 , which optionally tests the battery voltage, and/or the condition of the ultrasonic transducer, as described later. [0031] The flow diagram of the ping subroutine is shown in FIG. 9. The program first starts the pulse interval timer in block 58 , which begins generating the square wave output for the ultrasonic transmitter as described above. The interrupt routine for the pulse timer increments a counter after each cycle, which is checked in block 59 , and when a predetermined number of pulses have been sent, the program proceeds to block 60 and turns off the pulse timer. Next, the comparator capture timer is started in block 61 , and the program loops through blocks 62 and 63 waiting for the capture timer to expire, or a value to be captured, whichever comes first. The ping subroutine then ends, and returns either the captured timer value, or zero if the timer expired. The expiration time for the capture timer is at least the echo delay time required for echoes at the maximum range of the ultrasonic detection circuit from a large acoustically reflective surface. [0032] [0032]FIG. 10 is a flow diagram of an example of the calculation subroutine, corresponding to the evaluation components of the overhead obstacle detector. The critical condition for signaling the alarm is determined by the control program using the current value of the pulse echo delay returned by the ping routine of FIG. 9 to represent the distance between the obstacle detector and an obstacle, and the current value along with the stored previous value to calculate the relative speed between the detector and the obstacle. To facilitate parameterisation of the distance and speed components, and to provide a single parameter representing the risk of collision, the system may be modeled as a virtual spring and damper connected between the vehicle and the obstacle, where the virtual spring is compressed as the vehicle approaches the obstacle. The risk parameter could thus be the total virtual force F exerted by the spring and damper: F = kx + δ   x  t [0033] The virtual spring rate k and damping coefficient δ are determined empirically to provide a reasonable degree of advance warning, and to prevent undesirable false alarms, such as when approaching a slowing vehicle in traffic or stopping behind a truck or in front of a large acoustically reflective surface. The virtual spring compression x can be calculated by subtracting the current echo delay from a value representing the echo delay at the maximum range of the ultrasonic detection circuit. The velocity can be calculated using the difference between the current and previous echo delay values, divided by the elapsed time period between those two values, which in an alternate example of the program may be varied according to the current value of the delay time. Thus the virtual force F is: F = k  ( x max - x ) + δ  ( x - x t - 1 P ) [0034] where F is the virtual force, k is the virtual spring constant, x max is the maximum distance, x is the current distance, δ is the virtual damping coefficient, x t-1 is the previous sample distance, and P is the time between the current and previous samples. The alarm condition is met when: F>F max [0035] where F max may be determined empirically along with k and δ to correspond to the closest approach distance and highest approach speed that are acceptable under most actual circumstances. [0036] Returning to FIG. 10, program blocks 64 , 65 , and 66 correspond to an alternate example of the evaluation method, and will be described later. The example calculation subroutine begins at block 67 , calculating the velocity of the approach by dividing the difference between the current and last delay times by the sample period. The last delay time is represented in the diagram as REG, the current time by D, the sample period by P, and the velocity by V. In block 68 the program then calculates the virtual force parameter, represented in the diagram by F, using a representation of the force equation above where k represents the spring constant k, D max the value of x max , and d the damping coefficient δ. The subroutine then exits and returns the virtual force value to the main program. [0037] As discussed previously, some examples of the overhead obstacle detector may test the battery condition and/or transducer contamination. FIG. 11 shows the flow diagram for the test program code. Blocks 69 and 70 increment a counter to determine if it is time to run the battery test, and if so, block 71 is executed and uses the comparator or optionally an additional circuit on the circuit board to test the battery voltage. If the voltage is below a predetermined minimum, the alarm is signaled and the counter is reset in blocks 72 and 73 . The test for transducer contamination begins at block 74 incrementing the test counter, and if it is time to run the test executes block 75 , which sends a burst of pulses to the transducer. In block 76 , a timer is set up to isolate a time window in which to activate the comparator and corresponding to the period in which a clean transducer is still ringing. The comparator is used to measure the transducer voltage during this window, and if the transducer has been damped by dirt or other contaminants, the ringing amplitude will not be sufficient to trip the comparator, and the dirty transducer alarm is sent to the alarm device in block 77 . If the transducer is clean, the comparator will be set, and the alarm is not signaled. After clearing the alarm counter in block 78 , the subroutine returns. [0038] [0038]FIG. 12, which is closely related to FIG. 1, shows vehicle 79 closely approaching garage 80 , and depicts a condition referred to herein as echo fall-off. In this condition, vehicle 79 has advanced far enough toward or into garage 80 that the ultrasonic beam path 81 is no longer reflected by garage surface 82 , and echo signals are now reflected by objects on garage ceiling 83 , such as beams or garage door equipment, or reflected by back wall 84 of the garage. In an alternate example of the main and calculating routines of the microcontroller program logic, and in case the control logic of the device has not already signaled an alarm, the sudden increase in echo delay time as the echo signal falls off of surface 82 may be treated by the control logic as an indication that an echo fall-off has occurred, and the difference between the echo delay before and after the fall-off condition may be subtracted from subsequent echo delays. Looking at FIG. 10, program block 64 detects the echo fall-off, using the predetermined value MAXJUMP, and executes the offset adjusting block 65 . Block 64 tests for both echo fall-off and the inverse of echo fall-off, which occurs as the vehicle is backing away from the garage. In this way, a reasonably accurate representation of the position of the vehicle is maintained as long as the device is operating continuously during approach and backing maneuvers. The offset value may then subtracted from the current echo time value in block 66 , and the subsequent calculation of the virtual force continues with block 66 . In addition, the main program block in FIG. 8 contains an additional block 57 , to clear the offset value when the vehicle leaves the approach area and the ping subroutine begins timing out. [0039] [0039]FIG. 13 is a plot of data obtained with a prototype device as echo fall-off occurs. The horizontal axis represents the forward position of the vehicle as it approaches a garage, and the vertical axis is the echo delay measurement. The jump in echo delay time between points 85 and 86 represents a first echo fall-off condition, and the jump between points 87 and 88 show a second echo fall-off. The alternate example of the control logic described above effectively joins point 85 with point 86 , and point 87 with point 88 , to form a continuous curve. Thus the risk evaluation method can continue to function progressively as the vehicle moves into the garage. [0040] Having described the components of and examples of the device and methods of this disclosure, it should now be understood that many additional enhancements and modifications can be made to the device or methods which are still within the scope and intent of the disclosure.
Devices and methods for detecting the presence of and evaluating the approach to obstacles situated in the path of articles attached to the roof of a vehicle and alerting the driver of the vehicle when an impact or collision between the articles and the obstacles is likely to occur. An example device includes an ultrasonic transducer and circuitry to measure the distance to obstacles, an audible warning device, a microprocessor to perform such tasks as controlling the generation of ultrasonic pulses, measuring the echo delay, calculating the risk of collision, and signaling the warning device, and a housing which protects the components of the device and can be quickly and easily attached to and detached from the vehicle.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a camera which allows simultaneous sound recording and into which a film magazine allowing simultaneous sound recording which magazine houses photographing film allowing recording of sound information and an ordinary film magazine for photographing only can be selectively loaded. 2. Description of the Prior Art Recently in the field of a motion picture camera using 8 mm film it has become conventional to use a magazine housed type film which can be easily loaded into a camera. Lately, such film magazine has been designed to house a film having sound recording belt and which is easily loaded into a simultaneous sound recording camera which can perform photographing and sound recording simultaneously. Such film magazine has the construction that a sound recording opening is provided beside a conventional picture image recording opening and constant speed film advancement is done for sound recording and at the same time sound recording is done on a sound recording belt such as magnetic coating, etc., provided on the film by a sound recording means such as a magnetic head, etc. In such motion picture camera using a simultaneous recording film magazine, such sound recording elements as, for example, a continuous film advancing capstan, a pinch roller, a magnetic head, a head pad, a film guide, etc., are provided at such position within the film magazine chamber as corresponds to the sound recording opening of the magazine. However these elements need to have such structure that at the time when the film magazine is loaded into or unloaded from the camera, the capstan and the pinch roller are separated from each other and similarly does the magnetic head and the head pad to make insertion of film therebetween easy. Also during the operation of the camera after film magazine is loaded, the capstan and the pinch roller come into pressure contact to advance the film being pressure held thereby with a constant speed, and at the same time the magnetic head and head pad are in pressure contact with each other with the film interposed therebetween so that magnetic sound recording is done on the sound recording belt of said film. To this end, such structure is generally employed that the capstan and the magnetic head, etc., are made as the sound recording means is fixed to the film magazine chamber while the pinch roller, head pad, film guide, etc., are made as movable means so that the movable means come in pressure contact with or in separated position from the above mentioned sound recording means in an association with the loading into or unloading from the camera of the film magazine. On the other hand, when a conventional film magazine such as the one known under the name of "Super 8" is used, no sound recording is made. Therefore a safety means becomes necessary holding the above mentioned movable means at a position separated from the sound recording means at the same time thus making the sound recording impossible. SUMMARY OF THE INVENTION The first object of the present invention is to provide a camera allowing simultaneous sound recording of unique arrangement for meeting the above mentioned requirement. The second object of the present invention is to provide a camera allowing simultaneous sound recording having such arrangement that, only when the film magazine allowing simultaneous sound recording is loaded, various elements of the camera for sound recording are set at the state in which sound recording is possible (including the preparatory state) in an association with the closing action of the magazine chamber, while when an ordinary film magazine other than said simultaneous sound recording film magazine is loaded or when no magazine is loaded, the movable elements of the above mentioned sound recording elements have their linked relationship with the magazine chamber cover released so that they are retained at an inactive position in which sound recording is inoperable. The third object of the present invention is to provide a camera allowing simultaneous sound recording in which a biasing means to control particularly the action of the movable means out of the sound recording elements is provided so that the linked operation between said movable means and the magazine chamber cover is assured. The fourth object of the present invention is to provide a camera allowing simultaneous sound recording in which a switching means controlled by the movable means out of the sound recording elements is provided when said movable means is in inactive state being separated from the fixed means. Accordingly at least one of the sound recording circuit equipped or the driving circuit of the continuous film advancing means for sound recording provided at the camera can be retained in the blocked state by the above-mentioned switching means when the above mentioned simultaneous sound recording film magazine is not used. Other objects of the present invention will become clear by the specifications and the drawings which will be explained in detail below. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an oblique view to show one example of a camera allowing simultaneous sound recording by the present invention wherein a portion is cut out. FIG. 2 is a front elevation showing the camera shown in FIG. 1 into which a film magazine allowing simultaneous sound recording is loaded and the magazine chamber cover is opened. FIG. 3 is a front elevation showing the state in which the magazine chamber cover in FIG. 2 is closed. FIG. 4 is a front elevation of the state in which an ordinary film magazine for photographing only is loaded into the camera shown in FIG. 1 and the magazine chamber cover is closed wherein a portion thereof is cut away. DESCRIPTION OF THE PREFERRED EMBODIMENTS Now examples of the present invention will be explained in detail referring to the drawings. FIG. 1 is an oblique view to select and show a motion picture camera by way of example as a camera allowing simultaneous sound recording according to the present invention, showing the state in which the magazine chamber cover is opened, wherein a portion thereof is sectioned for explaining its structure. In the drawing, 1 is a camera main body, 2 is a photographing lens assembly housing photographing optical system, 3 is a magazine chamber into which a film magazine is loaded, 4 is a photographing film gate, 5 is a film advancing claw, and 6 is a take up part engaging with the take up axle of the film magazine to take up the film. 7 is a magazine chamber cover which can be opened and closed having a lock claw 8 being coupled with the camera main body 1 by a hinge 9. 10 is a part at the camera main body to engage with the lock claw 8, and 11 is a magazine chamber cover opening and closing knob to shift said engaging part 10. 12 is a sound recording part having a capstan 13 which is rotated through a flywheel by a conventionally known driving means and a sound recording head 14 connected to a conventionally known sound recording circuit. 15 is a movable member which can rotate around an axle 16 and rotatably supports a pinch roller 17 and has a head pad 18, being always biased to clockwise direction so that it comes in pressure contact with the sound recording part by a spring 19 which constitutes a first biasing means. 15a is a cut out hole having a tapered part 15b provided at the front end of the movable member. 20 is a member having a slot 20b engaged with a pin 20a planted on the camera main body and sliding to the direction of the slot, further having a pin 21 fixed on its raiser part. Said pin 21 is so made as its forward end sticks outside of the camera main body. 22 is a pin planted on the sliding member 20 and engages with the cut out hole 15a on the above-mentioned movable member 15. The sliding member 20 is always biased to such direction that the pin 21 protrudes outside of the camera main body by a spring 23 constituting a second biasing means. As the pin 22 is positioned at the tapered part 15b of the cut out hole 15a on the movable member 15 in said state, the pinch roller 17, head pad 18, etc., provided on the movable member 15, etc., are at the position of FIG. 1 being separated from the sound recording part. 24 is a leaf spring provided at the rear wall plane of the magazine chamber wall and has a protruding part 25 at its forward end. Said protruding part 25 is so made as engaging and disengaging with/from the end plane 15c at the forward end of the above mentioned movable member 15. 26 is a pin protruding from the hole 26a at the magazine chamber wall into the magazine chamber and is pushed by loading of the simultaneous sound recording magazine, being provided on the above-mentioned leaf spring 24. 27 is a switch to block the conventionally known sound recording electric circuit being equipped at the camera and/or the conventionally known driving circuit being equipped to the camera for continuously rotating the capstan. 28 is a pin provided on the above mentioned movable member 15 and is so positioned as opening the switch 27 at the position shown in the drawing being separated from the sound recording part. FIG. 2 shows a state in which simultaneous sound recording magazine is loaded into the camera according to the present invention shown in FIG. 1. FIG. 3 shows the same in the state wherein the magazine chamber cover is closed. FIG. 4 shows the state wherein an ordinary magazine for photographing only is loaded and the magazine chamber cover is closed. Now the operating state of the set-up of the present invention shown in FIG. 1 will be explained in detail using FIG. 2 to FIG. 4. In FIG. 2, 29 shows a simultaneous sound recording film magazine having a sound recording opening 30. 31 is a film having sound recording belt. The sound recording part 12 housing therein the capstan 13, and the sound recording head 14 is positioned at the sound recording opening of said magazine. The pin 26 protruding into the magazine chamber detects the simultaneous sound recording magazine 29 and is pushed by the loading of the latter, and the projection 25 at forward end of the lead spring 24 escapes from the engagement with the end plane 15b of the movable member. Next as the camera is placed in the state of FIG. 3 wherein the magazine chamber cover is closed from the above mentioned state, the pin 21 is pushed in correspondence with the closing action of the magazine chamber cover 7, and the sliding member 20 slides against the spring 23, while the pin 22 shifts from the tapered part 15b of the cut out hole 15a to the straight line part. By this the movable member 15 rotates to the clockwise direction by the biasing power of the spring 19, and the pinch roller 17, the head pad 18 are placed in pressure contact with the capstan 13, the sound recording head 14 with the film 31 being intervened therebetween, also the switch 27 is closed as the pin 28 is separated, thus preparation for sound recording photographing will be completed. Next, as the release member of a camera is activated ordinary photographing and sound recording are done simultaneously. The release of the above mentioned sound recording state is done by opening of the magazine chamber cover 7 in the manner reverse to that mentioned above. In FIG. 4, 32 shows a magazine only for ordinary photographing. When this magazine 32 is loaded as the size of the magazine is small the side plane of the magazine will not come to the position corresponding to the pin 26 which is protruding into the magazine chamber, and since this pin 26 is not pushed by the magazine it retains the protruding state. By this the projection part 25 at forward end of the leaf spring 24 retains the state being engaged with the end plane 15b of the movable member 15, therefore as the magazine chamber cover 7 is closed and the pin 21 is pushed, even when the pin 22 slides and is shifted from the tapered part 15b of the cut out hole 15a to its straight line part, the movable member 15 is blocked by the above-mentioned projection 25 and will not be activated. By this the pinch roller 17 and head pad 18, etc., retain their state as being separated from the sound recording part 12 and the switch 27 of the sound recording circuit and/or the capstan driving circuit is kept in the cut out state, therefore the change over from the simultaneous sound recording photographing to the ordinary photographing can be done automatically without any handling by a photographer only by loading such ordinary magazine as mentioned above into a camera. While the sound recording head is in fixed condition in the above-mentioned example, it can naturally be made movable. By the set-up or arrangement as explained in detail, the present invention will have such advantages that in a camera in which a film magazine allowing simultaneous sound recording and an ordinary film magazine for photographing only can be selectively used, when the simultaneous sound recording film magazine is loaded as a means to detect this kind of magazine is provided at a camera, said detection is used as a first stage to allow the action of the movable set member for next stage sound recording, then said movable member is made to be shifted to the position of the state of sound recording in correspondence with the closing action of the magazine chamber cover, thus by such indispensable handling in operation of a camera as loading of the simultaneous sound recording magazine and closing of the magazine chamber, all the necessary means for simultaneous sound recording can be automatically shifted to its sound recording state. Also when an ordinary film magazine for photographing other than the above mentioned simultaneous sound recording magazine is used or when no magazine at all is loaded in a camera, such safety action is exercised by the above mentioned detection means that even if the magazine chamber cover is closed the movable means for sound recording will not be shifted to the operating position for sound recording, therefore the sound recording means will not function erroneously when the simultaneous sound recording magazine is not in use. And this change over from the simultaneous sound recording to the ordinary photographing is made in a full automatic manner without any burdon to a photographer, by the above mentioned loading of different types of film magazine. Further, when a film magazine allowing simultaneous sound recording is loaded, not only the elements which mechanically works for sound recording are shifted to sound recording position, but an electrical sound recording circuit and a driving circuit for continuous film advancing are automatically formed in response to the closing of the magazine chamber cover. Thus, a photographer can have complete control on the simultaneous sound recording only by closing the cover after loading of the magazine followed by release action.
The present invention relates to a camera allowing simultaneous sound recording into which a film magazine housing a photographing film which can record sound information thus allowing simultaneous sound recording and an ordinary photographing film magazine can be selectively loaded. Also provided is a detection device to distinguish the kind of film magazines mentioned above and a linking mechanism which shifts the camera into a sound recording state in correspondence with the closing action of the magazine chamber cover of a camera only when the above mentioned detection device detects the film magazine which allows simultaneous sound recording.
6
This application is a continuation-in-part of U.S. patent application Ser. No. 07/989,507 filed Dec. 11, 1992, now U.S. Pat. No. 5,234,719. FIELD OF THE INVENTION The invention relates to microbicidal compositions for sanitizing inanimate surfaces. More specifically, the invention relates to microbicidal compositions which include an octanoic carboxylic acid and a sulfur containing compound as an antimicrobial agent. The composition is preferably safe for incidental human contact as well as food contact surfaces without requiring a post-sanitizing rinse. The microbicidal compositions of the invention are suitable for dairy farms, food and beverage processing plants, food preparation kitchens, food serving establishments, child-care, nursing-care and hospital-care applications, as well as for general utility in domestic households and institutions. BACKGROUND OF THE INVENTION The list of microbicidal agents has decreased due to their human toxicity and their detrimental effect on water supplies and the overall environment. Improving analytical capabilities to detect parts-per-billion levels in food, water and in the environment generally have raised important safety concerns about the application and misapplication of these chemicals. These issues have resulted in the banning of some antimicrobials, for example hexachlorophene; the retesting of others for animal toxicity, such as, the quaternary ammonium compounds; and, the increasing scrutiny of microbicidal species such as chlorine or hypochlorites which may form toxic halocarbons in effluent waters. There has been a long felt need for antimicrobial agents which have a high degree of antimicrobial efficacy, and which are preferably safely used around sensitive areas while also posing no environmental incompatibility. Those antimicrobial agents which are lethal to microorganisms, however, are also toxic in varying degrees to humans and animals in that both higher and lower forms of life share at least some common metabolic pathways. Competitive inhibition, non-competitive inhibition, protein coagulation, oxidative and reductive action, blockage of enzyme systems are thought to be some of the mechanisms involved in the destruction of microorganisms. Differentiation of antimicrobial "-cidal" or "-static" activity, the definitions which describe the degree of efficacy, and the official laboratory protocols for measuring this efficacy are important considerations for understanding the relevance of antimicrobial agents and compositions. Antimicrobial compositions may effect two kinds of microbial cell damage. The first is a truly lethal, irreversible action resulting in complete microbial cell destruction or incapacitation. The second type of cell damage is reversible, such that if the organism is rendered free of the agent, it can again multiply. The former is termed bactericidal and the latter, bacteriostatic. Sanitizers, disinfectants and tuberculocidal agents are, by definition, agents which provide bactericidal activity. In contrast, a preservative is generally described as inhibitory or bacteriostatic. A sanitizer is an agent that reduces the number of bacterial contaminants to safe levels as judged by public health requirements. Practically, a sanitizer must result in 99.999% reduction (5 log order reduction) for given organisms as defined by Germicidal and Detergent Sanitizing Action of Disinfectants, Official Methods of Analysis of the Association of Official Analytical Chemists ("A.O.A.C."), paragraph 960.09 and applicable sections, 15th Edition, 1990 (EPA Guideline 91-2). A disinfectant is an agent that kills all vegetative cells including most recognized pathogenic microorganisms. As such, it must pass a more stringent bactericidal test; the A.O.A.C., Use Dilution Methods, Official Methods of Analysis of the Association of Official Analytical Chemists, paragraph 955.14 and applicable sections, 15th Edition, 1990 (EPA Guideline 91-2). A tuberculocide is a higher order disinfectant which is capable of killing all vegetative tuberculosis bacteria cells. Tuberculocidal activity is determined by Tuberculocidal Activity of Disinfectants, Official Methods of Analysis of the Association of Official Analytical Chemists, paragraph 965.12 and applicable sections, 15th Edition, 1990. In contrast, a preservative is described as any agent that generally extends the storage life of perishable products such as food and non-food products by retarding or preventing deterioration of flavor, odor, color, texture, appearance, nutritive value, or safety. One method used for evaluating such materials is designated Minimum Inhibitory Method Concentration. Another procedure is entitled Zone of Inhibition. Preservatives, by definition, are therefore inhibitory substances added to food to prolong or enhance shelf-life. The principal differences between a preservative and a sanitizer are two-fold; 1) mode of action, a preservative prevents growth rather than killing microorganisms; and, 2) exposure time, a preservative has days to months. In contrast, a sanitizer must provide 99.999% kill (5 log order) within 30 seconds at nominal 20° C. Ideally, a sanitizing agent or compound will possess several important properties in addition to its microbicidal efficacy. The sanitizer should be no-rinse after application, and have residual antimicrobial activity. Residual activity implies a film of sanitizing material which will continue to have antimicrobial effect if the treated surface is contaminated by microorganisms during a storage or lag period. The sanitizer should be odor free to prevent transfer of undesirable odors onto contact surfaces or articles with which it otherwise comes into contact. The sanitizer should be composed of ingredients which will not affect food if incidental contact or contamination occurs, nor affect humans should incidental ingestion result. In addition, the sanitizer should be composed of naturally occurring or innocuous ingredients, which are chemically compatible with the environment and cause no concern for toxic residues in downstream water. Previously, certain compositions have been recognized as effective in providing sanitizing, disinfecting, and preservative effects. For example, U.S. Pat. No. 4,404,040 to Wang discloses the sanitizing properties of short chain fatty acids formulated with an ionic hydrotrope-solubilizer and compatible acids. U.S. Pat. No. 4,647,458 to Ueno et al, discloses bactericidal compositions comprising a large concentration of ethyl alcohol, an organic acid, and an inorganic acid. Moreover, U.S. Pat. No. 3,915,633 to Ramachandran, discloses a prewash composition for treating fabrics which includes an organic acid such as citric acid and either a nonionic or an anionic surfactant. U.S. Pat. No. 3,867,300 to Karabinos, discloses bactericidal compositions presumably for controlling the spread of nosocomial infections in hospitals consisting of an aliphatic monocarboxylic acids, and nonionic surfactants. U.K. Patent Application GB 2,103,089A to Kimberly Clark discloses the use of carboxylic acids as virucides. U.S. Pat. No. 4,715,980 to Lopes et al, discloses an antimicrobial concentrate composition containing a dicarboxylic acid, a solubilizer, an acid, and a diluent. U.S. Pat. No. 3,650,965 to Cantor et al, discloses clean-in-place detergent solutions for treating milk and food processing equipment based on two different nonionic surfactants. U.S. Pat. No. 4,002,775 to Kabara discloses the use of mono-esters of twelve carbon aliphatic fatty acids and polyols. European Patent Application No. 87303488 to Kabara discloses antimicrobial preservative compositions of glycerol mono esters, preferably monolaurin and fatty acids. However, similar to Wang and Ueno et al, the disclosure in these publications is not specific to C 8 acids and further does not discuss the antimicrobial activity of these acids in conjunction with their use with certain adjuvants. Currently, products used for sanitizing operations include strong oxidizing agents such as peracetic acid, iodophors, sodium hypochlorite and related n-chloro compounds such as chloro isocyanurates, quaternary ammonium compounds and the like. While these are no rinse sanitizers, they are not ideal for one reason or another. Peracetic acid, iodophors and chlorine based sanitizers are either decomposed or lost by evaporation when a film of sanitizer is left on the contact surface and allowed to dry. Thus no residual activity remains on the intended surface. Residual activity is necessary to provide continued antimicrobial effect if the surface is contaminated by microorganisms during storage. Quaternary ammonium compounds (QAC) have an excellent residual quality as they are stable and increase in concentration as the solvent (water) evaporates. Unfortunately, for many uses, this residue may carry into sensitive areas which do not tolerate QAC residues. For example, trace amounts of QAC in substances such as milk, inhibits the starter culture which produces lactic acid and flavor resulting in the curdling of milk protein. Acid based sanitizers often contain foam control agents or surfactant couplers which are also incompatible in sensitive areas. Moreover, carboxylic acid based sanitizers often have undesirable organoleptic properties exemplified by a "goat-like" odor. The longer chain fatty acids have limited solubilities in water and require thorough rinsing with potable water before contact of the sanitized surface to avoid imparting odors or flavors to articles contacting the surface. While all these compositions are excellent sanitizers, many of their ingredients are not applicable or otherwise compatible with contact sensitive surfaces. Consequently, these current, commercially successful products have not been designed for user safety, misapplication or environmental compatibility. Thus a sanitizing agent which specifically addresses these issues would possess utility and uniqueness not found in heretofore described sanitizers. SUMMARY OF THE INVENTION The invention is based on the surprising discovery of an antimicrobial composition which is capable of providing sanitizing and disinfecting antimicrobial efficacy as well as tuberculocidal activity. We have found that octanoic acid and when combined with various sulphur containing compounds have an unexpected level of antimicrobial properties in comparison to other antimicrobial compositions. The composition of the invention generally comprises a carrier and an antimicrobial agent of octanoic carboxylic acid and a sulfur compound. Optionally, the invention may also contain a variety of formulatory or application adjuvants. The invention also comprises concentrate compositions and methods of sanitizing and disinfecting using the antimicrobial composition of the invention. The claimed composition eliminates the potential for recontamination of sanitized surfaces by potable water which may be safe to drink but may contain microorganisms. This is particularly important in environments such as, for example, where there is a delay between sanitizing operation and use of food preparation equipment. In cases where equipment remains wet between uses, contaminating organisms may grow freely. Airborne contamination may also be retarded by the invention by retention of compositional residue on surfaces. Especially in the presence of moisture, this residue will continue its antimicrobial action. When residual amounts of the invention are retained on the surface of application, continued sanitizing action will occur in the face of exposure to contaminating splash and spray. The invention is also applicable to closed systems such as pipelines and holding tanks which may be difficult to completely drain. When used, the invention will continue to effectively destroy any microorganisms which might be present without creating risk of harmful food contamination or environmental contamination. DETAILED DESCRIPTION OF THE INVENTION The invention comprises a composition capable of imparting sanitizing and disinfecting antimicrobial efficacy as well as tuberculocidal activity. The composition may also comprise an acidulant along with any variety of other formulatory or application adjuvants. The invention also comprises concentrate and use dilution formulations which may take the form of liquid solutions, gels, as well as impregnated sponges, towelettes, aerosol and pump sprays or solids. The invention further comprises methods of sanitizing and disinfecting using the composition of the invention. I. Antimicrobial Agent The composition of the invention generally comprises an antimicrobial agent. The invention is based on a discovery that a specific carboxylic acid, octanoic acid when combined with a sulfur containing compound, surprisingly provides extraordinary sanitizing, if not tuberculocidal, disinfecting, antimicrobial efficacy. Generally, the antimicrobial agent of the invention functions to sanitize or disinfect the intended surface of application. Further, the composition of the invention also provides tuberculocidal activity. The antimicrobial agent of the invention is intended to provide tuberculocidal, sanitizing or disinfecting antimicrobial activity upon application to the intended surface, leaving a residue which upon contact with foodstuffs will not contaminate or otherwise preclude ingestion of the prepared food. Generally, the composition of the invention is applicable to all food collection, process, preparation and serving environments and facilities as well as other contact sensitive areas such as day and child care facilities, nursing homes and other health care facilities, and domestic households. Thus, a sanitizer and disinfectant which is excel lent microbiocidally, does not require a post-sanitizer rinse, imparts no off-flavor or odor to food, possess residual activity, and minimizes the potential for acute and chronic human toxicity and environmental contamination fulfills a need not currently met by presently available sanitizers. The antimicrobial agent of the invention comprises a carboxylic acid system of octanoic acid and derivatives thereof combined with a sulfur containing compound. Carboxylic acids are characterized by the presence of one or more carboxyl groups which generally have the structure: ##STR1## Carboxylic acids as a group are usually considered to be relatively weak acids. Even in view of the weakness of these acids, we have found that one carboxylic acid provides unique antimicrobial efficacy despite this classification. The antimicrobial agent of the invention consists of octanoic acid as well as, octanoic acid esters, or salts. Octanoic acid also known as caprylic acid, occurs naturally as glycerides and may generally be derived by saponification and subsequent distillation of coconut oil. Octanoic acid is generally an oily liquid having a boiling point of 239.7° C., a melting point of 16.7° C. and a density of 0.910 (at 20° C.). Octanoic acid is known by the formula: CH.sub.3 (CH.sub.2).sub.6 COOH. In addition to antimicrobial efficacy resulting from simple octanoic acid, antimicrobial efficacy may also result from octanoic acid esters, or salts. Specifically, the carboxylic acid of the invention may also be derivatized into the form of a carboxylic acid ester, or carboxylic acid salt. Further, as with all carboxylic acids, industrial grades of octanoic acid may also comprise minor proportions of other carboxylic acids as impurities. Generally, the linear carboxylic acid of the invention may also take the form of a salt formed by reaction with an alkaline substance most commonly from oxides, hydroxides or carbonates of monovalent and divalent metals in Periodic Groups IA and IIA; but, also with basic positive complexes such as the ammonium radical and organic amine moieties. The carboxylic acid of the invention may also comprise an ester derivative of that carboxylic acid. Common ester derivatives of carboxylic acids are those wherein the hydroxy group is replaced by an alkoxy group which may comprise any number of different alkyl moieties which do not impede the efficacy of the octanoic acid compound. The principal types of esters result from reaction with monohydric alcohols, polyhydric alcohols and ethylene or propylene oxide. The most common monohydric alcohols used are the simple alkyl alcohols such as methyl, ethyl, propyl, isopropyl, and the like. The most common polyhydric alcohols include polyethylene glycol, glycerol, sorbitol, and certain carbohydrates such as sucrose. Accordingly, the octanoic carboxylic acid of the invention may comprise any number of acid salts, acid esters, and the like. Preferably, the compound used in the invention is octanoic acid or an octanoic acid salt or an octanoic acid ester. Generally, depending on whether the composition is a use dilution or concentrate formulation, octanoic acid may be present in concentrations ranging generally from about 0.01 wt-% to about 45 wt-% preferably from about 0.03 wt-% to about 40 wt-%, and most preferably from about 0.05 wt-% to about 35 wt-%. The concentration figures detailed above for octanoic acid are presented as guidelines. Actual concentrations vary depending upon the carrier used in the formulation, whether aqueous, organic, inorganic or mixtures thereof; the overall nature of the formulation, whether neat solution, liquid concentrate, or aerosol, dispersion, emulsion, gel, or solid; the delivery and application method; and, the compositional adjustments necessary for physical and chemical stability during storage or use in adverse environments. Additionally, the antimicrobial agent of the invention also comprises a compound containing sulfur. Sulfur compounds and especially compounds such as sulfonates, and sulfates, among others, provide a tuberculocidal, sanitizing and disinfecting antimicrobial character when combined with octanoic acid and derivatives thereof. Further, these sulfur compounds may also function to increase acidity, as well as provide surface activity and coupling within the composition. Generally, this agent may comprise any compound, surfactant, polymer, or mixture thereof containing sulfur. Preferably the sulfur compound comprises an organic sulfonic acid moiety or sulfuric acid ester to provide antimicrobial efficacy, acidity, and surface activity. Generally, the sulfur compound may comprise an aliphatic, aromatic, or alicyclic structure and derivatized combinations thereof which have been subjected to sulfonation, or sulfation reactions. In sulfonation, a new C--S bond is created and a SO - 3 group is introduced into an organic molecule to provide a derivative with a C--SO - 3 linkage, a grouping known as a sulfonate which may remain protonated (sulfonic acid), or be neutralized with base (sulfonic acid salts). Sulfation results from any process of introducing an SO 3 group into an organic compound by forming a C--O or O--S of the C--O--S bond sequence. The reaction product, a sulfate, exhibits the characteristic --C--O--SO - 3 configuration. Generally, in the context of the claimed invention, the acid form of a sulfonated or sulfated compound or polymer is preferred. Compounds which may be sulfonated or sulfated for use in accordance with the invention include the acid and various salt derivatives of sulfonated paraffins, sulfonated olefins, sulfonated lignins, sulfonated mono and polycarboxylic acids and alcohol esters of these acids; and, sulfonated alicyclic, aromatic, and alkylaryl moieties; also, the acid and corresponding salt compounts of sulfated alcohols and ether alcohols; sulfated glycerol esters of fatty acids; and products obtained by sulfation of saturated, unsaturated and hydroxy fatty acids and natural fats and oils containing their glycerides, as well as monohydric and polyhydric alcohol esters of these acids, among others. One preferred class of compounds are alkyl-aryl sulfonates such as alkyl benzene sulfonates. Specifically preferred compounds are aromatic sulfonate compounds such as alkyl benzene sulfonates, decanoic benzene sulfonates, dodecanoic or dodecyl benzene sulfonates, tetradecanoic benzene sulfonates, and hexadecanoic benzene sulfonates, and mixtures thereof. These compounds may also be used in their acid form as sulfonic acid compounds. The most preferred sulfur compound has been found to be dodecyl benzene sulfonic acid as it is a very strong acid affecting protonation of weak fatty acids such as octanoic acid, and is of itself a microbiocide as well as a good surfactant. Generally, depending on whether the composition is a used dilution or concentrate formulation, octanoic acid may be present in concentrations ranging generally from about 0.01 wt-% to 45 wt-%, preferably from about 0.03 wt-% to 40 wt-%, and most preferably from about 0.05 wt-% to 35 wt-%. II. Carrier The antimicrobial composition of the invention also comprises a carrier. The carrier within this composition functions to transport the antimicrobial agents to the intended surface of application and define the forms of the composition whether liquid, semi-solid such as a gel, or solid. Moreover, depending upon the nature of the carrier, this constituent may be used to maintain the antimicrobial agent on the intended surface for an extended period of time in the form of a film or residue after application. Keeping these functions in mind, the carriers useful in the invention should preferably maintain and not obscure the efficacy of the antimicrobial agent. The composition of the invention may take the form of a neat solution or liquid concentrate, dispersion, emulsion, aerosol, gel, or solid. The invention may also take the form of a liquid impregnated sponge or towelette where the carrier comprises, in addition to a liquid, a chemically inert carrier such as a fabric or sponge. Accordingly, the choice of any carrier useful in the invention will depend somewhat on the intended form and intended use application of the final composition. If the invention takes the form of a solution, dispersion, gel, emulsion, aerosol, or solid, useful carriers include water or aqueous systems as well as organic or inorganic based carriers, or mixtures thereof. Organics which have been found especially useful include simple alkyl alcohols such as ethanol, isopropanol, n-propanol and the like. Polyols are also useful carriers in accordance with the invention, including propylene glycol, polyethylene glycol, glycerol, sorbitol and the like. Any of these compounds may be used singly or in combination with another organic or inorganic carrier or, in combination with water, or in mixtures thereof. If organic, the carrier may also comprise any number of surfactants or surfactant combinations. Surface active agents which have been found as useful carrier in accordance with the invention include anionic and nonionic agents such as, for example, propylene glycol esters, glycerol esters, polyoxyethylene glycerol esters, polyglycerol esters, sorbitan esters, polyoxyethylene sorbitan esters, sucrose esters, polyethylene glycol esters, polyoxyethylene-polyoxypropylene ether adducts, dioctyl sodium succinate, stearoyl lactylate, and esters of acetylated, lactylated, citrated, succinylated or diacetyl tartarated glycerides. Preferred surfactants include nonionic surfactants having a mixture of polyoxyethylene and polyoxypropylene moieties. Specifically, one nonionic surfactant found to be especially preferred is a polyoxyethylene, polyoxypropylene block copolymer having about 240 to 280 moles of ethoxylation and about 45-65 moles of propoxylation. If the invention is formulated as a solid, the carrier may be selected from any organic or inorganic compound which imparts a solid form and hardness to the composition of the invention either by a hot-melt, pour-cast process, by extrusion, or by compression. Typical organic ingredients which may be used in the solid antimicrobial composition of the invention to harden this composition include amides, polyols, and certain nonionic and anionic surfactants. For example, stearic monoethanol amide, stearic diethanol amide and urea have been found to effectively result in the formulation of a hardened product. Moreover, polyols such as polyethylene glycol, and polyhydric sugar alcohols such as mannitol and the like or mixtures thereof have all been found to impart a hardened but soluble character when combined in the composition of the invention. Surfactants useful in this invention as a hardening agent and carrier are solid, generally high melting analogs of nonionics and anhydrous metallic salts of anionic surfactants which include alkyl and dialkyl phenol ethoxylates, linear alkyl alcohol ethoxylates, polyalkoxide polymers of ethanolamines, ethylene oxide/propylene oxide block copolymers, polyalkylene oxide block polymers of ethylene diamine, glycerol esters, polyoxyethylene glycerol esters, polyglycerol esters, sorbitan esters, polyoxyethylene sorbitan esters, sucrose esters, polyethylene ethers, dioctyl sodium sulfo succinate, stearoyl lactylate, and complex esters such as acetylated, lactylated, citrated, succinylated, and diacetyl tartarated glycerides. Other compositions which may be used as hardeners within the composition of the invention include sugars, and modified starches or cellulosics which have been made water soluble through acid or alkaline treatment processes. Inorganics which may be used in forming the hardened antimicrobial composition of the invention include salts formed of periodic Groups IA and IIA metals, as well as ammonium, with the corresponding negative ions or radicals of mineral acids such as chloride ions, carbonate ions, nitrate ions, phosphate ions, and sulphate ions as well as their respective hydrates, protic salt forms, or in the case of phosphates, the various condensate species. Generally, any type-of carrier capable of solidifying the antimicrobial agent may be used in accordance with the invention. To this end, urea, Pluronic™ F-108 and polyethylene glycol have been found to be beneficial solidifying agents. Generally, the carrier comprises a large portion of the composition of the invention. Here again, the carrier concentration and type will depend upon the nature of the composition as a whole, the environment of storage and method of application including the concentration of antimicrobial agent, among other factors. Notably, the carrier should be chosen and used at a concentration which does not inhibit the antimicrobial efficacy of the active in the present composition. III. Adjuvants Alternatively, the composition of the invention may also comprise any number of adjuvants. Depending on the benefits provided by the adjuvant, adjuvants may partially or wholly displace the carrier in the composition. Generally, in accordance with the invention, there may be included within this composition formulatory adjuvants or adjuvants which assist in the application of the invention with respect to performance, form, aesthetics, and stability when stored or used within adverse conditions. Formulatory adjuvants include coupling agents, solubilizers, or hydrotropes used to maintain the storage stability of the present composition as well as solubilizing the antimicrobial agent of the invention. This function may be accomplished exclusively by the carrier whether aqueous, organic, inorganic or a mixture. thereof. However, in situations which require formulation of a concentrated antimicrobial system, an additional organic agent may be introduced into the system to facilitate solubilization of the antimicrobial agent. To this end, any number of organic coupling agents may be used including monofunctional and polyfunctional alcohols. Those coupling agents which have been found most useful include linear alkyl alcohols such as, for example, ethanol, isopropanol, and the like polyfunctional organic alcohols include glycerol, hexylene glycol, polyethylene glycol, propylene glycol, sorbitol and the like. Generally, depending on whether the composition is in the form of a concentrate or use dilution formulation, the concentration of these adjuvant compounds, when used in these capacities, ranges from about 0 wt-% to about 99 wt-%, preferably from about 0.1 wt-% to about 97 wt-%, and most preferably from about 0.15 wt-% to about 95 wt-%. The invention may also comprise one or more acidulants useful in lowering the pH of the present composition. Acidulants useful in the present composition include lactic acid, phosphoric acid, sulfuric acid, sulfamic acid, adipic acid, tartaric acid, succinic acid, acetic acid, propionic acid, citric acid, malic acid, or mixtures thereof. Further it has been found that a use dilution solution pH ranging from about 1.3 to 4, preferably from about 1.4 to 3, and most preferably from about 1.5 to 2.5 provide the most desirable antimicrobial efficacy. The composition of the invention may also comprise surface tension altering constituents such as various anionic and nonionic surfactants. These surfactants may be used to maintain constituents in solution over various temperature gradients as well as altering the wettability and cleaning capabilities of the composition of the invention to any variety of surfaces. Any number of surfactants or combinations thereof may be used in accordance with the invention. The surface active agents which have been found useful in accordance with the invention include anionic and nonionic agents including, for example, propylene glycol esters, glycerol esters, polyoxyethylene glycerol esters, polyglycerol esters, sorbitan esters, polyoxyethylene sorbitan esters, sucrose esters, polyethylene glycol esters, polyoxyethylene-polyoxypropylene ether adducts, dioctyl sodium succinate, stearoyl lactylate, and complex esters such as acetylated, lactylated, citrated, succinylated, or diacetyl tartarated glycerides. One class of surfactants which has been found especially useful in formulating the various embodiments of the present composition includes nonionic surfactants which have a mixture of hydrophilic and hydrophobic character. Generally, a mixture of hydrophilic and hydrophobic character in the surfactants has been found particularly useful in accordance with the invention and is created by the presence of polyoxyethylene and polyoxypropylene moieties. Nonionic surfactants which are especially useful include those surfactants having about 5-300 moles of ethoxylation and about 10-80 of propoxylation. One surfactant which has been found most useful is Pluronic™ F-108 which is a nonionic surfactant generally defined as a polyoxyethylene, polyoxypropylene block copolymer having about 240 to 280 moles of ethoxylation and about 45 to 65 moles of propoxylation, sold by BASF-Wyandotte Company Inc. We have found that BASF-Wyandotte Company Inc. Pluronic F-108 is useful for formulating solid and gel concentrates, and Pluronic L-44, (having about 5 to 15 moles of EO and 10 to 30 moles of PO), is useful for formulating liquid concentrates. Surface tension altering constituents of the invention may be used in the present composition, regardless of form or application, depending on whether the composition is a concentrate or use dilution formulation, in concentrations ranging from about 0 wt-% to 60 wt-%, preferably from about 0.01 wt-% to 50 wt-%, and most preferably from about 0.02 wt-% to 40 wt-% depending on whether the surfactant is present for wetting, detergency, or coupling. Here again, the concentration and type of surfactant used should not inhibit the antimicrobial action of the active within the invention. The concentration of surfactant adjuvant may also vary depending upon the nature of the formulatory composition as a whole, the concentration of antimicrobial agent, as well as the storage environment and method of application among other factors. As the invention may take the form of a spray, either pump or aerosol, adjuvants which may be used with the carrier in the invention include propellants. Any number of propellants may be used including n-butane, isobutane and propane, among others. The concentration of propellant will generally range from about 3 wt-% to about 25 wt-%, preferably from about 4 wt-% to about 20 wt-%, and most preferably from about 5 to about 15 wt-%. The composition of the invention may also comprise adjuvants which facilitate the application of this composition through various vehicles. Specifically, the composition of the invention is useful as an antimicrobial agent in hand creams, sponges, towelettes, hand cleansers, dips, sprays and washes among other uses. Accordingly, the composition of the invention may comprise any number of conditioners or emollients, humectants, perfumes, thickeners, opacifiers or particulates, colorants or dyes, cleansers or other agents useful in facilitating the application of the composition of the invention to its intended application. Table 1 provides a general directory of guideline concentrations for the various compositional forms of the invention. TABLE 1______________________________________ PRE- MOST USEFUL FERRED PREFERRED______________________________________USE-DILUTION CONCENTRATION RANGES (wt-%)ANTIMICROBIAL 0.02-1.0 0.06-0.7 0.1-0.4AGENTOCTANOIC ACID 0.01-0.5 0.03-0.35 0.05-0.2SULFUR 0.01-0.5 0.03-0.35 0.05-0.2COMPOUNDCARRIER 54.98-99.98 64.94-99.84 74.9-99.75ADJUVANTS 0-45 0.1-35 0.15-25pH 1.3-4 1.4-3 1.5-2.5LIQUID CONCENTRATE RANGES (wt-%)ANTIMICROBIAL 1-90 3-80 5-70AGENTOCTANOIC ACID 0.5-45 1-40 1.5-35SULFUR 0.5-45 1-40 1.5-35COMPOUNDCARRIER 0-99 0-95 0-91ADJUVANTS 0-99 2-97 4-95pH (USE- 1.3-4 1.4-3 1.5-2.5DILUTION)SOLID CONCENTRATE RANGES (wt-%)ANTIMICROBIAL 1-60 2-50 3-40AGENTOCTANOIC ACID 0.5-30 1-25 1.5-20SULFUR 0.5-30 1-25 1.5-20COMPOUNDCARRIER 40-99 48-96 56-93ADJUVANT 0-54 2-50 4-41pH (USE- 1.3-4 1.4-43 1.5-2.5DILUTION)GEL COMPOSITION RANGES (wt-%)ANTIMICROBIAL 1-50 2-40 3-30AGENTOCTANOIC ACID 0.5-25 1-20 1.5-15SULFUR 0.5-25 1-20 1.5-15COMPOUNDCARRIER 30-94 38-91 47-88ADJUVANTS 5-70 7-60 9-50pH (USE 1.3-4 1.4-3 1.5-2.5DILUTION)______________________________________ The concentrations provided above generally reflect a ratio of octanoic acid to the sulfur compound of about 1:1. This ratio may range from about 1:0.5 to 10, preferably about 1:0.5 to 2. In use we have found that a dilution rate which results in an active concentration of ranging from about 500 ppm to 1500 ppm, preferrably about 750 ppm to 1250 ppm, and most preferrably 900 ppm to 1100 ppm of each of octanoic acid and sulfur containing compounds has been found useful. The liquid concentrate may comprise water in the form of carrier ranging from about 0 wt-% to 70 wt-%, preferrably from about 15 wt-% to 70 wt-%, most preferrably from about 30 wt-% to 70 wt-% as a percentage of the total composition. The gel concentrate may comprise water in the form of carrier ranging from about 0 wt-% to 80 wt-%, preferrably from about 15 wt-% to 60 wt-%, and most preferrably about 25 wt-% to 40 wt-% as a percentage of the total composition. WORKING EXAMPLES Following below are formulatory, stability, application and microbiological working examples using the composition of the invention. While the invention is exemplified by the working examples, it is not limited to the examples shown hereinafter. WORKING EXAMPLES 1-40 Formulatory working examples, working examples 1-40, were prepared by combining the antimicrobial of the invention with various constituents to show compatibility as well as antimicrobial efficacy. Generally, nonionic coupling agents were thought not to be compatible with various fatty acid compounds such as octanoic acid. Contrary to this general statement, the working examples of Table 2 show that octanoic acid when combined into the composition of the invention are compatible with nonionics such as Pluronic™ F-108 (manufactured by BASF/Wyandotte); (all concentrations are in wt-%). This unexpected compatibility, exceeding 1 wt-% nonionic in use dilution, is important in that coupling agents may be used to stabilize the fatty acid against phase separation at extreme temperature. This is especially relevant when a concentrated sanitizer or disinfectant is desired. Moreover, this level of nonionic surfactant was shown to not affect the antimicrobial efficacy of the composition (see Table 3). TABLE 2______________________________________(wt-%)______________________________________COMPON-ENT 1 2 3 4 5 6 7 8______________________________________Octanoic 32.00 32.00 28.57 29.63 30.19 30.32 32.00 30.48AcidLAS* 20.00 20.00 17.86 18.52 18.87 18.95 20.00 19.05(97% w/v)Distilled 20.00 34.00 33.93 39.81 40.57 40.73 43.00 40.95WaterHexylene 28.00 14.00 6.25 7.41 5.66 4.76GlycolNonylphenol 13.39Ethoxylate(9.5 molesEO)Pluronic™ 4.63F-108**Pluronic™ 4.72F-38**Pluronic™ 10.00L-44**Phosphate 5.00ester (acid)of a C.sub.10-14alcoholethoxylate(60 molesEO)Alcohol 4.76ethoxylate(C.sub.10-14 20moles EO)______________________________________COMPON-ENT 9 10 11 12 13 14 15 16______________________________________Octanoic 31.37 25.60 24.33 22.82 24.38 24.38 23.46 24.38AcidLAS* 19.61 10.00 9.50 8.92 9.52 9.52 27.49 9.52(97% w/v)Distilled 42.16 49.40 46.96 44.04 47.05 47.05 36.11 47.05WaterHexylene 14.46 12.94GlycolNonylphenol 4.76Ethoxylate(9.5 molesEO)Nonylphenol 6.86Ethoxylate(15 molesEO)Pluronic™ 5.00 4.75 4.46 4.76 4.76F-108Sodium 5.00LaurylSulfatePropylene 5.00 19.76GlycolSodium 14.29XyleneSulfonateUrea 14.29Lactic Acid 14.29______________________________________COMPON-ENT 17 18 19 20 21 22 23 24______________________________________Octanoic 24.38 25.60 25.60 25.60 24.98 26.67 24.38 25.60AcidLAS* 19.05 20.00 20.00 20.00 12.20 12.50 19.05 12.00(97% w/v)Distilled 42.28 39.40 39.40 39.40 55.01 49.38 42.29 47.40WaterHexylene 10.00 10.00GlycolButyl 2.93 9.52 10.00CarbitolMethyl 6.25CarbitolPluronic™ 5.00 4.76 5.00F-108**Pluronic™ 5.00 5.00 4.88 5.20F-38**Pluronic™ 10.00L-44**Lactic Acid 14.29______________________________________COMPON-ENT 25 26 27 28 29 30 31 32______________________________________Octanoic 26.95 25.60 25.60 25.60 24.62 25.60 25.60 25.60AcidLAS* 12.63 20.00 12.00 12.00 19.23 25.00 12.00 20.00(97% w/v)Distilled 49.90 41.90 49.90 42.40 41.72 34.40 42.40 44.40WaterHexylene 10.00 10.00 10.00 4.81 5.00 10.00 5.00GlycolIsopropanol 5.26(91% w/v)Pluronic™ 5.26 2.50 2.50F-108**Pluronic 10.00 9.62 10.00 5.00L™-44**Ecolab 10.00LF071(BLOCKCO-POLYMER(mw 1400))______________________________________COMPON-ENT 33 34 35 36 37 38 39 40______________________________________Octanoic 12.80 12.80 12.80 6.40 25.60 25.60 25.60 12.80AcidLAS* 12.80 20.00 12.80 12.80 25.00 25.00 25.00 12.80(97% w/v)Distilled 64.40 57.20 57.40 67.80 34.40 34.40 33.40 56.40WaterHexylene 12.00 8.00 5.00 5.00 6.00 13.00GlycolPluronic 10.00 10.00 5.00 5.00 10.00 10.00 5.00L™-44**Pluronic™ 10.00L-35**______________________________________ COMPONENT 41 42______________________________________ Octanoic Acid 6.40 LAS* (97% w/v) 12.80 25.00 Distilled Water 66.80 59.00 Hexylene Glycol 9.00 6.00 Pluronic L™-44** 5.00 10.00______________________________________ (*Linear alkyl sulfonate) (**Nonionic surfactants sold by BASF/Wyandotte) TABLE 3______________________________________Working Concentra- Proskauer-Examples tion Beck* Kirshners* Middlebrook*______________________________________39 1 oz/2 gal 10/10 10/10 10/1039 2 oz/3 gal 10/10 10/10 10/1042 1 oz/2 gal 10/10 10/10 10/1042 2 oz/3 gal 10/10 10/10 10/10Control 1 1:50 10/10 10/10 10/10(phenol)Control 2 1:70 8/10 10/10 9/10(phenol)______________________________________ The results indicate tuberculocidal efficacy is being achieved with a ten minute exposure time using either the 1 ounce per 2 gallons or 2 ounces per 3 gallons dilution. *(# Negative Tubes/# Tubes Tested) .sup.1 Tuberculocidal Activity Disinfectants, Official Methods of Analysi of Official Analytical Chemists, Paragraph 969.12 and applicable sections 15 Edition, 1990. EXAMPLES 43-44 An A.O.A.C. Sterilant Test was performed on the formulations shown in Table 4A against C. sporogenies on silk sutures at a temperature of 80° C. with a 2.5 minute exposure time. Products were prepared in 100 ppm hard H 2 O at concentrations of 3, 4, 5, 6, & 7%. Results are as follows: TABLE 4A______________________________________(wt-%) EXAMPLE 43COMPONENT (wt-%) EXAMPLE 44______________________________________Octanic Acid 32.0 25.6Pluronic™ F-108** 19.2Lactic Acid 48.8(88 w/v)Pluronic™ L-44** 10.0Dodecyl Benzene 25.0Sulfonic Acid (97% w/v) 33.4Distilled Water 6.0Hexylene Glycol______________________________________ TABLE 4B______________________________________(wt-%) Conc. PrimaryExample (wt-%) Growth Tube Secondary Tube Growth______________________________________43 3% 17/20 16/20 4% 20/20 19/20 5% 20/20 20/20 6% 20/20 20/20 7% 20/20 20/2044 4% 20/20 20/20 5% 20/20 20/20 6% 20/20 20/20______________________________________ **Pluronics™ are EO/PO block copolymers of BASF/Wyandotte TABLE 5__________________________________________________________________________(Wt-%) Hard Surface Udder WipeCOMPONENTS (wt-%) Aerosol Wipes Hand Wipes Sanitizing Udder Prewipe__________________________________________________________________________Deionized Water 72.835 76.60 72.85 69.75 78.75Ethanol 17.100 18.00 18.00 18.00 14.00Octanoic Acid 0.143 0.15 0.15 0.15 0.10Lactic Acid 0.143 0.15 1.00 0.50 0.15Citric Acid 3.00 3.50Propylene Glycol 4.750 5.00 5.00 5.00 5.00Glycerol USP 3.00 2.00Pluronic™ F-108 0.029 0.10 0.10Propellant A-31* 5.000__________________________________________________________________________ (Isobutane) The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
This invention is a microbicidal and tuberculocidal composition comprising a major portion of carrier and an effective sanitizing amount of octanoic acid, or octanoic acid derivatives, and a sulfur containing compound. Optionally, the invention may also comprise any variety of formulatory ingredient options or application adjuvants. The invention comprises concentrate compositions and methods of sanitizing and disinfecting using the antimicrobial composition of the invention.
2
FIELD OF THE INVENTION The present invention relates in general to a hand hold assembly that is mounted on railroad cars. Railroad car hand holds must meet stringent safety standards, but also conform to the variable topographies of railroad cars. The present invention provides a hand hold assembly which can be adapted to conform to the various topographies of railroad car walls and at the same time satisfy applicable safety standards. BACKGROUND OF THE INVENTION The Federal Railroad Administration requires that railroad cars be equipped with hand holds on the top and side walls of railroad cars, so a person can safely maneuver about the railroad car. Hand holds are mounted on railroad cars in a variety of configurations to conform to the irregular topography of railroad car walls and to comply with applicable safety regulations. Hand hold configurations have permeated into scores of different hand hold designs. Hand holds must be made of a reliable material, usually steel, for safety purposes. For the same reason, hand holds must be securely mounted to the exterior wall of the railroad car and be in a state of good repair. Detached or broken hand holds must be replaced immediately for the railroad car to operate without violating governmental safety regulations. To keep all railroad cars operational, a railroad company must stock a matching replacement for every one of its uniquely configured hand holds which is in use. Railroad companies face inventory problems because hand holds come in a variety of configurations. Inventory problems include multiplied inventory, excessive storage space and exorbitant replacement costs. Attempts have been made heretofore to mitigate inventory problems by providing hand hold assemblies for railroad cars having fewer components. U.S. Pat. No. 4,463,827 to Sittner employs an assembly of five different parts, and U.S. Pat. No. 4,871,047 to McLean employs an assembly with two different parts to minimize inventory. The present invention employs an assembly which has three different parts, but the new assembly offers much more versatility and security than the prior art assemblies. Thus, an object of this invention is to provide an improved hand hold assembly which reduces the number of replacement parts necessary for an adequate reserve inventory. Another object of the invention is to provide an improved hand hold assembly which is easily adaptable to installation on the variable surfaces of railroad cars. A further object of the invention is to provide an improved hand hold assembly which securely connects the hand hold to the railroad car. SUMMARY OF THE INVENTION The disclosed assembly has three elements: a first mount, an elongated rod, and a second mount. The elongated rod is cut to an appropriate length and bent or otherwise contorted to a desirable configuration to conform to the topography of the installation site on the railroad car wall. The mounts are used to connect the ends of the rod to the railroad car wall. The ends of the rod are forged into the mounts which are in turn secured to the railroad car. The mount used to connect each end of the rod to the railroad car preferably is selected from two alternatives consisting of an offset mount and a straight mount. The particular type of mount chosen is dependent upon the topography of the installation site on the railroad car and also the configuration mandated by the applicable governmental regulation. If the rod end is to be mounted perpendicular to the wall, the offset mount normally will be used for that end. If the rod end is to be mounted parallel to the wall, the straight mount will normally be used for that end. The mount is preferably made from cast steel The rod may be mounted by use of the same type of mount on each end, or by use of different mounts on either end. The type of mount selected for one end is independent of the type selected for the other end. In accordance with this invention, only three different parts need be stocked in inventory: rods, straight mounts and offset mounts. This assembly offers versatility because each end of the rod may be mounted either perpendicular or parallel to the railroad car wall, irrespective of the other end, and the rod may be cut and bent to conform to the topography of the installation site. Therefore, the invented assembly can adapt to any of the countless topographies that are present on railroad car walls. The ends of the rod are integrally interconnected or united with their respective mounts by heating the ends of the rod and forging them into bores of sockets in the mounts. While integrally interconnecting the heated end of the rod to the mount, the end is upset to provide a stronger union. The bore in each socket has an interior configuration that facilitates upset. Upset is achieved either by forcing the end of the rod to bend in the bore of the mount, or by swaging the end of the rod into the bore. After the rod is forged into the bore and allowed to cool, the bore provides a secure interconnection upon cooling. BRIEF DESCRIPTION OF THE DRAWINGS In the detailed description of the preferred embodiment of the invention presented below, reference is made to the accompanying drawings, in which: FIG. 1 is a perspective view of a hand hold assembly, in accordance with the present invention, connected to a wall of a railroad car; FIG. 2 is a top plan of the hand hold assembly of FIG. 1 taken along line 2--2 which shows that the rod is connected to the uneven wall by two different mounts, a straight mount and an offset mount; FIG. 3 is an elevational plan view of the hand hold assembly of FIG. 1; FIG. 4 is a partially cut-away side view of the straight mount of FIG. 1; FIG. 5 is a plan view of the straight mount of FIG. 4; FIG. 6 is a partially cut-away side view of the offset mount of FIG. 1; FIG. 7 is a plan view of the offset mount of FIG. 6; FIG. 8 is an elevational plan view of the hand hold assembly of the present invention where the rod is connected to a wall using two offset mounts with one mount being connected vertically and the other mount being connected horizontally; FIG. 9 is a side view of the of the vertically connected mount of FIG. 8; FIG. 10 is an elevational plan view of a rod connected to the wall with an offset mount and a straight mount; FIG. 11 is a top plan view of a hand hold assembly with each end of the rod connected with a straight mount to a stile of a ladder which is secured to a railroad car wall; FIG. 12 is an elevational plan view of the assembly of FIG. 11; FIG. 13 is an elevational plan view of a hand hold assembly with each end of the rod vertically connected with a straight mount to the wall; FIG. 14 is a partially cut-away side view of a modified straight mount; FIG. 15 is a plan view of the modified straight mount of FIG. 14; FIG. 16 is a partially cut-away side view of a modified offset mount; and FIG. 17 is a plan view of the modified offset mount of FIG. 16. DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of a new assembly for installing both hand holds on a wall of a railroad car is illustrated in FIGS. 1-17. FIG. 1 shows the new and improved hand hold assembly 20 in actual use on a railroad car wall 22. FIG. 2 is a top view and FIG. 3 is a plan view of the assembly 20 of FIG. 1. FIGS. 2 and 3 show all three components of the assembly 20. Hence, the configuration of FIGS. 2 and 3 will be referred to initially to describe the invention. However, different configurations may be desirable, depending on the topography of the installation site on the railroad car wall 22 and other factors. An elongated rod 24 has a first end 26 and a second end 28. The two ends 26, 28 of the rod 24 are connected to the wall of the railroad car via two mounts, 30 and 32. A straight mount 30 connects end 26 and an offset mount 32 connects end 26. The rod 24 is preferably made of rolled steel, ASTM A-576, Grade 1015-1020, and preferably has a diameter of three-quarters inches. The rod 24 can be cut to an appropriate length and bent or otherwise contorted to a desired configuration to conform to any topography of the railroad car wall 22, as illustrated in the various embodiments illustrated herein. In accordance with the present invention, one of two types of mounts 30, 32 is selected to connect each end 26 and 28 to the wall 22 of the railroad car. The type of mount 30, 32 selected for the first end 26 is selected independently of the mount 30, 32 selected for the second end 28. Selection of the type of mount 30, 32 is dependent on the desired manner in which the end 26 or 28 is to be connected to the wall 22. When the first end 26 is connected parallel to the wall 22, a straight mount 30 is used, as shown in FIGS. 2 and 3. The straight mount 30 is clearly illustrated in FIGS. 4 and 5. Because the second end 28 is connected perpendicular to the wall 22, an offset mount 32 is used, as shown in FIGS. 2 and 3. The offset mount 32 is clearly illustrated in FIGS. 6 and 7. Both types of mounts 30 and 32 are similar in several respects. They are both cast with AISI-1330 steel by any suitable method, such as sand casting. The steel should preferably have the mechanical properties set out in TABLE I. TABLE I______________________________________Mechanical Property ValuesMechanical Property Minimum Value______________________________________Tensile Strength (lb/in.sup.2) 90,000Yield Strength (lb/in.sup.2) 60,000Elongation (%) 20Reduction of Area (%) 40Brinell Hardness (BHN) 180-220______________________________________ The straight mount 30 has a support flange 36 which is used to connect the mount 30 to the railroad car wall 22. The offset mount 32 has a support flange 38 which is used to connect the mount 32 to the railroad car wall 22. As viewed in FIGS. 4 and 5, the flange 36 on the straight mount 30 is contiguous with a cylindrical socket 42. Said flange 36 defines an aperture 40. As shown in FIGS. 5-7, the flange 38 on the offset mount is contiguous with cylindrical socket 46. Said flange 38 defines an aperture 44. The straight mount 30 has a base 48 sustaining the flange 36 and the socket 42. The offset mount 32 has a base 50 sustaining the flange 38 and the socket 46. The straight mount 30 is connected to the wall 22 by placing the base 48 flush with the wall 22 and inserting a bolt 52 through the aperture 40 and through the wall 22 of the railroad car. The offset mount 32 is connected to the wall 22 by placing the base 50 flush with the wall 22 and inserting a bolt 53 through the aperture 44 and through the wall 22 of the railroad car. Standard nuts 54, 55 or equivalents can be used to secure bolts 52, 53 to the wall 22. The cylindrical socket 42 is employed to integrally interconnect the end 26 of the rod 24 to the straight mount 30. The cylindrical socket 46 is employed to integrally interconnect the end 28 of the rod 24 to the offset mount 32. On the straight mount 30, a cylindrical bore 60 extends all the way through the socket from an entry 62 to an outlet 64 as best illustrated in FIGS. 4-5. On the offset mount 32 as best illustrated in FIGS. 6-7, a cylindrical bore 66 extends all the way through the socket from an entry 68 to an outlet 70. The entry 62 of the bore 60 on the straight mount 30 and the entry 68 of the bore 62 on the offset mount 32 both have a diameter that is sufficiently large, preferably thirteen-sixteenths inches, to receive the end 26 and 28, respectively, of the rod 24. The difference between the straight mount 30 and the offset mount 32 stems from the way the flanges 36 and 38 relate to the sockets 42 and 46, respectively. On the straight mount 30, the socket 42, and the bore 60 therethrough, is substantially parallel to the support flange 36. Hence, the end 26 of the rod 24 connected with the straight mount 30 is connected parallel to the wall 22 of the railroad car. Whereas, the socket 46 on the offset mount 32, and the bore 66 therethrough, is perpendicular to the support flange 38. Consequently, the end 28 of the rod 24 is connected perpendicular to the railroad car wall 22 when the offset mount 32 is employed. As seen in FIG. 4, the bore 60 in the straight mount 30 is not parallel to the support flange 36 all the way through from the entry 62 to the outlet 64. At a crook 74 within the bore 60 of the straight mount 30, the bore 60 bends unparallel to the flange 36 between the crook 74 and the outlet 64 of the bore 60. The angled outlet 64 is designed to effectuate an integral interconnection between the end 26 of the rod 24 and the straight mount 30. The end 26 of the rod 24 is interconnected to the straight mount 30 by first heating it to a red-hot temperature of around 2000° F. At this hot temperature, the steel end 26 is relatively ductile. The hot end 26 is then forced into the bore 60 of the straight mount 30 past the crook 74 and into the outlet 64 of the bore 60. When the hot end 26 encounters the crook 74 in the bore 60, it bends to occupy the outlet 64. Upon cooling, the end 26 of the rod 24 and the straight mount 30 are integrally interconnected. Turning to the offset mount 32, FIG. 6 shows that the socket 46 is perpendicular to the support flange 38. The bore 66 in the offset mount 32 is perpendicular to the flange 38 all the way through from the entry 68 to the outlet 70, but the diameter of the bore 66 is not uniform all the way through to the outlet 70. The diameter of the bore remains constant from the entry 68 to an intermediate point 80. The bore flares out from the intermediate point 80 to the outlet 70 of the bore 66. The outlet 70 is arranged to generate an integral interconnection between the end 28 of the rod 24 and the offset mount 32. The end 28 of the rod 24 is integrally interconnected to the offset mount 32 similar to the method used for the straight mount 30. The end 28 is first heated to a red-hot temperature of around 2000° F. to obtain relative ductility. The hot end 28 is then forced into the bore 66 of the offset mount 32, all the way through, slightly beyond the outlet 70. A hammer or other means is used to swage the end 28 of the ductile hot steel rod 24 to fill most of the outlet 70. Upon cooling, an integral interconnection is forged between the end 28 of the rod 24 and the offset mount 32. The description related to FIGS. 1-3 illustrates just one configuration of the handhold invention. One of the primary advantages of the present invention, however, is that several other configurations may be employed to conform to the topography of the railroad car wall 22. Other configurations are achieved by bending or otherwise contorting the rod 24 differently and substituting different mounts 30 or 32 for each end 26 and 28. FIGS. 8, 9 and 10 show one way that the rod 24 may be contorted when supported on the railroad car wall 22 by the offset mount 32. The end 28 is interconnected to the socket 46, so that the end 28 is perpendicular to the railroad car wall 22, as shown in FIG. 9. The end 28 is bent perpendicularly and downwardly to form a guard 86 which is parallel to the wall 22. The guard 86 then is bent laterally to form a rest 88. The rest 88 is also parallel to the wall 22, but perpendicular to the guard 86. The rod 24 may extend from the guard 86 into a variety of configurations which may be either symmetrical as in FIG. 8 or asymmetrical as in FIG. 10. The other end 26 may be connected with an offset mount 32, as shown in FIG. 8, or a straight mount 30, as shown in FIG. 10. In the symmetrical configuration shown in FIG. 8, the rest 88 is bent upward and perpendicular to form a second guard 90. The guard 90 is then bent toward and perpendicular to the wall 22 to form end 26 which is connected to the wall 22 with the offset mount 32. The offset mount 32 can be rotated to a nonvertical position to connect the end 26 of the rod 24 to the wall 22, as shown in FIG. 8. Such a configuration is useful if an obstacle 92 prevents the end 26 from being vertically mounted to the wall 22. Frequently, hand holds 20 are mounted in vertical series to form a ladder on the railroad car wall 22, as shown in FIG. 1. Alternatively, the end 26 of the rod 24 may be mounted to a stile 94. As shown in FIGS. 11 and 12, the stile is connected to the railroad car wall 22 by using any conventional means, such as a nut 54 (not shown) and bolt 52 assembly. The end 28 may or may not be mounted to a stile 96 in the same manner. As shown in FIGS. 11 and 12, both ends 26 and 28 are connected to the stiles 94 and 96, respectively, using straight mounts 30 to form a ladder rung. A series of rods 24 can be so connected to form an entire ladder up the side of the railroad car wall 22. A rod 24 can be connected at both ends 26, 28 in a vertical configuration as shown in FIG. 13. The configurations and uses offered by the present invention are numerous. The combination of one rod 24 and two mounts, which are each selected from two types of mounts 30 and 32, provides a hand hold assembly 20 that can virtually adapt to any topography of a railroad car wall 22 and meet any governmental regulation. It may be advantageous to substitute into the assembly 20 a modified straight mount 100, as shown in FIGS. 14 and 15. The modified straight mount 100 is substantially similar to the straight mount 30. It has a support flange 102, with an aperture 104 therethrough, for securing the straight mount 100 to the railroad car wall 22, and a socket 106 contiguous with said flange 102. A base 108 sustains the socket 106 and the flange 102. The modified straight mount 100, however, has a bore 110 that is shaped like the bore 66 of the offset mount 32. The bore 110 has an entry 112 and an outlet 114. The bore 110 is parallel to the flange 102 all the way from the entry 112 to the outlet 114. The diameter of the bore 110 is large enough to receive an end 26 or 28 of the rod 24 and is constant from the entry 112 to an intermediate point 116. At the intermediate point 116, the bore 110 flares out to the outlet 114. The end 26 or 28 is interconnected to the modified straight mount 100 the same way as described for the offset mount 32, previously. Furthermore, it also may be advantageous to substitute into the assembly 20 a modified offset mount 130, as shown in FIGS. 16 and 17. The modified offset mount 130 is substantially similar to the offset mount 32. It has a support flange 132, with an aperture 134 therethrough, for securing the offset mount 130 to the railroad car wall 22, and a socket 136 contiguous with said flange 132. A base 138 sustains the socket 136 and the flange 132. The modified offset mount 130, however, has a bore 140 that is shaped like the bore 60 of the straight mount 30. The bore 140 has an entry 142 and an outlet 144 and has a diameter large enough to receive an end 26 or 28 of the rod 24. The bore 140 is perpendicular to the support flange 136, between the entry 142 and a crook 146. From the crook 146 to the outlet 144, the bore 140 bends unperpendicular to the flange 132. The end 26 or 28 is interconnected to the modified offset mount 130 the same way as described for the straight mount 30, previously. Either or both of these modified mounts 100 and 130 may supplant or supplement mounts 30 and 32 in a railroad company's replacement inventory for the disclosed assembly. The invention has been described in detail with particular reference to preferred embodiments thereof. However, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described hereinabove and as set forth in the claims.
A hand hold assembly and method for installation of the same on railroad car walls. The assembly has only three components, but can adapt to virtually any railroad car wall topography of the installation site. An elongated rod is bent or otherwise contorted and cut to fit the topography. Each end of the rod is mounted to the railroad car wall using one of two mounts, either a straight mount or an offset mount. If selected, the straight mount connects the end of the rod parallel to the railroad car wall, and the offset mount, if selected, connects the end of the rod perpendicular to the railroad car wall. The end of the rod is united to the selected mount by heating it, forging it into a bore of the mount and upsetting the end. Upon cooling, a steadfast union is formed. The new and improved assembly provides security and flexibility not before known in the art.
4
BACKGROUND OF THE INVENTION This invention relates to corporate feed networks for antenna systems. Corporate feed networks are conventionally used to distribute power from transmit/receive (T/R) modules to array radiating elements. Vertical distribution of RF signals in active arrays is presently accomplished by means of suspended stripline feeds with in-line coaxial interconnects. Two feeds are required for every column of T/R modules, one for the upper half of the column and one for the lower half. A typical array might require a total of 120 feeds, which make up a significant portion of the total array cost. The feed housings are made entirely from machined aluminum. They are fabricated and assembled separate from the heat exchangers and installed at a higher assembly level. This method is heavy and consumes a considerable amount of space. An object of this invention is to provide a feed network which can be smaller, lighter and less expensive to fabricate than conventional feed networks. SUMMARY OF THE INVENTION In accordance with the invention, a suspended stripline corporate feed is described with an orthogonal transition to a matched coaxial transmission line at each of its input/output ports. The suspended stripline can have circuit traces plated on one side or the other or both. Alternate input/output (I/O) ports are pointed in opposite directions, so that T/R modules on both sides of the feed can be serviced by the same circuit. This reduces by half the number of feeds required for a given array. According to one aspect of the invention, half of the feed housing is machined as an integral part of the heat exchanger which cools the T/R modules. The other half is made from injection molded plastic, copper plated to make the surface electrically conductive. The plastic is loaded with glass fibers so that its thermal coefficient of expansion is matched to that of aluminum. BRIEF DESCRIPTION OF THE DRAWING These and other features and advantages of the present invention will become more apparent from the following detailed description of an exemplary embodiment thereof, as illustrated in the accompanying drawings, in which: FIG. 1 is an exploded perspective view illustrative of a feed network embodying the invention. FIG. 2 shows the feed network of FIG. 1 in assembled form. FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2. FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3. FIG. 5 is a cross-sectional view illustrative of an alternate interconnection technique. FIG. 6 is a simplified schematic of elements of an active array system embodying this invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 illustrates an active array system assembly 50 embodying the present invention. The array includes a plurality of transmit/receive (T/R) modules 52 and 54 disposed respectively on opposite sides of the assembly. The assembly further includes a heat exchanger 60, and the modules 52 and 54 sandwich the heat exchanger for cooling of the modules. The heat exchanger 60 includes cooling fin stock 62 sandwiched by upper and lower metal plate surfaces 64 and 66, typically formed of aluminum. The lower surface 66 is extended to form aluminum surface 66A, which in turn provides a ground plane channel 72 for a suspended stripline transmission line corporate feed circuit 70 which matches the layout of the feed circuit layout. The other ground plane channel completing the transmission line circuit 70 is defined by a feed cover 80. The cover 80 is fabricated, in accordance with the invention, of injection molded plastic, and copper plated to make the surface electrically conductive. It is desired that the plastic material have a thermal coefficient of expansion matched to that of aluminum. A plastic such as polyetherimide or that marketed under the trade name ULTEM, both of which are marketed by General Electric Company, loaded with 30% by weight of glass fibers, has been found suitable for the purpose. The cover 80 has a relieved channel pattern formed therein which is the mirror image of the channel pattern formed in the surface 66A. A pair of power and control signal distribution printed wiring boards (PWBs) 84 and 86 sandwich the aluminum surface member 62A, and the cover 80. The PWBs 84 and 86 carry dc power and control signals for the active elements comprising the assembly 50. Alternate input/output ports for the transmission line 70 are pointed in opposite directions so that the modules on either side of the heat exchanger can be serviced by the feed comprising the transmission line 70. This is depicted generally in FIG. 1 by coaxial pin launchers 92 and 96, pointing in opposite directions, and the dielectric concentric spacer elements 94 and 98. FIG. 2 shows the active array system assembly 50 in a assembled configuration. FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2. FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3. FIGS. 3 and 4 illustrate in further detail the relationship of the transmission line circuit and the coaxial pin launchers. An end of the dielectric stripline substrate board 70A is supported by a shoulder 67 of the heat exchanger plate 66A, so that the board 70A is suspended between the plate 66A and cover plate 80. As shown in FIG. 3, cover 80 is plated with a copper coating 80A. A conductive line 70B is defined on the upper surface of the substrate board 70A, thereby defining a suspended substrate stripline transmission line. The line 70B makes electrical contact with the conductive coaxial pin launcher 92 extending upwardly through a circular opening formed 104 in the cover 80. The dielectric spacer 94 supports the pin 92 within the opening 104. An RF/DC flexible interconnect circuit 110 includes a flexible dielectric substrate 112, on which is defined an RF conductive trace 114. The conductive trace 114 contacts the pin launcher 92 to electrically connect to the coaxial line, thereby coupling the suspended stripline circuit 70 to the interconnect circuit 110. The trace 114 in turn leads to a connection (not shown) with circuitry comprising the T/R module 52. The suspended stripline circuit 70 is also electrically coupled to the T/R module 54 located on the opposite side of the heat exchanger 60 from the module 52. This is done via the coaxial feedthrough comprising coaxial pin launcher 96 and dielectric spacer 98 fitted within circular opening 106 (shown in phantom) in the plate 66A. This coaxial feedthrough extends orthogonally to the suspended stripline circuit, but in the opposite direction from the coaxial feedthrough comprising pin launcher 92, thus allowing the suspended stripline feed network 70 to service T/R modules located on both sides of the heat exchanger. The pin launcher 96 makes electrical contact with the conductive trace 120 comprising flexible interconnect circuit 116, which also includes a flexible dielectric substrate 118. The conductive trace 120 in turn leads to a connection (not shown) with circuitry comprising the T/R module 54. FIG. 5 shows an alternative embodiment of the manner for connecting the T/R modules 52 and 54 to the suspended stripline feed circuit 70. In this embodiment, the orthogonal pin launchers are connected to orthogonally disposed coaxial feedthroughs, in turn connected through short coaxial cables to coaxial feedthroughs on the T/R modules. The pin launchers 92' and 96' have material removed at the ends thereof to form shoulders 122 and 134, respectively. Coaxial center conductor pins 140 and 150 of respective sub-subminiature assembly (SSMA) connectors extend through bores formed in the cover 80 and in the plate 66A, and are supported by dielectric plugs 142 and 152. The ends of the pins 140 and 150 intersect the respective ends of the pin launchers 92' and 96' and make electrical contact therewith. Connector fittings 144 and 154 complete the respective SSMA connectors. Coaxial cables 160 and 170 electrically interconnect between these SSMA connectors and corresponding connectors 174 and 176 of the T/R modules 52 and 54, thereby completing the connection between the suspended stripline feed circuit 70; and the T/R modules 52 and 54. Covers 130 and 132 seal the exposed ends of the coaxial transitions. FIG. 6 shows a simplified schematic diagram of components of an active array system 200 embodying the present invention. The system 200 includes a suspended stripline RF feed network 202 including a plated plastic housing as described above. Orthogonal coaxial transitions 204 connect the suspended stripline feed network 202 and the T/R modules 206, the T/R modules 206 are in turn connected to the array radiating elements 208. The feed network 202 further includes an I/O port 210. It is understood that the above-described embodiments are merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope and spirit of the invention.
A suspended stripline corporate feed with an orthogonal transition to a coaxial transmission line at each of its input/output ports. Alternate I/O ports are pointed in opposite directions so that devices on both sides of the feed can be serviced by the same circuit. The cover for the feed is made out of injection molded, copper plated plastic. When utilized to distribute RF energy to T/R modules in an Active Array, the feed is machined as an integral part of the heat exchanger which cools the modules.
7
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a method of making a perpendicular recording magnetic head pole tip with an etchable adhesion CMP stop layer and, more particularly, to the steps in making the perpendicular recording pole tip wherein such a layer adheres well to bottom and top layers, is commonly etchable with the bottom layer, adheres well to the pole tip during chemical mechanical polishing (CMP) to prevent delamination and indicates a stop point during the CMP for proper pole tip definition. [0003] 2. Description of the Related Art [0004] The heart of a computer is a magnetic disk drive which includes a rotating magnetic disk, a slider that has write and read heads, a suspension arm and an actuator arm. When the disk is not rotating the actuator arm locates the suspension arm so that the slider is parked on a ramp. When the disk rotates and the slider is positioned by the actuator arm above the disk, air is swirled by the rotating disk adjacent an air bearing surface (ABS) of the slider causing the slider to ride on an air bearing a slight distance from the surface of the rotating disk. When the slider rides on the air bearing the actuator arm positions the write and read heads over selected circular tracks on the rotating disk where field signals are written and read by the write and read heads. The write and read heads are connected to processing circuitry that operates according to a computer program to implement the writing and reading functions. [0005] A write head is typically rated by its areal density which is a product of its linear bit density and its track width density. The linear bit density is the number of bits which can be written per linear inch along the track of the rotating magnetic disk and the track width density is the number of tracks that can be written per inch along a radius of the rotating magnetic disk. The linear bit density is quantified as bits per inch (BPI) and the track width density is quantified as tracks per inch (TPI). The linear bit density depends upon the length of the bit along the track and the track width density is dependent upon the width of the second pole tip at the ABS. Efforts over the years to increase the areal density have resulted in computer storage capacities increasing from kilobytes to megabytes to gigabytes. [0006] The magnetic moment of each pole piece of a write head is parallel to the ABS and to the major planes of the layers of the write head. When the write current is applied to the coil of the write head the magnetic moment rotates toward or away from the ABS, depending upon whether the write signal is positive or negative. When the magnetic moment is rotated from the parallel position, magnetic flux fringing between the pole pieces writes a positive or a negative bit in the track of the rotating magnetic disk. As the write current frequency is increased, the linear bit density is also increased. An increase in the linear bit density is desirable in order to increase the aforementioned areal density which increase results in increased storage capacity. [0007] There are two types of magnetic write heads. One type is a longitudinal recording write head and the other type is a perpendicular recording write head. In the longitudinal recording write head the flux induced into first and second pole pieces by a write coil fringes across a write gap layer, between the pole pieces, into the circular track of the rotating magnetic disk. This causes an orientation of the magnetization in the circular disk to be parallel to the plane of the disk which is referred to as longitudinal recording. The volume of the magnetization in the disk is referred to as a bit cell and the magnetizations in various bit cells are antiparallel so as to record information in digital form. The bit cell has a width representing track width, a length representing linear density and a depth which provides the volume necessary to provide sufficient magnetization to be read by a sensor of the read head. In longitudinal recording magnetic disks this depth is somewhat shallow. The length of the bit cell along the circular track of the disk is determined by the thickness of the write gap layer. The write gap layer is made as thin as practical so as to decrease the length of the bit cell along the track which, in turn, increases the linear bit density of the recording. The width of the second pole tip of the longitudinal write head is also made as narrow as possible so as to reduce the track width and thereby increase the track width density. Unfortunately, the reduction in the thickness of the write gap layer and the track width is limited because the bit cell is shallow and there must be sufficient bit cell volume in order to produce sufficient magnetization in the recorded disk to be read by the sensor of the read head. [0008] In a perpendicular recording write head there is no write gap layer. The second pole piece has a pole tip with a width that defines the track width of the write head and a wider yoke portion which delivers the flux to the pole tip. At a recessed end of the pole tip the yoke flares laterally outwardly to its full width and thence to a back gap which is magnetically connected to a back gap of a first pole piece. The perpendicular write head records signals into a perpendicular recording magnetic disk. In the perpendicular recording magnetic disk a soft magnetic layer underlies a perpendicular recording layer which has a high coercivity H C . The thicker disk permits a larger bit cell so that the length and the width of the cell can be decreased and still provide sufficient magnetization to be read by the read head. This means that the width and the thickness or height of the pole tip at the ABS can be reduced to increase the aforementioned TPI and BPI. The magnetization of the bit cell in a perpendicular recording scheme is perpendicular to the plane of the disk as contrasted to parallel to the plane of the disk in the longitudinal recording scheme. The flux from the pole tip into the perpendicular recording magnetic disk is in a direction perpendicular to the plane of the disk, thence parallel to the plane of the disk in the aforementioned soft magnetic underlayer and thence again perpendicular to the plane of the disk into the first pole piece to complete the magnetic circuit. Accordingly, the width of the perpendicular recording pole tip can be less than the width of the second pole tip of the longitudinal write head and the height or thickness of the perpendicular recording pole tip can be less than the length of the longitudinal recorded bit cell so as to significantly increase the aforementioned areal density of the write head. [0009] The perpendicular recording pole tip is typically constructed by frame plating in the same manner as the construction of the second pole piece in a longitudinal recording head. It is desirable that the pole tip be fully saturated during the write function. This allows an increase in the write signal frequency so as to increase the linear density of the recording. Unfortunately, when the length of the pole tip is short, it is difficult to fabricate a narrow width pole tip because of the loss of the process window of the pole tip in a region where the pole tip meets the flared portion of the second pole piece. SUMMARY OF THE INVENTION [0010] One approach to overcome this problem is to fabricate the perpendicular recording pole tip by a damascene process whereby a planar, homogenous dielectric layer is deposited with a carbon or diamond like carbon (DLC) hard mask thereon to serve as a chemical mechanical polishing (CMP) stop layer. The hard mask is patterned by photoresist and the dielectric is etched to form a beveled deep trench. Either deposition of a seed layer followed by plating or sputter deposition of an appropriate material with high moment can be used to fill the trench. Pole tip definition is achieved by CMP the structure back to the hard mask. A silicon adhesion layer on top and bottom of the hard mask has been required for adhesion of the hard mask to the dielectric and photoresist layers, thus increasing the number of processing steps. Silicon has excellent adhesion to DLC but does not adhere well to high moment material such as NiFe, CoNiFe and CoFe, which frequently results in delamination of the high moment material which forms the pole tip during CMP. [0011] In order to overcome the aforementioned problems with the damascene process the present invention provides a non-silicon commonly etchable adhesion CMP stop layer (adhesion/stop layer) in the process of fabricating the second pole piece pole tip. The adhesion layer is tantalum (Ta). The improved adhesion/stop layer has several desirable attributes, namely: (1) improved adherence to a bottom pole tip forming layer which may be selected from the group consisting of Mo, W, Ta 2 O 3 , SiON X , SiO 2 and Si 3 N 4 , and to a top photoresist layer; (2) etchable by the same reactive ion etching (RIE) process that etches the forming layer; (3) adheres well to the iron alloys employed for the perpendicular recording second pole tip, such as NiFe, CoNiFe and CoFe, thereby preventing delamination of the pole tip during chemical mechanical polishing (CMP) to define the height of the pole tip; and (4) provides a stop indication during CMP so that the pole tip can be fabricated with a precise height. [0012] A method of the invention comprises forming a second pole piece layer that is recessed from a head surface of the magnetic head assembly, forming a reactive ion etchable (RIEable) pole tip forming layer on the second pole piece layer, forming the adhesion/stop layer of Ta on the pole tip forming layer, forming a photoresist mask on the adhesion/stop layer with a first opening for patterning the adhesion/stop layer and the pole tip forming layer with a second opening, reactive ion etching (RIE) through the first opening to form the second opening, forming the second pole piece pole tip in the second opening with a top which is above a top of the adhesion/stop layer and chemically mechanically polishing (CMP) the top of the second pole piece pole tip until the CMP contacts the adhesion/stop layer. An aspect of the invention is that after forming the second pole piece layer and before forming the pole tip forming layer, alumina is formed on the second pole piece layer and in a field about the second pole piece layer and then CMP is implemented until a top of the second pole piece layer is exposed and a flat surface is formed, followed by forming the pole tip forming layer on the flat surface. [0013] Other aspects of the invention will be appreciated upon reading the following description taken together with the accompanying drawings wherein the various figures are not to scale with respect to one another nor are they to scale with respect to the structure depicted therein. BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 is a plan view of an exemplary prior art magnetic disk drive; [0015] FIG. 2 is an end view of a prior art slider with a magnetic head of the disk drive as seen in plane 2 - 2 of FIG. 1 ; [0016] FIG. 3 is an elevation view of the prior art magnetic disk drive wherein multiple disks and magnetic heads are employed; [0017] FIG. 4 is an isometric illustration of an exemplary prior art suspension system for supporting the slider and magnetic head; [0018] FIG. 5 is an ABS view of the magnetic head taken along plane 5 - 5 of FIG. 2 ; [0019] FIG. 6 is a longitudinal cross-sectional view of the slider taken along plane 6 - 6 of FIG. 2 showing the present perpendicular recording head in combination with a read head; [0020] FIG. 7 is an ABS view of the slider taken along plane 7 - 7 of FIG. 6 ; [0021] FIG. 8 is a view taken along plane 8 - 8 of FIG. 6 with all material above the coil layer and leads removed; [0022] FIG. 9 is an isometric view of a second pole piece of FIG. 6 which includes a bottom pole piece and a top pole tip layer; [0023] FIG. 10 is a top view of FIG. 9 ; [0024] FIGS. 11A and 11B are a longitudinal view and an ABS view of the steps involved in fabricating the read head portion 72 of FIG. 6 ; [0025] FIGS. 12A and 12B are the same as FIGS. 11A and 11B except the first pole piece has been planarized, the coils are fabricated, insulation is provided for the coils, a back gap has been constructed and an alumina layer has been deposited; [0026] FIGS. 13A and 13B are the same as FIGS. 12A and 12B except the top of the partially completed head has been chemically mechanically polished (CMP) to provide a flat surface where an alumina isolation layer is formed; [0027] FIGS. 14A and 14B are the same as FIGS. 13A and 13B except a second pole piece layer has been formed; [0028] FIGS. 15A and 15B are the same as FIGS. 14A and 14B except an alumina layer has been deposited and CMP has been implemented to provide a flat surface; [0029] FIGS. 16A and 16B are the same as FIGS. 15A and 15B except a hard mask has been formed; [0030] FIGS. 17A and 17B are the same as FIGS. 16A and 16B except an adhesion/stop seed layer of Ta has been formed and a photoresist layer, which is being patterned, is formed on the Ta layer; [0031] FIGS. 18A and 18B are the same as FIGS. 17A and 17B except reactive ion etching has been implemented into the hard mask and the adhesion/stop seed layer producing an opening for a second pole piece pole tip; [0032] FIGS. 19A and 19B are the same as FIGS. 18A and 18B except a NiFe seed layer has been formed in the opening; [0033] FIGS. 20A and 20B are the same as FIGS. 19A and 19B except the opening has been filled with ferromagnetic material; [0034] FIGS. 21A and 21B are the same as FIGS. 20A and 20B except the magnetic head has been CMP until the CMP reaches the adhesion/stop seed layer; [0035] FIGS. 22A and 22B are the same as FIGS. 21A and 21B except the hard mask has been removed by RIE; [0036] FIG. 23 is an enlarged ABS illustration of the perpendicular recording pole tip in FIG. 22B ; and [0037] FIG. 24 is an enlarged ABS illustration of another embodiment of the perpendicular recording second pole tip. DESCRIPTION OF THE PREFERRED EMBODIMENTS Magnetic Disk Drive [0038] Referring now to the drawings wherein like reference numerals designate like or similar parts throughout the several views, FIGS. 1-3 illustrate a magnetic disk drive 30 . The drive 30 includes a spindle 32 that supports and rotates a magnetic disk 34 . The spindle 32 is rotated by a spindle motor 36 that is controlled by a motor controller 38 . A slider 42 has a combined read and write magnetic head 40 and is supported by a suspension 44 and actuator arm 46 that is rotatably positioned by an actuator 47 . A plurality of disks, sliders and suspensions may be employed in a large capacity direct access storage device (DASD) as shown in FIG. 3 . The suspension 44 and actuator arm 46 are moved by the actuator 47 to position the slider 42 so that the magnetic head 40 is in a transducing relationship with a surface of the magnetic disk 34 . [0039] When the disk 34 is rotated by the spindle motor 36 the slider is supported on a thin (typically, 0.05 μm) cushion of air (air bearing) between the surface of the disk 34 and the air bearing surface (ABS) 48 . The magnetic head 40 may then be employed for writing information to multiple circular tracks on the surface of the disk 34 , as well as for reading information therefrom. Processing circuitry 50 exchanges signals, representing such information, with the head 40 , provides spindle motor drive signals for rotating the magnetic disk 34 , and provides control signals to the actuator for moving the slider to various tracks. In FIG. 4 the slider 42 is shown mounted to a suspension 44 . The components described hereinabove may be mounted on a frame 54 of a housing 55 , as shown in FIG. 3 . [0040] FIG. 5 is an ABS view of the slider 42 and the magnetic head 40 . The slider has a center rail 56 that supports the magnetic head 40 , and side rails 58 and 60 . The rails 56 , 58 and 60 extend from a cross rail 62 . With respect to rotation of the magnetic disk 34 , the cross rail 62 is at a leading edge 64 of the slider and the magnetic head 40 is at a trailing edge 66 of the slider. [0041] FIG. 6 is a side cross-sectional elevation view of a merged magnetic head assembly 40 , which includes a write head portion 70 and a read head portion 72 , the read head portion employing a read sensor 74 . FIG. 7 is an ABS view of FIG. 6 . The sensor 74 is sandwiched between nonmagnetic electrically nonconductive first and second read gap layers 76 and 78 , and the read gap layers are sandwiched between ferromagnetic first and second shield layers 80 and 82 . In response to external magnetic fields, the resistance of the sensor 74 changes. A sense current I S (not shown) conducted through the sensor causes these resistance changes to be manifested as potential changes. These potential changes are then processed as readback signals by the processing circuitry 50 shown in FIG. 3 . [0042] As shown in FIGS. 6 and 7 , the write head portion 70 includes first and second pole pieces 100 and 102 which extend from the ABS to back gap portions 104 and 106 which are recessed in the head and which are magnetically connected to a back gap layer 108 . Located between the first and second pole pieces 100 and 102 is an insulation stack 110 which extends from the ABS to the back gap layer 108 and has embedded therein at least one write coil layer 112 . The insulation stack 110 may have a bottom insulation layer 114 which insulates the write coil from the first pole piece 100 and insulation layers 116 and 118 which insulate the write coil layer from the second pole piece 102 , respectively. An alumina layer 119 is located between the coil layer and the ABS. [0043] Since the second shield layer 82 and the first pole piece layer 100 are a common layer this head is known as a merged head. In a piggyback head the second shield layer and the first pole piece layer are separate layers which are separated by a nonmagnetic layer. As shown in FIGS. 2 and 4 , first and second solder connections 120 and 121 connect leads (not shown) from the spin valve sensor 74 to leads 122 and 123 on the suspension 44 , and third and fourth solder connections 124 and 125 connect leads 126 and 127 from the coil 84 (see FIG. 8 ) to leads 128 and 129 on the suspension. [0044] As shown in FIGS. 9 and 10 , the second pole piece 102 includes a bottom ferromagnetic layer 130 and a top ferromagnetic pole tip layer 132 . The layers 130 and 132 have flare points 134 and 136 where the layers first commence to extend laterally outwardly after the ABS. The pole tip layer 132 has a pole tip 138 and a yoke which is located between the pole tip 138 and the back gap 108 (see FIG. 6 ). The width of the top of the pole tip 138 is the track width (TW) of the recording head. The pole tip 138 is shown extended forward of the ABS in FIGS. 9 and 10 since this is its configuration when it is partially constructed on a wafer where rows and columns of magnetic head assemblies are fabricated. After completion of the magnetic head assemblies, which will be discussed hereinafter, the head assemblies are diced into rows of magnetic head assemblies and lapped to the ABS shown in FIG. 6 . Each row of magnetic head assemblies is then diced into individual head assemblies and mounted on the suspensions, as shown in FIG. 3 . [0045] As shown in FIGS. 6 and 7 , an insulative pole tip forming layer (PT forming layer) 140 is located between the flare point 134 and the ABS. The PT forming layer 140 is not a write gap layer as employed in a longitudinal recording head and therefore does not determine the linear bit density along the track of the rotating magnetic disk. In contrast, the thickness or height of the pole tip 138 along with media and spacing requirements determine the linear bit density since the flux signal magnetizes the bit cells in the recording disk in a perpendicular direction with the flux from the second pole piece returning to the first pole piece 100 via a soft magnetic layer in the perpendicular recording disk. [0046] It should be noted that when the second pole piece layer 130 is employed, as shown in FIG. 9 , the length of the head assembly 40 between the ABS and the back gap 108 can be shortened so that the write coil frequency can be increased for further increasing the linear bit density of the write head. It should also be understood that the magnetic head assembly may include multiple write coil layers which are stacked one above the other instead of a single write coil layer, as shown in FIG. 6 , and still be within the spirit of the invention. In addition, the relative location and orientation of the write and read portions of the head may also vary. Method of Making [0047] FIGS. 11A and 11B to FIGS. 22A and 22B illustrate various steps in the fabrication of the magnetic head assembly 40 shown in FIGS. 6 and 7 . In FIGS. 11A and 11B the first and second shield layers 80 and 82 may be fabricated by well-known frame plating techniques and the first and second read gap layers 76 and 78 and the sensor 74 may be fabricated by well-known vacuum deposition techniques. [0048] In FIGS. 12A and 12B a thick alumina layer is deposited (not shown) and the thick alumina is chemically mechanically polished (CMP) to the first pole piece layer (P 1 ) 100 leaving alumina layers 200 and 202 on each side of the first pole piece layer as shown in FIG. 12B . Next, the insulation layer 114 , such as alumina, is deposited for insulating a subsequent write coil layer 112 from the first pole piece layer 100 . The write coil layer 112 is then formed and is insulated by insulation 116 which may be baked photoresist. After photopatterning (not shown) and ion milling down to the first pole piece layer 100 the back gap 108 is formed. This is followed by depositing a thick layer of alumina 119 . In FIGS. 13A and 13B the magnetic head is CMP flat and an isolation layer 118 , which may be alumina, is deposited and patterned so as to leave the back gap 108 exposed. [0049] In FIGS. 14A and 14B the second pole piece (P 2 ) layer 130 is formed with a front end 134 which is recessed from the ABS and the back gap portion 106 which is magnetically connected to the back gap 108 . In FIGS. 15A and 15B a thick alumina layer is deposited (not shown) and CMP flat leaving the alumina layer 140 between the front end 134 of the second pole piece layer and the ABS. In FIGS. 16A and 16B a pole tip forming layer (PT forming layer) 204 is formed on the second pole piece layer 130 and the alumina layer 140 which provides a form for fabricating the pole tip layer 132 with the pole tip 138 which will be discussed in more detail hereinafter. The mask may be Mo, W, Ta 2 O 3 , SiON X , SiO 2 or Si 3 N 4 and is etchable by a fluorine based reactive ion etching (RIE). In FIGS. 17A and 17B an adhesion/stop layer 206 is formed on the PT forming layer 204 followed by a photoresist layer 208 which is photopatterned to define a shape of the second pole tip layer 132 which includes the perpendicular recording pole tip 138 , as shown in FIG. 6 . [0050] The adhesion/stop layer 206 is tantalum (Ta). A Ta adhesion/stop layer provides all of the desirable attributes as described hereinabove. In FIGS. 18A and 18B a fluorine based reactive ion etch is implemented into the adhesion/stop layer and into the PT forming layer for producing a slanted profile for the pole tip 138 as shown in FIG. 7 . An aspect of this invention is that both of the adhesion/stop layer 206 and the PT forming layer 204 can be etched by the same fluorine based RIE step. As can be seen from FIGS. 18A and 18B a trench is formed for the second pole tip layer. In FIGS. 19A and 19B a seed layer 210 is sputter deposited into the trench as well as on the front and rear pedestals or the trench may be filled with a ferromagnetic material, such as CoFe, by sputtering (not shown). In FIGS. 20A and 20B plating is implemented to fill the trench to a level slightly above the front and rear pedestals. In FIGS. 21A and 21B CMP is implemented until the CMP stops on the adhesion/stop layer 206 . In FIGS. 22A and 22B , optionally, fluorine based RIE may be implemented to remove any remaining portions of the hard mask layer. A thick alumina layer may then be deposited (not shown) and the magnetic head planarized leaving an alumina layer 212 as shown in FIG. 6 . A capping layer 214 , as shown in FIG. 6 , may then be formed of any suitable material such as alumina. Perpendicular Recording Pole Tip [0051] The perpendicular recording pole tip 138 , as shown in FIG. 21B , is enlarged substantially in FIG. 23 . FIG. 23 shows the seed layer 210 which is employed when the pole tip 138 is plated. As shown in FIGS. 6 and 23 , the pole tip is bounded by oppositely facing ABS and back surfaces, top and bottom surfaces 216 and 218 and, with the seed layer 210 , first and second side surfaces 216 and 218 . As shown in FIG. 23 , edge surfaces of layer portions 206 of the adhesion/stop seed layer interface first and second top side surface portions 220 and 222 . Because of the good adhesion between the adhesion/stop seed layer portions 206 and the pole tip 138 there is no delamination at the interfaces 220 and 222 during the CMP step in FIGS. 21A and 21B . FIG. 24 is the same as FIG. 23 except the pole tip 138 has been sputter deposited which eliminates the need for the seed layer 210 shown in FIG. 23 . Discussion [0052] It should be understood that vacuum deposition may be employed in lieu of the aforementioned frame plating step. Further, in a broad concept of the invention the pole tip layer can be employed without the aforementioned bottom second pole piece layer. The materials of the various layers are optional in some instances. For instance, photoresist may be employed in lieu of the alumina layers and vice versa. Further, while the magnetic head is planarized at various steps, planarization may occur only for the second pole piece and pole tip layers. Further, the magnetic head assembly may be a merged or piggyback head, as discussed hereinabove. The pole pieces are ferromagnetic materials and are preferably nickel-iron. It should be noted that the second pole piece layer may be a different ferromagnetic material than the pole tip layer. For instance, the second pole piece layer may be Ni 45 Fe 55 and the pole tip layer may be Ni 80 Fe 20 . [0053] Clearly, other embodiments and modifications of this invention will occur readily to those of ordinary skill in the art in view of these teachings. Therefore, this invention is to be limited only by the following claims, which include all such embodiments and modifications when viewed in conjunction with the above specification and accompanying drawings.
The method of making a magnetic head assembly includes forming a second pole piece layer that is recessed from a head surface, forming a reactive ion etchable (RIEable) pole tip forming layer on the second pole piece layer, forming an adhesion/stop layer of tantalum (Ta) on the pole tip forming layer, forming a photoresist mask on the adhesion/stop layer with an opening for patterning the adhesion/stop layer and the pole tip forming layer with another opening, reactive ion etching (RIE) through the opening to form the other opening, forming the second pole piece pole tip in the other opening with a top which is above a top of the adhesion/stop layer and chemical mechanical polishing (CMP) the top of the second pole piece pole tip until the CMP contacts the adhesion/stop layer. The invention also includes the magnetic head made by such a process.
8
CROSS REFERENCE DATA [0001] The present patent application is a divisional of co-pending U.S. patent application Ser. No. 12/756,444, incorporated herein by reference, which was a Continuation-In-Part of U.S. patent application Ser. No. 11/813,471, which was an Entry into U.S. National Phase of PCT application No. PCT/CA2006/000907 filed on Jun. 2, 2006 and also claimed conventional priority of U.S. provisional patent application No. 60/886,336 filed Jun. 8, 2005. FIELD OF THE INVENTION [0002] The present invention relates to cleaning devices, and more particularly to a portable dusting tool for cleaning delicate surfaces. BACKGROUND OF THE INVENTION [0003] Digital cameras comprise an electronic sensor, such as a charge-coupled device (CCD) sensor or Complementary Metal Oxide Semiconductor (CMOS) sensor, lodged in a recessed sensor chamber of the camera, and onto which is projected the image of what is seen through the lens of the camera. This sensor can acquire the image projected thereon and convert it into electronic data, which is thereafter forwarded to data processing means provided on the digital camera. The data processing means then converts this electronic data into an image file of known format, such as in JPEG, TIFF or RAW formats, stored thereafter on the memory card of the camera. Of course, this sensor must remain as clean as possible, since impurities deposited thereon can undesirably alter the final image acquired by the camera. [0004] It is inevitable that during normal use of a digital camera, its sensor will become exposed to the atmosphere and its airborne impurities, such as minute airborne dust particles. More particularly, on professional digital cameras having interchangeable lenses such as digital single-lens reflex (DSLR) cameras, the sensor exposed lens surface inevitably becomes contaminated by the atmosphere and its impurities whenever the lens is removed from the body of the camera, for example when switching lenses. [0005] To clean the sensor of their digital cameras, and more particularly to remove dust particles from its surface, digital camera owners have come up with a number of cleaning methods. [0006] A common cleaning technique used by digital camera owners is to blow air from a canned air duster directly about the surface of the sensor. This technique, in addition to blowing away the dust on the sensor, has the adverse effect of dispersing and not removing dust particles. [0007] An alternate technique is to blow canned air into the bristles of a brush and then sweeping the surface of the sensor with the brush. Pressurized air is blown on the bristles for two purposes: (1) for blowing away all impurities that may be present between the bristles of the brush, and (2) for electrostatically charging the bristles of the brush, and thus enhancing the brush's capacity to pick up dust particles present on the camera sensor. [0008] However, this latter technique also has its drawbacks. Indeed, liquid sometimes squirts out of canned air dusters when air is blown on the bristles, and liquid can thereafter be undesirably smeared on the surface of the sensor when the brush is swept thereacross. Another disadvantage of using canned air dusters is that they are pressurized containers and it is prohibited to bring them aboard aircrafts, which can be inconvenient for travelling photographers for example. Furthermore, pressurized air duster cans are not reusable, and after such a duster has been emptied, it is disposed of and a new one must be purchased. SUMMARY OF THE INVENTION [0009] The invention relates to a non-scrubbing dusting tool for cleaning the exposed surface of a digital camera sensor lens in a recessed digital camera sensor chamber, said dusting tool comprising : a duster member defining an elongated shank having opposite one and another end, a tuft of bristles having electrostatic charge built up therein, and first connector means directly coupling said tuft of bristles to said shank one end; a handle; and second connector means directly coupling said handle to said shank another end; wherein each of said bristles define a corresponding leading edge tip opposite said shank, said leading edge tips for operative engagement with the sensor lens; wherein said duster member is sized to adjustably fit inside the camera sensor chamber in such a fashion that said bristles leading edge tips will be able to reach all of the exposed surface of the camera sensor lens while avoiding contaminating contact with the camera sensor chamber; and wherein in an operative sensor lens cleaning condition of said dusting tool, said duster member remains motionless relative to said handle while said dusting tool bristles leading edge tips are manually swept over the camera sensor lens to be cleaned. [0010] Preferably, there is further included a selectively activated duster actuator, fixedly mounted to said handle and rotatably mounted to said shank; said actuator operating only when said dusting tool is not cleaning the sensor lens; wherein once said electrostatic charge of said tuft of bristles has been depleted, said electrostatic charge thereof is recharged while concurrently removing dust collected by said bristles by bringing said duster tool to an inoperative sensor lens cleaning condition away from the camera sensor chamber and with said actuator being powered to power rotate said shank, wherein said bristles will fan out radially under centrifugal forces. [0011] Said actuator could then be lodged into a cavity made into said handle. Said first connector means could also consist of a tubular element, integral to said shank one end and defining a flattened mouth portion opposite said shank one end, said tuft of bristles defining an inner end portion frictionally taken in sandwich within said tubular element flattened mouth portion. [0012] Preferably, said tubular element flattened mouth portion further defines a pair of opposite notches, said notches engaged by registering bristles from said tuft of bristles, wherein said tuft of bristles form a V-shape in said operative lens cleaning condition of said dusting tool, said V-shape providing enhanced lens cleaning capabilities The bristles could be made from polyimide, and preferably having a thickness with the range of 40 to 60 micrometers, and preferably being tapered at their leading edge tip portion. The electrostatic charge build up of said bristles could enable attraction of macroscopic particles up to 14 millimeters in total length, and/or attraction of macroscopic particles down to 1 micrometer in total length. [0013] The invention also relates to a method of use of a dusting tool for cleaning the exposed surface of a camera sensor lens in a recessed digital camera sensor chamber while avoiding contaminating contact with the side walls of the camera sensor chamber, the method comprising the following steps: a) providing a non-scrubbing duster member defining an elongated shank having opposite one and another ends, a tuft of bristles having electrostatic charge built up therein and first connector means directly coupling said tuft of bristles to said shank one end; a handle; and second connector means directly coupling said handle to said shank another end, with each of said bristles defining a corresponding leading edge tip opposite said shank; b) engaging said duster member inside the camera sensor chamber; [0014] c) operatively engaging said bristles leading edge tips onto the exposed surface of the camera sensor lens; d) manually sweeping said dusting tool bristles leading edge tips over the full exposed surface of the camera sensor lens including the peripheral edge portion thereof but excluding contaminating contact with the side walls of the camera sensor chamber, while said duster member remains motionless relative to said handle. [0015] Preferably, in step (a), the electrostatic charge build-up is imparted to said bristles by applying a chemical to said bristles. Alternately, in step (a), the electrostatic charge build-up if said bristles is imparted to said bristles by applying an ionization treatment to said bristles. There could also be further included the steps of: providing a selectively activated duster actuator, fixedly mounted to said handle and rotatably mounted to said shank; depleting said electrostatic charge of said tuft of bristles following said sweeping action of said dusting tool bristles leading edge tips; bringing said duster tool to an inoperative sensor lens cleaning condition and away from the camera sensor chamber; and powering said actuator wherein said shank is power rotated and said bristles are brought to fan out radially under centrifugal forces leading to recharging of said electrostatic charge of said bristles while concurrently removing dust collected by said bristles during said manual sweeping step. [0016] Preferably, in step (c), said operative engagement of the bristles leading edge tips includes the step of non-contacting sweeping action over the exposed surface of camera sensor lens in closely spaced fashion relative thereto. Alternately, in step (c), said operative engagement of the bristles leading edge tips includes the step of direct contacting sweeping action against the exposed surface of camera sensor lens. [0017] The invention also relates to the combination of a digital camera having a recessed camera sensor chamber and a sensor lens at a flooring section of said camera sensor chamber, said sensor lens having an exposed surface opening into said camera sensor chamber, and a non-scrubbing dusting tool for cleaning said exposed surface of said camera sensor lens, said dusting tool comprising : a duster member defining an elongated shank having opposite one and another end, a tuft of bristles having electrostatic charge built up therein and first connector means directly coupling said tuft of bristles to said shank one end; a handle; and second connector means directly coupling said handle to said shank another end; wherein each of said bristles define a corresponding leading edge tip opposite said shank, said leading edge tips adapted to operatively engage with said sensor lens; wherein said duster member is sized to adjustably fit inside the camera sensor chamber in such a fashion that said bristles leading edge tips will be able to reach all of the exposed surface of the camera sensor lens while avoiding contaminating contact with the camera sensor chamber; and [0018] wherein in an operative sensor lens cleaning condition of said dusting tool, said duster member remains motionless relative to said handle while dusting tool bristles leading edge tips are manually swept over the camera sensor lens to be cleaned. [0019] Preferably, there is further included an elongated protective cap, releasably mounting over said duster member in friction fit fashion against said second connector means when said dusting tool is not in use. BRIEF DESCRIPTION OF THE DRAWINGS [0020] In the annexed drawings: [0021] FIG. 1 is a perspective view of a dusting tool according to a first embodiment of the present invention; [0022] FIG. 2 is a front elevation of the dusting tool of FIG. 1 with the handle member and the brush connector cut away, and showing how the bristles of the brush fan out and are rid of dust when the user activates the dusting tool shank rotating motor; [0023] FIG. 3 is an exploded front perspective view of the embodiment of dusting tool of FIG. 1 , the dusting tool having a brush and corresponding brush connector; [0024] FIG. 4 is a partially exploded, front elevation view of a dusting tool according to a second embodiment of the present invention. [0025] FIG. 5 , on the third sheet of drawings, is a view similar to FIG. 3 , but showing a third embodiment of dusting tool; [0026] FIG. 6 is a plan view of a fourth embodiment of dusting tool; [0027] FIG. 7 is a top end view of the dusting tool of FIG. 6 ; [0028] FIG. 8 is a view similar to FIG. 6 , but with the dusting tool rotated by a quarter of a turn; [0029] FIG. 9 is an enlarged perspective view of the top end portion of the dusting tool of FIG. 6 ; [0030] FIG. 10 is a plan view of the dusting tool components of FIG. 9 ; [0031] FIG. 11 is a perspective view of a portion of a digital camera in partially cut-away view, suggesting how the dusting tool of the present invention can be used to clean in a non-scrubbing fashion the exposed surface of the flat sensor lens on the floor of the camera sensor chamber; [0032] FIG. 12 is a partly schematic side elevational view of the camera sensor chamber of FIG. 11 , suggesting how the non-spinning bristles of the dusting brush of the present invention can reach out to the full peripheral edge portion of the exposed surface of the sensor lens of the camera sensor chamber while avoiding contaminating contact with the adjacent upright walls of the camera sensor chamber; and [0033] FIGS. 13 to 17 show a prior art roller-type dusting tool, with FIGS. 13-15 being views from a perspective similar to FIGS. 6 to 8 respectively, but showing only part of the handle, and with FIGS. 16 and 17 being views from a perspective similar to FIGS. 11 and 12 respectively, wherein there is suggested that the prior art dusting tool cannot reach the peripheral edge portion of the sensor lens exposed surface. DETAILED DESCRIPTION OF THE EMBODIMENTS [0034] FIGS. 1-3 show a portable dusting tool 10 for digital camera sensors according to one embodiment of the present invention. Sensor dusting tool 10 comprises a handle member 12 , in turn comprising a casing 14 . Casing 14 defines an elongated main body portion 14 a, and a neck portion 14 b extending from one end of main body portion 14 a. [0035] Casing 14 , as can be seen in FIG. 2 , is at least partially hollow and in one embodiment may comprise a brush actuator therein, such as an electric rotary motor 16 powered by batteries 18 . Batteries 18 are electrically connected to motor 16 as known in the art, for example by wires (not shown). Handle member 12 is also provided with a switch 20 controlling the selective powering of motor 16 by batteries 18 , and which the user can depress with his finger F (as suggested in FIG. 2 ) to activate motor 16 . [0036] Motor 16 comprises a rotary shaft 22 connected to and rotating as one with the rotor (not shown) of motor 16 . Shaft 22 extends within the hollow casing neck portion 14 b. [0037] Dusting tool 10 also comprises a duster member connected to the brush actuator. More particularly, dusting tool 10 is provided with a duster brush 24 that may be operatively coupled to motor 16 through the instrumentality of a brush connector 30 . Brush connector 30 comprises a cylindrical and tubular socket portion 32 , in turn having an open top to allow insertion of the butt end portion of duster brush 24 therein. Socket portion 32 defines four slots 33 extending from its top rim end towards its bottom end and stopping short of the latter. Slots 33 allow the sections of socket 32 therebetween to radially outwardly spread apart as duster brush 24 is inserted in socket portion 32 . [0038] Moreover, brush connector 30 also comprises an elongated coupling pin 34 tapering towards its outer end, integrally and coaxially affixed to the bottom end of elongated socket portion 32 . The outer free end of coupling pin 34 is centrally and axially bored, and an elongated and cylindrical cavity 35 thus extends coaxially along coupling pin 34 (only shown in FIG. 2 ). [0039] Brush connector 30 can be coupled to motor 16 by inserting coupling pin 24 in the opening 14 c at the outermost end of casing neck portion 14 b, such that the motor's shaft 22 becomes snugly friction-fitted in cavity 35 of coupling pin 34 . [0040] As mentioned above, brush connector 30 is preferably operatively coupled to the duster brush motor 16 . Duster brush 24 comprises a shank 25 , made of wood for example, and whose butt end portion 25 a is destined to be received and friction-fitted in the lumen of brush connector socket portion 32 . Shank 25 , at its upper end portion 25 b, comprises a brush head formed of a ferrule 26 holding a bunch of bristles 29 in a tuft 28 . Bristles 29 are destined to be swept about the sensor of a digital camera to pick up and collect dust that may be present thereon, as described hereinafter. [0041] Importantly, rotary motor 16 is always inoperative when bristles 29 sweep the sensor lens 160 ( FIGS. 11-12 ), i.e. bristles 29 never spin during sensor lens cleaning operations. [0042] Casing 14 , motor shaft 22 , brush 24 , connector socket portion 32 and coupling pin 34 , are all elongated structures and are arranged coaxially to each other, and define a common longitudinal axis 15 . [0043] Bristles 29 are preferably made of a synthetic material, e.g. a polyamide material such as Nylon®, but could also be made of a natural material such as feather, wool, or fur. Moreover, bristles 29 are imparted with the following characteristics: They are preferably soft and resilient. If the bristles are not flexible and resilient enough, they will be prone to breaking during use, and thus broken pieces of bristles may become lodged in the recessed digital camera sensor chamber (not shown) in which the camera sensor lens is nested. Moreover, softer and more resilient bristles are less prone to breaking and are thus more durable. Finally, the bristles need to be delicate enough to be swept about a sensitive surface (e.g. that of a camera sensor) without scratching it. For optimal performance, bristles 29 preferably have a thickness ranging between 40 to 60 μm (micrometers). They have an enhanced electrostatic charge build-up capability. The bristles can readily accumulate electrostatic charges, in order to be able to electrostatically attract dust particles and other macroscopic impurities (e.g. maximum total length of 15 mm) and preferably microscopic impurities (e.g. minimum total length of 1 μm). This characteristic could be imparted to the bristles either (1) during pre-processing, by producing the bristles out of a material having inherent electrostatic charge build-up capabilities; or (2) during post-processing, by applying a chemical or ionization treatment to the produced bristles. Enhanced resistance to chemical substances. This is a desirable characteristic since any alteration in chemical composition of the bristles will affect its capability to electrostatically attract dust. [0048] The width of the tuft of bristles 28 should be adapted to the size of the optical sensor it is destined to be used on. The tuft of bristles 28 can have a width ranging for example between 1 and 60 millimetres, and should be small enough to fit into the camera's recessed sensor chamber, and it may be large enough to sweep the entire surface of the camera's sensor in a single stroke. Moreover, and as suggested in FIG. 11 , ferrule 26 must have a smaller width than that of the tuft of bristles such that a clearance exists between ferrule 26 and the walls 264 of the sensor chamber 262 when the duster brush 24 is used to sweep the sensor 260 , hence preventing scratching by the ferrule 26 of the sensor chamber walls 264 . For example, a brush 24 with a ferrule 26 having a width of 20 mm, and a tuft of bristles 28 having a width of 24 mm, should preferably be used when cleaning a full frame sensor having dimensions of 36 mm×24 mm. [0049] The dusting tool according to the illustrated embodiment is made modular in order to be able to receive brushes of different dimensions. This is suggested in FIGS. 3 and 5 , where dusting tools 10 and 10 ′ respectively have differently sized brushes 24 , 24 ′ and complementary brush connectors 30 , 30 ′ respectively. These brush/connector combinations, even though they have differing dimensions, can be coupled to a same handle member 12 . [0050] To use the dusting tool 10 , it must first be assembled. To do so, the user first inserts batteries 18 in the battery housing if necessary. The user then selects a duster brush 24 of the desired dimensions and inserts the butt end portion 25 a of its shank 25 in the corresponding brush connector socket 32 . The user then connects brush connector 30 to motor 16 by inserting its coupling pin 34 through casing neck portion opening 14 c, and by friction-fitting motor shaft 22 in the coupling pin cavity 35 . [0051] Prior to dusting a surface such as a camera sensor 260 , it is desirable to rid the tuft of bristles 28 from ambient dust particles that may have gravitated towards it, and/or to remove dust particles that may have remained within the tuft of bristles 29 after a previous use of the dusting tool. It is further necessary to electrostatically charge the bristles 29 in order for them to be able to electrostatically attract and collect dust from the surface to be dusted. [0052] To do so, the user depresses switch 20 , which activates motor 16 and consequently spins elongated brush 24 along its longitudinal axis at a substantially high speed. This causes the bristles 29 of the brush to fan out radially as suggested in FIG. 2 . The rotation of brush 24 has two effects: the bristles 29 of the brush move rapidly relative to ambient air molecules. Bristles 29 , as mentioned above, have the inherent capacity to easily build-up an electrostatic charge. Thus, the friction between the rotating bristles 29 and the ambient air molecules causes the bristles 29 to develop an increased electrostatic charge. the dust particles P that may have become lodged between bristles 29 centrifugally accelerate and are expelled from the tuft of bristles 28 . [0055] Activating motor 16 thus charges the bristles 29 and concomitantly rids brush 24 from dust particles and various other impurities that may be lodged between its bristles 29 , and prepare dusting tool 10 for future use on a surface to be dusted. [0056] After motor 16 has been deactivated and after rotation of brush 24 has stopped, brush 24 can then be inserted in the sensor chamber 262 of the digital camera 266 , and the non-spinning tuft of bristles 28 can be gently swept across the surface of the camera sensor. Mechanical contact between the distal end portion of the bristles 29 and the digital camera sensor 260 is possible but not essential. Indeed, bringing the tip of the bristles 29 in closely spaced fashion to the digital camera sensor 260 may be sufficient to enable the dust to be attracted by and gravitate towards the electrostatically charged bristles 29 , and to be fully operational to dislodge dust. Since bristles 29 are electrostatically charged, dust particles present on the sensor's surface 260 cling to the bristles 29 of the brush 24 , and are hence removed form the sensor surface 260 . [0057] Modifications to the above-described embodiment could be made without departing from the scope of the present invention. For example, the dusting tool 10 could be provided with means enabling the user to select various motor speeds for example between 5000 to 20000 RPM in order to vary the rotation speed of the duster brush 24 . Alternately, the duster actuator 16 could be something else than a mere rotary motor; it could for example be a powered actuator selectively activated to engender vibration, rotation, sonication, reciprocating axial motion, or a combination of these actions, of the duster brush 24 including its bristles 29 , in order for the bristles 29 to become electrostatically charged and for impurities lodged between the bristles to be expelled out of the brush. [0058] Alternatively, the motor 16 could be replaced by an alternate duster actuator that does not require batteries, for example a manual actuator composed of a series of cooperating gears which can be set in motion by manually rotating a crank. [0059] It is also understood that the brush connector 30 providing modularity to the dusting tool, and releasably connecting the duster brush 24 to the motor 16 , is optional. It is understood that any suitable fastening means, whether they be permanent or quick-release fastening means, could be used to fasten the duster member to the duster actuator. Alternately, the duster brush 24 could be directly connected to the duster actuator 16 in any conventional manner. [0060] FIG. 4 shows a duster tool 110 according to an alternate embodiment of the present invention. Duster tool 110 comprises a handle member 112 defining a casing 114 , in turn defining an ergonomically shaped main portion 114 a and a neck portion 114 b. Casing 114 houses a motor therein (not shown), the motor having a rotary shaft (not shown) extending at least partially in casing neck portion 114 b and whose rotary movement is controlled by a switch 120 . Moreover, duster tool 110 has a brush member 124 defining a tubular shank 125 (metallic for example), the upper end of which is pressed around a tuft of bristles 128 . Shank 125 fixedly carries, at its bottom end, a connector member 130 (made of plastic for example). Connector member 130 defines a cavity therein (not shown), similar to cavity 35 of brush connector 30 of FIG. 2 , into which can be snugly friction fitted the shaft of the duster tool's rotary motor. In the embodiment of FIG. 4 , brush member 124 and the connector member 130 are fixedly assembled together, and it is this fixed assembly as a whole that is releasable from handle member 112 . Moreover, duster tool 110 is provided with a hollow, elongated protective cap 150 which can be slipped around the brush 124 and secured to the casing 114 by twisting it in place to friction-fit a projection 154 made on the inner peripheral wall of the protective cap 150 within a groove 152 made into the casing neck portion 114 b. [0061] In still another embodiment of dusting tool 210 shown in FIGS. 6 to 10 , a contoured unibody handle 214 is provided. Socket 232 interconnects handle neck 214 b to duster brush 224 . In brush 224 , ferrule 226 coaxially interconnects elongated shank 225 with the tuft of bristles 228 . Ferrule 226 includes a flattened outer end mouth portion 226 A into which becomes frictionally interlocked the inner end portion of the tuft of bristles 228 . Ferrule mouth portion 226 A further includes two opposite notches 226 B, 226 C, that enable some adjacent bristles to engage therein. Hence, notches 226 B, 226 C enable the tuft of bristles 228 to form an outwardly diverging V-shape, as best shown in FIGS. 6 and 10 . The V-shape of the tuft of bristles 228 optimizes performance of the dust brush 124 , in facilitating access of the bristles to hard to reach areas in the recessed digital camera sensor chamber 262 ( FIG. 11 ). [0062] Preferably, and as best illustrated in FIGS. 8 , 11 and 12 , the leading edge tip portion 228 A of the tuft of bristles will be tapered, to provide precision in the sensor lens surface to be cleaned while facilitating avoidance of accidental contaminating bristles engagement with the side walls 264 of the sensor chamber 262 of the digital camera 266 . [0063] FIGS. 13 to 17 show a prior art scrubbing channel 300 , having a handle 302 , a cylindroid roller 304 and a bracket 306 rotatably interconnecting handle 302 and roller 304 . During cleaning operations, roller 304 rotates under power from a spin-inducing electric motor. It is clearly shown in FIG. 17 that as roller 304 moves toward but short of the peripheral edge of sensor lens 260 , roller 304 comes to undesirably abut against the side wall 264 of the camera lens recessed chamber 262 preventing a peripheral edge portion 260 A of the sensor remains uncleaned. [0064] Clearly, such a prior art scrubbing tool 300 would be inefficient and in fact inoperative in removing dust particles from exposed surface 260 of the digital camera lens sensor at the bottom flooring 266 of this sensor chamber 262 . Indeed, since some dust particles will always remain at peripheral edge 260 A because of the incomplete cleaning operation of scrubbing tool 300 , any motion of the digital camera will inevitably bring about migration of these remaining dust particles towards more central parts of this recessed sensor lens 260 that where previously cleaned, thus rendering useless the previous cleaning in the first place. [0065] It is further noted that although the present cleaning tool has been described as a cleaning tool for digital camera sensors, the present cleaning tool could be used for cleaning other delicate surfaces, such as optics, i.e. the various glass elements of a camera lens, the mirror of a SLR camera, negative film, transparencies, electro-optical devices such as digital imaging devices, etc.
A method of use of a dusting tool for cleaning the exposed surface of a camera sensor lens in a recessed digital camera sensor chamber while avoiding contaminating contact with the side walls of the camera sensor chamber, the method comprising the steps of providing a non-scrubbing duster member having opposite one and another ends, and a tuft of bristles having electrostatic charge built up therein; engaging the duster member inside the camera sensor chamber; operatively engaging the bristles leading edge tips onto the exposed surface of the camera sensor lens; and manually sweeping the dusting tool bristles leading edge tips over the full exposed surface of the camera sensor lens including the peripheral edge portion thereof but excluding contaminating contact with the side walls of the camera sensor chamber, while the duster member remains motionless relative to the handle.
0
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a spinning ring structure for winding a yarn delivered from a yarn delivery unit on a bobbin. 2. Description of the Related Art A spinning frame employing spinning ring structures of the foregoing kind, and a conventional spinning ring structure will be described. Referring to FIG. 1, a plurality of roving packages 70 are supported on package support bars extending perpendicularly to the sheet of the drawing in an upper portion of a spinning frame. A plurality of drafting units 72 are arranged in rows perpendicular to the sheet of the drawing under the roving packages 70 on the right and the left side of the spinning frame substantially at the middle of the height of the spinning frame. Ring rails 74 are extended perpendicularly to the sheet of the drawing as shown in FIG. 4. The ring rails 74 are supported for vertical reciprocation on vertical ring rail lifting pillars 78 which are driven for vertical movement by a motor, not shown. A plurality of mounting holes 75 (FIG. 4) are formed in a longitudinal arrangement in each ring rail 74 and spinning ring structures 110 are fitted in the mounting holes 75, respectively. Referring again to FIG. 1, a plurality of yarn guides 76 each having a guide hole 77 are supported on vertically movable yarn guide lifting pillars 79 so as to correspond to the spinning ring structures 110, respectively. Separators 95 are disposed between adjacent spinning ring structures 110, respectively, as shown in FIG. 7. A spindle 80 is supported for spinning so as to extend through and coaxially with the spinning ring structure 10. The spindle 80 is driven for spinning by a motor, not shown. A bobbin 82, not shown in FIG. 1, is put on the spindle 80 and is restrained from turning relative to the spindle 80. FIG. 14 shows a spinning ring structure 110 as disclosed in, for example, International Publication No. WO96/08592. This prior art spinning ring structure 110 has a stationary ring 20, a rotary ring 30 disposed inside and supported for rotation on the stationary ring 20 and having a flange 32 at its upper end, and a traveler 50 put on the flange 32 of the rotary ring 30 for sliding along the flange 32. A brake ring 160 is disposed under the rotary ring 30. The brake ring 160 is provided on its lower surface with a plurality of radial vanes 168 as shown in FIG. 15. A roving T 1 unwound from the roving package 70 is drafted by the drafting unit 72 into a fleece, the fleece is twisted into a yarn T 2 as the same advances through the guide hole 77 of the yarn guide 76 and the traveler 50 put on the flange 32 of the rotary ring 30 toward the bobbin 82, and the yarn T 2 is taken up on the bobbin 82 by the agencies of the rotating bobbin 82 (spindle 80), the revolving traveler 50 and the rotation of the rotary ring 30 as the spinning ring structure 110 is vertically reciprocated together with the ring rail 74. Since the traveler 50 is pressed strongly against the rotary ring 30 by a centrifugal force, the rotary ring 30 always rotates together with the traveler 50 excluding an initial period subsequent to the start of the spinning frame. The brake ring 160 brakes the rotating rotary ring 30 properly to restrain the rotary ring from rotation at an excessively high rotating speed. A yarn winding speed at which the yarn T.sub. 2 is taken up on the bobbin 82 is equal to a value obtained by subtracting the traveling speed of the traveler 50 on the flange 32 of the rotary ring 30 from the effective circumferential speed of the cop, i.e., the circumferential speed of a portion of a cop built by winding the yarn T 2 on the bobbin 82, in a plane including the yarn T2 being taken up on the bobbin 82. The roving T 1 is fed from the roving 70 at a fixed feed speed. A yarn winding speed at which the yarn T 2 is taken up on the bobbin 82 must be equal to a fleece delivery speed at which the drafting unit 72 delivers the fleece. However, while the spinning ring structure 110 is reciprocated for a cop building operation between a height A and a height B as shown in FIG. 5 and the yarn T 2 is being taken up on the bobbin 82, the diameter d 2 of a portion of the cop corresponding to the height B is large, and the diameter d 1 of a portion of the cop corresponding to the height A is small. Since the angular velocity ω 0 . of the spindle 80, hence that of the bobbin 82, is constant, the circumferential speed v 2 =d 2 ω 0 /2 of the portion of the cop corresponding to the height B is higher than the circumferential speed v 1 =d 1 ω 0 /2 of the portion of the cop corresponding to the height A. Accordingly, the traveling speed of the traveler 50, hence the rotating speed of the rotary ring 30, must vary according to the variation of the effective circumferential speed of the cop built on the bobbin 82 as indicated by a curve in FIG. 6 for an ideal mode. However, when the conventional spinning ring 110 is used, the deceleration of the traveling speed of the traveler 50 (the rotational speed of the rotary ring 30) is retarded as indicated by alternate long and two short dashes lines in FIG. 6 in an initial period of upward movement of the spinning ring unit 110 from the height B toward the height A and the actual traveling speed of the traveler 50 exceeds the ideal traveling speed. Consequently, a balloon formed by the yarn T 2 between the guide hole 77 of the yarn guide 76 and the traveler 50 expands or ballooning occurs, and the yarn touches the separator 95 and, in the worst case, breaks, so that the balloon collapses. In FIG. 7, a normal balloon is indicated by alternate long and short dash lines and an expanded balloon is indicated by alternate long and two short dashes lines. It is inferred from the results of experimental spinning operation that the deceleration of the traveling speed of the traveler 50 is retarded because whirling air currents produced between the cop and the rotary ring 30 by the rotating cop act on the vanes 168 of the brake ring 160 to urge the decelerating rotary ring 30 in its rotating direction. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a spinning ring structure including a rotary ring which can properly be decelerated when the same needs deceleration so that the collapse of a balloon of a yarn can be avoided. According to the present invention, a spinning ring structure for twisting a fleece produced by drafting a roving supplied from a roving feed means into a yarn and taking up the yarn on a bobbin comprises: a stationary ring fixedly mounted on a ring rail; a rotary ring disposed for rotation about its own axis inside the stationary ring coaxially therewith so as to surround the bobbin coaxially with the stationary ring; a traveler put on the rotary ring so as to be able to revolve along the circumference of the rotary ring to guide the yarn toward a cop formed by winding the yarn on the bobbin; and a brake member mounted on the rotary ring and provided with means for producing resistance against the turning of the brake member. The spinning ring structure is provided with an air pressure evading wall for preventing a pressure generated by whirling air currents produced by the rotating cop from influencing a braking motion of the brake member. The yarn being guided toward and wound on the cop formed on the bobbin causes the traveler to revolve on the rotary ring as the bobbin rotates and the revolving traveler drags the rotary ring so that the rotary ring rotates. The brake member exerts a braking force on the rotary ring in order that the rotary ring may not rotate at an excessively high rotating speed. Since there is provided the air pressure evading wall, the undesirable acceleration of the brake member, hence the undesirable acceleration of the rotary ring, by the whirling currents produced by the rotating cop, can be avoided. Consequently, the rotary ring is able to be decelerated according to the decrease of the effective circumferential speed of the cop, i.e., the circumferential speed of a portion of the cop on which the yarn is being wound, varying with the height of the spinning ring structure. Therefore, the collapse of a balloon formed by the yarn can be avoided and a satisfactory spinning operation can be achieved. In the spinning ring structure according to the present invention, the brake member may be a brake ring combined coaxially with the rotary ring and provided with a plurality of radial vanes, and the air pressure evading wall screens at least portions of the radial vanes from the whirling air currents on the side of the cop. The air pressure evading wall may screen the radial vanes entirely or partly from the whirling air currents on the side of the cop. The radial vanes includes vanes extending radially of the brake member and those extending substantially radially of the brake member. In the spinning ring structure according to the present invention, the vanes may be those not exposed to a space around an upper portion of the spinning ring structure. The vanes not exposed to the space around the upper portion of the spinning ring structure are desirable in view of safety for the operator. In the spinning ring structure according to the present invention, the vanes may substantially be screened from the ambience. Since the vanes of the brake ring are not exposed to the frictional resistance of air when the brake ring rotates together with the rotary ring, the braking effect of the brake ring does not increase progressively with the increase of its rotating speed and hence excessively high braking force is not generated and, consequently, load on a driving system for driving the cop for rotation is not increased excessively and the driving system does not require high energy. In the spinning ring structure according to the present invention, the plurality of vanes are formed under the rotary ring, the lower ends of the plurality of vanes may be covered with a lower screening wall, and an imaginary cylindrical surface including the outer edges of the plurality of vanes is close to the stationary ring. The lower screening wall may be joined to the lower ends of the plurality of vanes and may rotate together with the plurality of vanes or may be fixedly disposed under the plurality of vanes. The effect of suppressing the excessive increase of load on the driving system for driving the cop and suppressing the energy requirement of the driving system can be enhanced by this arrangement, because the lower ends of the plurality of vanes are covered with the lower screening wall and the outer ends of the radial vanes are close to the stationary ring and substantially isolated from the ambient air. In the spinning ring structure according to the present invention, a gap terminating at a portion of a member with which the rotary ring is in sliding contact may be formed between the stationary ring and the brake ring so as to open into a circumferential space around the spinning ring structure. If the gap is thus opens into a circumferential space around the spinning ring structure, radial air currents produced by the rotating brake ring flow to the outside through the gap to dissipate effectively heat generated by friction between the rotary ring and the member with which the rotary ring is in sliding contact when the rotary ring rotates. Accordingly, the rotary cylinder may not be caused to expand by the heat to increase frictional resistance against its rotation and hence the rotary ring is able to rotate smoothly for a smooth spinning operation. The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a general end view of a spinning frame that can use conventional spinning ring structures or spinning ring structures in accordance with the present invention; FIG. 2 is an enlarged fragmentary longitudinal sectional view of a spinning ring structure in a first embodiment according to the present invention; FIG. 3 is a perspective view of a brake ring included in the spinning ring structure of FIG. 2; FIG. 4 is a fragmentary perspective view of a ring rail for supporting either the conventional spinning ring structure or the spinning ring structure of the present invention shown in FIG. 2; FIG. 5 is a fragmentary front view of a cop, for assistance in explaining a dynamic mechanism of a cop building operation for taking up a yarn on a bobbin to build a cop; FIG. 6 is a diagram for assistance in explaining the relation between the vertical position of a traveler and the traveling speed of the same; FIG. 7 is a fragmentary front view of the spinning frame, for assistance in explaining the variation of the diameter of a balloon of a yarn during a spinning operation; FIG. 8 is a fragmentary sectional view of a spinning ring structure in a second embodiment according to the present invention; FIG. 9 is a fragmentary sectional view of a spinning ring structure in a third embodiment according to the present invention; FIG. 10 is a fragmentary sectional view of a spinning ring structure in a fourth embodiment according to the present invention; FIG. 11 is a fragmentary sectional view of a spinning ring structure in a fifth embodiment according to the present invention; FIG. 12 is a fragmentary sectional view of a spinning ring structure in a sixth embodiment according to the present invention; FIG. 13 is a fragmentary sectional view of a spinning ring structure in a seventh embodiment according to the present invention; FIG. 14 is a sectional view of a conventional spinning ring structure; and FIG. 15 is a perspective view of a brake ring included in the spinning ring structure of FIG. 14, in an inverted position. DESCRIPTION OF THE PREFERRED EMBODIMENTS Spinning ring structures in accordance with the present invention are used on a spinning frame as previously described with reference to FIG. 1. First Embodiment Referring to FIG. 2, a spinning ring structure 10 according to a first embodiment of the present invention comprises a stationary ring 20 made of a synthetic resin, a rotary ring 30, a sliding ring 40, a traveler 50 and a brake ring 60A made of a synthetic resin. The stationary ring 20 has a fitting portion 22 having a cylindrical outer circumference provided with a groove 26 for receiving a rubber retaining ring 90, and an annular flange 24. The fitting portion 22 of the stationary ring 20 is fitted in a mounting hole 75 of a ring rail 74 with the flange 24 seated on the surface of the ring rail 74, and then the rubber retaining ring 90 is fitted in the groove 26 to hold the stationary ring 20 in place on the ring rail 74. The rotary ring 30 is disposed inside the stationary ring 20 coaxially with the stationary ring 20 and is supported for rotation about its axis. The sliding ring 40 is made of an engineering plastic and interposed between the stationary ring 20 and the rotary ring 30 to enable the rotary ring 30 to rotate smoothly relative to the stationary ring 20. The sliding ring 40 is retained in place by a retaining cover 42 fixedly put on the stationary ring 20. An annular dustproof cover 44 is attached to an upper portion of the rotary ring 30 to exclude dust from gaps between the stationary ring 20 and the rotary ring 30. The rotary ring 30 is provided at its upper end with an annular flange 32. The traveler 50 is put on the flange 32 of the rotary ring 30 for circumferential revolution along the flange 32. As shown in FIGS. 2 and 3, the brake ring 60A has an annular fitting portion 61 at its upper end, a flange 62 formed at the lower end of the annular fitting portion 61, a plurality of radial vanes 68A formed on the lower surface of the flange 62 at equal angular intervals, an annular screening flange 66A contiguous with the lower edges of the radial vanes 68A, and a cylindrical air pressure evading wall 64A formed integrally with the inner edges, i.e., the edges on the side of a bobbin 82 put on a spindle 80, of the radial vanes 68A. The screening flange 66A extends radially outward from the lower end of the air pressure evading wall 64A and underlies the lower end of the stationary ring 20. As shown in FIG. 2, the fitting portion 61 of the brake ring 60A is fixedly fitted in a skirt 34 formed in a lower end portion of the rotary ring 30 with the flange 62 thereof pressed against the lower end of the skirt 34. A narrow gap 67 is formed between the outer edge of each radial vane 68A and the inner circumference of the stationary ring 20. The air pressure evading wall 64A isolates the radial vanes 68A from a space around a cop formed by winding a yarn on the bobbin 82. The radial vanes 68A are surrounded by the flange 62, the air pressure evading wall 64A, the lower screening flange 66A and the stationary ring 20 so as to be isolated from the space around the spinning ring structure 10. A gap 48A is formed between the stationary ring 20 and the combination of the rotary ring 30 and the brake ring 60A. The gap 48A terminates at the sliding ring 40 and opens into a circumferential space around the spinning ring structure 10. The stationary ring 20, the rotary ring 30, the sliding ring 40, the traveler 50 and the brake ring 60A of the spinning ring structure 10 are designed so that the sum of a frictional resistance of the sliding ring 40 against the rotation of the rotary ring 30 and a resistance of air against the rotation of the brake ring 60A makes the rotary ring 30 rotate together with the traveler 50 when the bobbin 82 is rotating in a steady state (not necessarily immediately after the rotation of the bobbin 82 has become a steady state) at a high rotational speed in the range of 10,000 to 15,000 rpm. As mentioned above with reference to FIG. 1, the ring rail 74 is reciprocated vertically to reciprocate the spinning ring structure 10 vertically, and the spindle 80 supporting the bobbin 82 spins. The traveler 50 is dragged for revolution along the flange 32 of the rotary ring 30 by a yarn T 2 being wound on the bobbin 82, and the rotary ring 30 is rotated by a frictional dragging force exerted thereon by the traveler 50. The drafting unit 72 drafts a roving T 1 into a fleece and delivers the fleece at a predetermined delivery speed, the fleece is twisted into a yarn T 2 , the yarn T 2 travels through the guide hole 77 of the yarn guide 76 and through the traveler 50 of the spinning ring structure 10 and is taken up on the bobbin 82. When the spindle 80 supporting the bobbin 82 starts rotating, the traveler 50 starts revolving along the flange 32 of the rotary ring 30, and the rotary ring 30 is dragged for rotation by the frictional dragging force of the traveler 50. The traveler 50 is pressed strongly against the rotary ring 30 by a high centrifugal force acting thereon when the spindle 80 supporting the bobbin 82 spins in a steady state, i.e., at a fixed angular velocity ω 0 , at a high rotational speed in the range of 10,000 to 15,000 rpm, so that the rotary ring 30 rotates substantially together with the traveler 50. As mentioned previously with reference to FIGS. 5 and 6, while the spinning ring structure 10 is reciprocated vertically for a cop building operation between the height A and the height B as shown in FIG. 5 and the yarn T 2 is being taken up on the bobbin 82, the diameter d 2 of a portion of a cop corresponding to the height B is large, and the diameter di of a portion of the cop corresponding to the height A is small. Since the angular velocity ω 0 of the spindle 80, hence that of the bobbin 82, is constant, the circumferential speed v 2 =d 2 ω 0 /2 of the portion of the cop corresponding to the height B is higher than the circumferential speed v 1 =d 1 ω 0 /2 of the portion of the cop corresponding to the height A. Accordingly, the traveling speed of the traveler 50, hence the rotational speed of the rotary ring 30, must vary according to the variation of the effective circumferential speed of the cop built on the bobbin 82 as indicated by a curve in FIG. 6 for an ideal mode. Since the brake ring 60A of the spinning ring structure 10 is provided with the air pressure evading wall 64A facing the cop formed by winding the yarn T 2 on the bobbin 82, the radial vanes 68A of the brake ring 60A is not affected by whirling air currents produced by the rotating cop, and the brake ring 60A is not urged by the whirling currents in its rotating direction. Therefore, when the working circumferential speed of the cop starts decreasing when the spinning ring structure 10 starts rising from the height B toward the height A, the rotational speed of the rotary ring 30 and the revolving speed of the traveler 50 are decreased by a braking force of the brake ring 60A along an ideal speed reducing curve indicated by continuous lines in FIG. 6. Therefore, the deceleration of the rotary ring 30 and the traveler 50 is not retarded, a balloon indicated by long and short dash lines in FIG. 7 formed by the yarn T 2 will not expand and will not collapse, so that a spinning operation is smoothly carried out. The brake ring 60A provided at its lower end with the screening flange 66A exercises the following effects. The radial vanes 68A do not stir the atmosphere and hence do not generate an excessively high braking force when the brake ring 60A rotates together with the rotary ring 30 because the radial vanes 68A are surrounded by the flange 62, the air pressure evading wall 64A, the lower screening flange 66A and the stationary ring 20 so as to be isolated from the space around the spinning ring structure 10. If the radial vanes 68A were not thus surrounded by the air pressure evading wall 64A and so on, the braking force of the brake ring 60A would increase progressively with the increase of the rotational speed of the same. Thus, the brake ring 60A included in the spinning ring structure 10 generates a necessary but not excessively high braking force. Accordingly, load on the spindle 80 is not increased excessively, and electrical energy for rotating the spindle 80 can be saved for energy conservation. The gap 48A formed between the stationary ring 20 and the combination of the rotary ring 30 and the brake ring 60A, terminating at the lower surface of the sliding ring 40 and opening into a circumferential space around the spinning ring structure 10 exercises the following effect. The sliding ring 40 is heated by frictional heat generated by friction between the rotary ring 30 and the sliding ring 40 and the temperature of the sliding ring 40 tends to rise. If heated at high temperature, the sliding ring 40 expands and its frictional resistance against the rotating rotary ring 30 increases to obstruct the rotation of the rotary ring 30. Since the gap 48A contiguous with the sliding ring 40 opens into the circumferential space surrounding the spinning ring structure 10, air in the gap 48A is urged to flow to the outside by centrifugal force as the rotary ring 30 rotates, while air is induced from above the sliding ring 40 through minute clearances existing between the ring 40 and the stationary and rotary rings 20 and 30 into the gap 48A, and consequently, heat generated in the sliding ring 40 can smoothly be dissipated, and the smooth rotation of the rotary ring 30 is ensured for smooth spinning operation. On the other hand, the rotation of the screening flange 66A causes air in the gap between the stationary ring 20 and the outer peripheral portion of the screening flange 66A to flow radially outward. This radially outward flow of air serves to prevent ingress of flies into the gap 48A adjacent the sliding ring 40, whereby smooth rotation of the rotary ring 30 can be maintained over a long period of time. Second Embodiment A spinning ring structure in a second embodiment according to the present invention is similar in construction to the spinning ring structure 10 in the first embodiment and hence only the difference of the second embodiment from the first embodiment will be described with reference to FIG. 8. The spinning ring structure in the second embodiment includes a brake ring 60B provided with a fitting portion 61, an air pressure evading wall 64B of an inside diameter somewhat greater than that of the fitting portion 61, radial vanes 68B each divided into an outer portion 68Ba and an inner portion 68Bb by the air pressure evading wall 64B, and a lower screening flange 66B extending radially outward from the lower end of the air pressure evading wall 64B. Although the inner portions 68Bb of the radial vanes 68B are exposed to the whirling air currents produced by the cop, the effect of the whirling air currents on the action of the brake ring 60B is not very significant and the collapse of the balloon formed by the yarn T 2 is avoided. Third Embodiment A spinning ring structure in a third embodiment according to the present invention is similar in construction to the spinning ring structure 10 in the first embodiment and hence only the difference of the third embodiment from the first embodiment will be described with reference to FIG. 9. The spinning ring structure in the third embodiment includes a brake ring 60C provided with a flange 62, an air pressure evading wall 64A, radial vanes 68A, and a lower screening flange 66C extending radially outward from the lower end of the air pressure evading wall 64B to the outer edges of the radial vanes 68A, i.e., an imaginary cylindrical surface including the circumference of the flange 62. The lower screening flange 66C is on substantially the same level as that of the lower end of a stationary ring 20, and hence a gap 48C corresponding to the gap 48A of the spinning ring structure 10 in the first embodiment opens downward. Fourth Embodiment A spinning ring structure in a fourth embodiment according to the present invention is similar in construction to the spinning ring structure in the third embodiment and hence only the difference of the fourth embodiment from the third embodiment will be described with reference to FIG. 10. The spinning ring structure in the fourth embodiment includes a brake ring 60D provided with a fitting portion 61, an air pressure evading wall 64B of an inside diameter somewhat greater than that of the fitting portion 61, radial vanes 68B each divided into an outer portion 68Ba and an inner portion 68Bb by the air pressure evading wall 64B, and a lower screening flange 66D extending radially outward from the lower end of the air pressure evading wall 64B. Fifth Embodiment A spinning ring structure in a fifth embodiment according to the present invention is similar in construction to the spinning ring structure 10 in the first embodiment and hence only the difference of the fifth embodiment from the first embodiment will be described with reference to FIG. 11. The spinning ring structure in the fifth embodiment includes a brake ring 60E similar to the brake ring 60A of the first embodiment, except that the brake ring 60E is not provided with any part corresponding to the lower screening flange 66A, and a lower screening member 44E attached to the lower portion of a stationary ring 20 and having a lower screening flange 66E extending radially inward from the lower end of the stationary ring 20 to an imaginary cylindrical surface including the inner surface of an air pressure evading wall 64A so as to underlie radial vanes 68A included in the brake ring 60E close to the lower edges of the radial vanes 68A. The radial vanes 68A are thus surrounded by the flange 62, the air pressure evading wall 64A, the lower screening flange 66E and the stationary ring 20 and is substantially isolated from a space around the spinning ring structure. In this spinning ring structure, a gap 48E corresponding to the gap 48A in the spinning ring structure 10 in the first embodiment opens radially inward into a space surrounded by the spinning ring structure. Sixth Embodiment A spinning ring structure in a sixth embodiment according to the present invention is similar in construction to the spinning ring structure in the fifth embodiment and hence only the difference of the sixth embodiment from the fifth embodiment will be described with reference to FIG. 12. The spinning ring structure in the sixth embodiment has a brake ring 60F provided with a fitting portion 61, and an air pressure evading wall 64B of a diameter somewhat greater than that of the fitting portion 61. A lower screening member 44F has a lower screening flange 66F extending radially inward from the lower end of a stationary ring 20 to an imaginary cylindrical surface including the inner circumference of the air pressure evading wall 64B. Seventh Embodiment A spinning ring structure in a seventh embodiment according to the present invention is similar in construction to the spinning ring structure 10 in the first embodiment and hence only the difference of the seventh embodiment from the first embodiment will be described with reference to FIG. 13. The spinning ring structure in the seventh embodiment includes a brake ring 60G not provided with any parts corresponding to the air pressure evading wall 64A and the lower screening flange 66A of the spinning ring structure 10 in the first embodiment. A lower screening member 44G is attached to a lower portion of a stationary ring 20 and has a lower screening flange 66G and an air pressure evading wall 64G. The lower screening flange 66G extends close to the lower edges of radial vanes 68G from the lower end of a stationary ring 20 to an imaginary cylindrical plane at a short distance inward from an imaginary cylindrical plane including the inner edges of the radial vanes 68G. The air pressure evading wall 64G extends close to the inner edges of the radial vanes 68G from the inner end of the lower screening flange 66G upward substantially to a plane including the upper surface of a flange 62. The radial vans 68G are thus surrounded by the flange 62, the air pressure evading wall 64G, the lower screening flange 66G and the stationary ring 20. A gap 48G corresponding to the gap 48A of the first embodiment opens upward. In the embodiments shown in FIGS. 9 to 13, the stationary rings 20 respectively surrounding the brake rings 60C, 60D, 60E, 60F and 60G, and the lower screening flanges 66E, 66F and 66G may be provided with air holes 65 and 69 for heat dissipation as shown in FIG. 13. The brake rings may be provided with a plurality of ridges instead of the radial vanes. Although the invention has been described in its preferred forms with a certain degree of particularity, obviously many changes and variations are possible therein. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein without departing from the scope and spirit thereof.
A spinning ring structure (10) for twisting a fleece into a yarn and taking up the yarn on a bobbin (82) comprises a stationary ring (20) fixedly mounted on a ring rail (74), a rotary ring (30) disposed for rotation about its own axis inside the stationary ring (20) coaxially therewith so as to surround the bobbin (82) disposed with the stationary ring (30). A traveler (50) is put on the rotary ring (30) so as to revolve along the circumference of the rotary ring, and a brake ring (60) is mounted on the rotary ring (30) and provided with a plurality of radial vanes (68) to which air applies resistance against the turning of the brake ring. The brake ring (60) is provided with an air pressure evading wall (64) for avoiding the influence of a pressure generated by whirling air currents produced by the rotating cop, on the brake ring (60) to prevent retardation of the variation of the rotational speed of the rotary ring according to the variation of the effective circumferential speed of the cop built on the bobbin during a cop building operation so that a balloon formed by the yarn will not expand and will not collapse.
3
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a level shift device, and in particular to a level shift device capable of providing about the same positive and negative duty cycles, and a method for the same. [0003] 2. Description of the Related Art [0004] To reduce power consumption, it is a trend to decrease the operational voltage within a circuit chip to, e.g., 1.2V or lower, but the communication between circuit chips operates in a higher voltage such as 3.3V. For this reason, a level shift device is required as an input/output interface circuit to shift the operational level within a circuit chip to a higher level for inter-chip communication. FIG. 1 shows the basic structure of a conventional level shift circuit 10 , which comprises two PMOS transistors M 1 and M 2 , and two NMOS transistors M 3 and M 4 . Assuming the function of the circuit is to convert the voltage level from 1.2V to 3.3V, the input IN in the shown circuit may thus be an operational voltage of 1.2V (the first operational voltage), and the voltage supplied from the voltage source VP 2 may be 3.3V (the second operational voltage). [0005] Referring to FIGS. 1 and 2 , the conventional level shift circuit operates as follows. At time T 0 , the initial state of the circuit, the input IN is at the low level of the first operational voltage (e.g., 0V), while the inverted input INB is at the high level of the first operational voltage (e.g., 1.2V). Because the inverted input INB is at the high level, the NMOS transistor M 4 is ON, whereby the node B is grounded through the NMOS transistor M 4 and is at the low level of 0V. The voltage level of the node B is exactly the voltage level of the output OUT, which is thus also at the low level of 0V (the low level of the second operational voltage). Because the node B is low, the PMOS transistor M 1 is ON, whereby the voltage VP 2 reaches the node A through the PMOS transistor M 1 so that the node A is at a high level equivalent to VP 2 (the high level of the second operational voltage, such as 3.3V). Because the node A is high, the PMOS transistor M 2 is OFF; the voltage VP 2 does not affect the voltage level at the output OUT. [0006] When it is desired for the circuit to generate a high voltage level output, as shown at time T 1 in FIG. 2 , the input IN switches from low to high, whereby the NMOS transistor M 3 turns ON so that the node A is grounded through NMOS transistor M 3 . However, during the transition state, the PMOS transistor M 1 is still partially conductive, and therefore the voltage VP 2 still affects the node A; the voltage at the node A does not reach low instantly, but rather drops slowly. The PMOS transistor M 2 is controlled by the node A and thus gradually turns ON until time T 2 . At time T 2 , the PMOS transistor M 2 fully turns ON, and from this time on the voltage VP 2 completely passes through the PMOS transistor M 2 and reaches the node B so that the output OUT is pulled high to a level equivalent to VP 2 . In the meantime, since the node B is high, the PMOS transistor M 1 fully turns OFF to stabilize node A at the low level of 0V. [0007] FIG. 2 shows ideal waveforms under an assumption that the PMOS and NMOS transistors in each of the PMOS-NMOS transistor pairs M 1 and M 3 , M 2 and M 4 have about the same driving strength. However, to ensure that the NMOS transistors M 3 and M 4 can over-drive the PMOS transistors M 1 and M 2 during the transition from low level to high level, in particular to cope with the situation where the NMOS transistors are in their worst case and the PMOS transistors are in their best case, the width of the NMOS transistors are typically made longer to increase their driving strength. Hence the driving strength of the PMOS transistor M 1 is weaker than that of the NMOS transistor M 3 , and the driving strength of the PMOS transistor M 2 is weaker than that of the NMOS transistor M 4 , resulting in the waveforms shown in FIG. 3 , wherein the output signal of the level shift device is far slower in switching from low to high than from high to low, as referring to the time points T 2 , T 3 , T 4 and T 5 . [0008] Referring to FIG. 4 , when the switching time from low to high and the time from high to low are not comparable, the positive (high level) and negative duty cycles (low level) are not equal to each other (TL>TH, in other words, the rising and falling time of a signal are different). If such a level shift device is used in a product wherein both the rising and falling edges of a signal are meaningful, such as a DDR DRAM or other similar products, the uneven positive and negative duty cycles will significantly impact the accuracy of the clock, data, data strobe and other signals. To ensure the accuracy of such the signals, the processing time of the signals such as the set-up time and the hold time has to be prolonged, degrading the performance of the product. [0009] In view of the above, a level shift device providing about the same positive and negative duty cycles is desired. SUMMARY OF THE INVENTION [0010] A first objective of the present invention is to provide a level shift device capable of providing about the same positive and negative duty cycles. [0011] A second objective of the present invention is to provide a level shift method. [0012] To achieve the foregoing objectives, according to an aspect of the present invention, a level shift device comprises: a first level shift circuit for converting an input signal with a first voltage level to a first signal and a second signal with a second voltage level, wherein the first voltage level is different from the second voltage level, and the first signal and the second signal are substantially opposite in phase, and an output stage circuit for generating an output signal according to the relationship between the first signal and the second signal. [0013] In the above-mentioned level shift device, the output stage circuit for example can be a comparator or a second level shift circuit. [0014] According to another aspect of the present invention, a level shift method comprises: receiving an input signal with a first voltage level; converting the input signal to a first signal and a second signal with a second voltage level, wherein the first voltage level is different from the second voltage level, and the first signal and the second signal are substantially opposite in phase, and generating an output signal according to the relationship between the first signal and the second signal. [0015] Preferably, in the above-mentioned circuit and method, the output signal is high when the voltage level of the signal with the second voltage level is higher than the voltage level of the inverted signal of the second operational voltage, and the output signal is low when the voltage level of the inverted signal of the second operational voltage is higher than the voltage level of the signal of the second operational voltage. [0016] For better understanding the objects, characteristics, and effects of the present invention, the present invention will be described below in detail by illustrative embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0017] FIG. 1 is a circuit diagram schematically showing a conventional level shift circuit. [0018] FIG. 2 is a time diagram showing the voltage level transition at the critical nodes in the conventional level shift circuit shown in FIG. 1 . [0019] FIGS. 3 and 4 explain the drawback in the prior art. [0020] FIG. 5 is a circuit diagram schematically showing a level shift device according to a first preferred embodiment of the present invention. [0021] FIG. 6 is a time diagram showing the voltage level transition at the critical nodes in the level shift device shown in FIG. 5 . [0022] FIG. 7 is a circuit diagram schematically showing a level shift device according to a second preferred embodiment of the present invention. [0023] FIG. 8 is a time diagram showing the voltage level transition at the critical nodes in the level shift device shown in FIG. 7 . DESCRIPTION OF THE PREFERRED EMBODIMENTS [0024] For purpose of simplicity, in all of the following embodiments, it is assumed that the first operational voltage has a high level of 1.2V and low level of 0V, and the second operational voltage VP 2 has a high level of 3.3V and a low level of 0V. The input and output signals are, e.g., clock signals. However, the present invention should not be limited as such, but may be applied to level shift between any two voltage levels and any other forms of signals. [0025] FIG. 5 schematically shows a first preferred embodiment according to the present invention. As shown in the figure, the level shift device 100 comprises a pair of PMOS transistors M 1 and M 2 , and a pair of NMOS transistors M 3 and M 4 (the PMOS and NMOS pairs constituting a basic level shift circuit 20 ). In addition to the above, the level shift device 100 according to this embodiment further comprises an output stage circuit which determines the level of the output OUT according to the difference between the voltages at the nodes A and B. The voltage signal at the node B is an inverted signal of that at the node A; there is 180° phase difference between the signals at the nodes A and B. There are various ways to embody the output stage circuit; in this embodiment, the output stage circuit is a comparator 30 . [0026] Referring to FIG. 6 in conjunction with FIG. 5 , when the input IN switches from low (0V) to high (1.2V), the voltage at the node A rapidly drops, and the voltage at the node B slowly increases. However, the output OUT of the overall circuit is not from the node B, but from the output of the comparator 30 which compares the voltages at the node A and node B; thus, the output OUT does not switch to high (3.3V) until the voltage at the node B is higher than that at the node A, as referring to time T 1 . [0027] Likely, when the input IN switches from high to low, the output OUT does not switch to low until the voltage at the node B is lower than that at the node A, as referring to time T 2 . [0028] Thus, as seen from FIG. 6 , the positive and negative duty cycles of the output OUT are the same, i.e., TH=TL, achieving the objectives of the present invention. [0029] One important feature of the present invention is that the output OUT of the overall circuit is generated according to the relationship between the voltages at the node A and node B. This can be embodied by many other ways than the comparator 30 described above. [0030] FIG. 7 schematically shows a second preferred embodiment according to the present invention. As shown in the figure, the level shift device 200 further comprises another level shift circuit 40 which includes a pair of PMOS transistors M 5 and M 6 , and a pair of NMOS transistors M 7 and M 8 . In the level shift circuit 40 , the NMOS transistors M 7 and M 8 have the same width as that of the PMOS transistors M 5 and M 6 . The level shift circuit 40 in this embodiment may be deemed as an equal-level shift circuit because its first operational voltage (the gate voltage of the transistors M 7 and M 8 ) is the same as its second operational voltage (its output), which are both 3.3V in this embodiment. [0031] Referring to FIG. 8 in conjunction with FIG. 7 , when the input IN switches from low to high, the voltage at the node A rapidly drops, while the voltage at the node B slowly increases. Correspondingly, the NMOS transistor M 7 rapidly turns OFF but the NMOS transistor M 8 slowly turns ON. Thus, the gate voltage of the PMOS transistor M 5 drops slowly, and the output OUT of the overall circuit does not change state immediately. Only until the voltage at the node B is higher than that at the node A that the output OUT switches state to high, as referring to time T 1 . [0032] Likely, when the input IN switches from high to low, the output OUT does not switch to low until the voltage at the node B is lower than that at the node A, as referring to time T 2 . [0033] Thus, as seen from FIG. 8 , the positive and negative duty cycles of the output OUT are the same, i.e., TH=TL, achieving the objectives of the present invention. [0034] The features, characteristics and effects of the present invention have been described with reference to its preferred embodiments, for illustrating the spirit of the invention and not for limiting the scope of the invention. Various other substitutions and modifications will occur to those skilled in the art, without departing from the spirit of the present invention. For example, there are various ways to determine the overall output OUT according to the relationship between the voltages at the node A and node B, and these variations should all belong to the scope of the present invention. As another example, in each of the described embodiments, the level shift device is for converting a low voltage level to a high voltage level, but the present invention may be applied to a level shift circuit for high-to-low level shift as well. Therefore, all such substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims.
The present invention discloses a level shift device which comprises: a level shift circuit for receiving an input with a first voltage level and generating a first signal and a second signal with a second voltage level; and an output circuit which generates an output according to the first signal and the second signal.
7
RELATED APPLICATIONS [0001] This application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2016-051497 filed on Mar. 15, 2016, the entire content of which is hereby incorporated by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a voltage regulator, and more particularly, to a voltage regulator having an overcurrent protection function. [0004] 2. Description of the Related Art [0005] FIG. 4 is a circuit diagram for illustrating a related-art voltage regulator 300 . [0006] The related-art voltage regulator 300 includes a power supply terminal 301 , a ground terminal 302 , a reference voltage source 310 , an error amplifier circuit 311 , resistors 312 , 317 , 318 , and 319 , an NMOS transistor 316 , PMOS transistors 313 , 314 , and 315 , and an output terminal 320 . [0007] The PMOS transistor 315 has a source connected to the power supply terminal 301 , and a drain connected to the output terminal 320 and one end of the resistor 318 . The resistor 318 has another end connected to one end of the resistor 319 and a non-inverting input terminal of the error amplifier circuit 311 . The resistor 319 has another end connected to the ground terminal 302 . The PMOS transistor 314 has a source connected to the power supply terminal 301 , and a drain connected to one end of the resistor 317 and a gate of the NMOS transistor 316 . The PMOS transistor 313 has a source connected to the power supply terminal 301 , a drain connected to a gate of the PMOS transistor 315 , a gate of the PMOS transistor 314 , and an output of the error amplifier circuit 311 . The resistor 312 has one end connected to the power supply terminal 301 , and another end connected to a gate of the PMOS transistor 313 and a drain of the NMOS transistor 316 . The error amplifier circuit 311 has an inverting input terminal connected to one end of the reference voltage source 310 . The reference voltage source 310 has another end connected to the ground terminal 302 . The NMOS transistor 316 has a source connected to the ground terminal 302 . [0008] The related-art voltage regulator 300 operates such that, through a negative feedback circuit forming of the error amplifier circuit 311 , the PMOS transistor 315 , and the resistors 318 and 319 , a voltage at the one end of the resistor 319 is equal to a voltage VREF at the reference voltage source 310 . [0009] When a current that flows to a load (not shown) connected to the output terminal 320 increases in this state, a drain current I 1 of the PMOS transistor 315 increases. Then, a drain current I 2 of the PMOS transistor 314 , which is formed to have a predetermined size ratio to the PMOS transistor 315 , also increases. The current I 2 is supplied to the resistor 317 such that a voltage Vx is generated at the one end of the resistor 317 . When the voltage Vx increases to exceed a threshold of the NMOS transistor 316 , the NMOS transistor 316 is turned on, to thereby generate a drain current. The drain current of the NMOS transistor 316 is supplied to the resistor 312 , such that a voltage at the other end thereof decreases, to thereby turn on the PMOS transistor 313 . When the PMOS transistor 313 is turned on, a gate voltage of the PMOS transistor 315 increases, thereby limiting the drain current I 1 . [0010] Now, when a resistance value of the resistor 317 is represented by R 1 , the size ratio between the PMOS transistors 315 and 314 is represented by K, and a threshold voltage of the NMOS transistor 316 is represented by |VTHN|, a limited current I 1 m of the current I 1 is expressed by Expression (1). [0000] I   1  m = K × VTHN R   1 ( 1 ) [0011] As described above, the related-art voltage regulator 300 has an overcurrent protection function, and an output current may be limited when the load is short-circuited, for example (see, for example, Japanese Patent Application Laid-open No. 2003-29856). [0012] However, the related-art voltage regulator 300 has a problem in that fluctuation in the limited current I 1 m is large. This is because fluctuation in the threshold voltage VTHN affects the limited current I 1 m , as can be seen in Expression (1). [0013] FIG. 5 is a graph for showing a waveform of an output voltage VOUT relative to an output current IOUT of the related-art voltage regulator 300 . The dotted lines indicate a fluctuation range of the limited current. In general, the fluctuation in the threshold voltage VTHN is about ±0.1 from a center value of 0.6 V, and hence the fluctuation in the limited current I 1 m caused by the threshold voltage VTHN is ±16.7%, which is a very large fluctuation. SUMMARY OF THE INVENTION [0014] The present invention has been made in order to solve the above-mentioned problem, and provides a voltage regulator capable of suppressing fluctuation in a limited current. [0015] According to one embodiment of the present invention, there is provided a voltage regulator including: a first differential amplifier circuit configured to compare a voltage based on an output voltage and a reference voltage to each other, to thereby output a first voltage; a second differential amplifier circuit configured to compare the first voltage and a second voltage to each other, to thereby output a third voltage; a first transistor configured to receive the third voltage at a gate of the first transistor such that the output voltage is generated at a drain of the first transistor; a second transistor, which includes a gate connected in common to the gate of the first transistor and has a predetermined size ratio to the first transistor; and a voltage generating unit, which includes one end connected to a drain of the second transistor and is configured to generate the second voltage at the one end. [0016] According to the voltage regulator of the present invention, the first voltage, which is an output voltage of the first differential amplifier circuit, is a reference value for a limited current of a drain current of the first transistor, and the second voltage, which is generated by the second transistor and the voltage generating unit, is a value in proportion to the drain current of the first transistor. Those first and second voltages are compared to each other by the second differential amplifier circuit, which forms a negative feedback circuit with the second transistor and the voltage generating unit, to thereby achieve an overcurrent protection. At this time, fluctuation in the limited current, which is a criterion for determining an overcurrent, is almost completely dependent on fluctuation in the reference voltage. Therefore, for example, by generating the reference voltage using a voltage source in which fluctuation is significantly small, for example, a bandgap voltage source, the fluctuation in the limited current can be suppressed. BRIEF DESCRIPTION OF THE DRAWINGS [0017] FIG. 1 is a circuit diagram for illustrating a voltage regulator of a first embodiment of the present invention. [0018] FIG. 2 is a graph for showing a waveform of an output voltage VOUT relative to an output current of the voltage regulator of FIG. 1 . [0019] FIG. 3 is a circuit diagram for illustrating a voltage regulator of a second embodiment of the present invention. [0020] FIG. 4 is a circuit diagram of the related-art voltage regulator. [0021] FIG. 5 is a graph for showing a waveform of the output voltage VOUT relative to an output current of the voltage regulator of FIG. 4 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0022] Now, embodiments of the present invention are described with reference to the drawings. [0023] FIG. 1 is a circuit diagram for illustrating a voltage regulator 100 of a first embodiment of the present invention. [0024] The voltage regulator 100 of this embodiment includes a power supply terminal 101 , a ground terminal 102 , a first differential amplifier circuit 127 , a second differential amplifier circuit 128 , a voltage generating unit 129 , PMOS transistors 112 and 113 , a reference voltage source 114 , resistors 124 and 125 , and an output terminal 126 . [0025] The first differential amplifier circuit 127 includes PMOS transistors 115 and 116 , NMOS transistors 117 and 118 , and a current source 110 . [0026] The second differential amplifier circuit 128 includes NMOS transistors 119 and 120 , a current source 111 , and a resistor 121 . [0027] The voltage generating unit 129 includes a PMOS transistor 123 and a resistor 122 . [0028] The PMOS transistor 113 has a source connected to the power supply terminal 101 , and a drain connected to the output terminal 126 and one end of the resistor 125 . The PMOS transistor 112 has a source connected to the power supply terminal 101 , and a drain connected to one end of the voltage generating unit 129 (source of PMOS transistor 123 ) and a gate of the NMOS transistor 120 . The current source 111 has one end connected to the power supply terminal 101 , and another end connected to a drain of the NMOS transistor 119 , a gate of the PMOS transistor 112 , and a gate of the PMOS transistor 113 . The resistor 125 has another end connected to one end of the resistor 124 and a gate of the PMOS transistor 116 . The resistor 124 has another end connected to the ground terminal 102 . The PMOS transistor 123 has a gate connected to a drain thereof and one end of the resistor 122 . Another end of the resistor 122 (another end of voltage generating unit 129 ) is connected to the ground terminal 102 . The NMOS transistor 120 has a drain connected to the power supply terminal 101 , and a source connected to a source of the NMOS transistor 119 and one end of the resistor 121 . The resistor 121 has another end connected to the ground terminal 102 . The current source 110 has one end connected to the power supply terminal 101 , and another end connected to a source of the PMOS transistor 115 and a source of the PMOS transistor 116 . The PMOS transistor 115 has a gate connected to one end of the reference voltage source 114 , and a drain connected to a gate and a drain of the NMOS transistor 117 . The reference voltage source 114 has another end connected to the ground terminal 102 . The PMOS transistor 116 has a drain connected to a gate of the NMOS transistor 119 and a drain of the NMOS transistor 118 . The NMOS transistor 118 has a gate connected to the gate of the NMOS transistor 117 , and a source connected to the ground terminal 102 . The NMOS transistor 117 has a source connected to the ground terminal 102 . [0029] In the first differential amplifier circuit 127 , the gate of the PMOS transistor 115 and the gate of the PMOS transistor 116 are inputs, and the drain of the PMOS transistor 116 is an output. In the second differential amplifier circuit 128 , the gate of the NMOS transistor 119 and the gate of the NMOS transistor 120 are inputs, and the drain of the NMOS transistor 119 is an output. [0030] For illustrative purposes, a drain current of the PMOS transistor 113 is represented by I 1 , and a drain current of the PMOS transistor 112 is represented by I 2 . The PMOS transistor 112 has a predetermined size ratio to the PMOS transistor 113 , and is configured to operate as a replica element. Further, a voltage at the output terminal 126 , a gate voltage of the NMOS transistor 120 , a gate voltage of the NMOS transistor 119 , a voltage at the another end of the current source 110 , a voltage at the one end of the resistor 121 , and a voltage at the one end of the reference voltage source 114 are represented by VOUT, VG 2 , VG 1 , VS 1 , VS 2 , and VREF, respectively. Further, a resistance value of the resistor 122 is represented by R, a voltage at the one end of the resistor 124 is represented by VFB, and a voltage at the another end of the current source 111 is represented by VGATE. [0031] Next, operation of the voltage regulator 100 having the above-mentioned configuration is described. [0032] A first state in which a load current supplied to the output terminal 126 is much smaller than the limited current is described. [0033] In this case, the current I 1 and the current I 2 , which is determined by the size ratio between the PMOS transistor 113 and the PMOS transistor 112 , each have a small current value. Further, the current I 2 is supplied to the voltage generating unit 129 , and hence the voltage VG 2 , which is generated at the one end of the voltage generating unit 129 , also has a small value. When the voltage VG 2 is below a threshold of the NMOS transistor 120 , the NMOS transistor 120 is off. [0034] In this situation, the first differential amplifier circuit 127 compares the voltage VREF and the voltage VFB to each other, and then amplifies a difference therebetween to output the voltage VG 1 . In the second differential amplifier circuit 128 , the NMOS transistor 120 is off. Thus, the voltage VG 1 is amplified by the NMOS transistor 119 , the resistor 121 , and the current source 111 such that the voltage VGATE is output. The PMOS transistor 113 receives the voltage VGATE at the gate thereof to generate the drain current I 1 , and then supplies the drain current I 1 to a load (not shown) connected to the output terminal 126 . [0035] The voltage VOUT is divided by the resistor 125 and the resistor 124 so that the divided voltage is input to the first differential amplifier circuit 127 . Through the loop as described above, a negative feedback functions and the first differential amplifier circuit 127 operates such that the voltage VREF and the voltage VFB become equal to each other. [0036] A second state in which the load current increases as compared to the first state is described. [0037] When a current that flows to the load (not shown) connected to the output terminal 126 increases, the current I 1 of the PMOS transistor 113 and the current I 2 of the PMOS transistor 112 each increase. As a result, the voltage VG 2 also increases, to thereby turn on the NMOS transistor 120 . Thus, the drain current of the NMOS transistor 120 is supplied to the resistor 121 , and the voltage VS 2 rises. [0038] It may be thought that the NMOS transistor 119 is turned off because a gate-source voltage thereof reduces. However, due to the function of the negative feedback, the NMOS transistor 119 is not turned off. In particular, through the function of the negative feedback, the voltage regulator 100 operates such that the voltage VREF and the voltage VFB become equal to each other. Thus, when the voltage VS 2 rises, the voltage VG 1 is increased by a corresponding amount. As a result, a predetermined voltage difference is maintained between the gate and the source of the NMOS transistor 119 . In other words, even if the load current increases to thereby increase the voltage VG 2 , the predetermined voltage VOUT may be obtained. [0039] A third state in which the load current further increases as compared to the second state such that the overcurrent protection function is put into operation is described. [0040] When the current that flows to the load (not shown) connected to the output terminal 126 further increases, the voltage VG 1 rises in the same mechanism as in the second state, but an upper limit of a voltage value of the voltage VG 1 is limited by the voltage VS 1 . The voltage VS 1 is determined by a sum of the voltage VREF and an absolute value |VGSP 1 | of the gate-source voltage of the PMOS transistor 115 , and is expressed by Expression (2). [0000] VS1=VREF+|VGSP1|  (2) [0041] When the voltage VG 2 becomes equal to the voltage VS 1 , the gate-source voltage of the NMOS transistor 119 decreases. Thus, when the drain current of the NMOS transistor 119 decreases, the voltage VGATE increases, thereby limiting the drain current I 1 of the PMOS transistor 113 . When an absolute value of a gate-source voltage of the PMOS transistor 123 is represented by |VGSP 2 |, and the size ratio between the PMOS transistors 113 and 112 is represented by K, the voltage VG 2 at this time is expressed by Expression (3). [0000] VG   2 = I   1 × R K + | VGSP   2 | ( 3 ) [0042] As described above, when the drain current I 1 of the PMOS transistor 113 is limited, the voltage VS 1 and the voltage VG 2 are equal to each other, and the absolute values VGSP 1 and VGSP 2 are substantially equal to each other. Thus, from Expression (2) and Expression (3), a limited current I 1 m of the current I 1 is expressed by Expression (4). [0000] I   1  m = K × VREF R ( 4 ) [0043] As described above, the limited current I 1 m of the current I 1 is determined, and the overcurrent protection function is put into operation. It is understood from Expression (4) that the limited current I 1 m is in proportion to the voltage VREF. [0044] FIG. 2 is a graph for showing a waveform of the output voltage VOUT relative to an output current IOUT of the voltage regulator 100 of this embodiment. The dotted lines indicate a fluctuation range of the limited current I 1 m . When the reference voltage source 114 is configured as a bandgap voltage source, fluctuation in the voltage VREF is about ±3%. Thus, fluctuation in the limited current I 1 m caused by the fluctuation in the voltage VREF may be suppressed to ±3%. [0045] As described above, in the voltage regulator 100 of this embodiment, the fluctuation in the limited current I 1 m may be made much smaller than that in the related-art voltage regulator 300 . [0046] Next, with reference to FIG. 3 , a voltage regulator 200 of a second embodiment of the present invention is described. [0047] The voltage regulator 200 of this embodiment is different from the voltage regulator 100 of the first embodiment in that the voltage generating unit 129 has a different configuration. That is, as illustrated in FIG. 3 , the voltage generating unit 129 is formed of the resistor 122 having one end connected to the drain of the PMOS transistor 112 , and another end connected to the ground terminal 102 . [0048] Other configurations are the same as those of the voltage regulator 100 of FIG. 1 . Thus, the same components are denoted with the same symbols and overlapping descriptions are omitted as appropriate. [0049] Operation of the voltage regulator 200 of this embodiment is described. A difference in operation from the voltage regulator 100 of the first embodiment is described as in the description of the difference in configuration. In the operation of the voltage regulator 200 of this embodiment, the voltage VG 2 in the third state is different from that in the voltage regulator 100 of the first embodiment, and is expressed by Expression (5) instead of Expression (3). [0000] VG   2 = I   1 × R K ( 5 ) [0050] The voltage VS 1 is the same as in Expression (2). Further, the voltage VS 1 and the voltage VG 2 are equal to each other in the third state, and hence the limited current I 1 m of the current I 1 is expressed by Expression (6) from Expression (2) and Expression (5). [0000] I   1  m = K R  ( VREF + | VGSP   1 | ) ( 6 ) [0051] The limited current I 1 m of the current I 1 is determined in this way, and the overcurrent protection function is put into operation. It is understood from Expression (6) that the limited current I 1 m of this embodiment is in proportion to a sum of the voltage VREF and the absolute value |VGSP 1 | of the gate-source voltage of the PMOS transistor 115 . [0052] When the reference voltage source 114 is configured as the bandgap voltage source, the voltage of the voltage VREF and fluctuation thereof is 1.2 V±0.036 V. Here, when the absolute value |VGSP 1 | is 0.6 V±0.1 V, a voltage of a sum of the values is 1.8 V±0.136 V. As a result, the fluctuation in the limited current I 1 m caused by fluctuation in the sum of the voltage VREF and the absolute value |VGSP 1 | may be suppressed to ±7.6%. [0053] As described above, even when the voltage generating unit 129 is formed of only the resistor 122 , the fluctuation in the limited current I 1 m may be significantly suppressed as compared to the related-art voltage regulator 300 . In general, the resistance value R has a negative temperature coefficient in many cases and the absolute value |VGSP 1 | also has a negative temperature coefficient. Thus, it is also possible to balance out those coefficients to improve temperature characteristics. [0054] As described above, in the voltage regulator 200 of this embodiment, the fluctuation in the limited current I 1 m may be reduced and the temperature characteristics may be improved as compared to the related-art voltage regulator 300 . [0055] The embodiments of the present invention have been described above, but the present invention is not limited to the above-mentioned embodiments. It is to be understood that various modifications can be made to the present invention without departing from the gist thereof. [0056] For example, in the example described in the first embodiment, the voltage generating unit 129 is formed of the PMOS transistor 123 and the resistor 122 connected in series. Further, the PMOS transistor 123 is arranged on the PMOS transistor 112 side, and the resistor 122 is arranged on the ground terminal 102 side. However, the resistor 122 may be arranged on the PMOS transistor 112 side, and the PMOS transistor 123 may be arranged on the ground terminal 102 side. [0057] Further, in the embodiments, the examples in which MOS transistors are used in the voltage regulator are described. However, bipolar transistors or the like may be used. [0058] Further, in the embodiments, a circuit configuration in which the polarities of the PMOS transistors and the NMOS transistors are reversed may be used.
Provided is a voltage regulator capable of suppressing fluctuation in a limited current. The voltage regulator includes: a first differential amplifier circuit configured to compare a voltage based on an output voltage and a reference voltage to each other, to thereby output a first voltage; a second differential amplifier circuit configured to compare the first voltage and a second voltage to each other, to thereby output a third voltage; a first transistor configured to receive the third voltage at a gate thereof such that the output voltage is generated at a drain thereof; a second transistor, which includes a gate connected in common to the gate of the first transistor and has a predetermined size ratio to the first transistor; and a voltage generating unit, which includes one end connected to a drain of the second transistor and is configured to generate the second voltage at the one end.
6
TECHNICAL FIELD The present invention relates generally to optical communication systems, and more particularly, to methods and devices for receiving and processing optical communication signals. BACKGROUND Optical communication technology has moved from simple amplitude modulation (AM) to more advanced modulation techniques using both amplitude and phase. With increasing demand for higher throughput, optical communication systems have adopted these more advanced modulation formats which require increasing spectral efficiency of the system. One of these formats is differential QPSK (DQPSK), in which information bits are coded as phase transient between adjacent symbols. DQPSK has a high tolerance for phase noise. One simple way to decode a DQPSK signal is by using an analog DQPSK decoder, sometimes referred to as an optical delay interferometer. With reference to FIG. 1 , there is illustrated such a prior art decoder or interferometer in which the optical signal is delayed and added before detected by an intensity detector. However, the drawback to this simplicity is that only amplitude is detected and all of the phase information of the received signal is lost. With increasing baud rates, the signal is more and more sensitive to link impairment, such as dispersion and Polarization Mode Dispersion (PMD), which introduces amplitude and phase distortion to the optical signal. With only signal amplitude being detected, there is no effective method to compensate for these impairments and increase performance. To recover both amplitude and phase of the received optical signal, coherent detection techniques have been widely adopted in new generation optical communication systems. Turning to FIG. 2 , there is illustrated the basic structure of a coherent detection system or receiver. The outputs of this receiver are two electrical signals corresponding to the in-phase (I) and the quadrature (Q) of received optical signal E s . In the coherent detection technique, an important aspect is carrier phase recovery or estimation (CPR) which recovers and compensates for phase noise in the received optical signal, thus enabling recovery of the information data. FIG. 3 illustrates an example structure of a prior art CPR. For DQPSK signals, a digital differential decoding module is usually implemented after the CPR. There are drawbacks to using coherent detection with CPR. Implementation of the CPR can be quite complex, and a CPR's bandwidth is limited by hardware feasibility. As a result, CPR is limited and cannot handle high phase noise with wide bandwidth. In an optical communication system, there may be present some specific link conditions which could lead to high phase noise due to fiber nonlinearity. In these applications, the conventional CPR (feed forward or backward) does not provide a large enough bandwidth to compensate for the phase distortion. The inventors have determined that one possible way to effectively overcome these issues is to utilize a digital delay interferometer (similar to FIG. 1 ) but utilize a digitally recovered signal to replace the analog optical signal. Compared to the analog optical interferometer mentioned above, there would be several advantages. First, existing DSP techniques can be used to compensate for link impairments. Second, CPR can be eliminated thus dramatically simplifying implementation and reducing cost. Lastly, this method can tolerate high phase noise. However, in such a proposed system, the recovered electrical signals may incur a constant phase ramp because of frequency offset between the laser in the transmitter and the laser utilized as the local oscillator (e.g., LO in FIG. 2 ). In the reception of optical signals by an optical signal receiver, unwanted laser phase noise and frequency offset resulting from application of a local oscillator laser in the receiver (that is different from the laser in the transmitter) are injected into the received optical signals. These must be removed (or substantially reduced) prior to demodulation to enable successful recovery of the information data. Because of this, optical transmitters and receivers have commonly utilized oscillator lasers with low phase noise. These low phase noise oscillator lasers are expensive. Therefore, there is needed a method and system that improves coherent detection in optical communications systems that implement advanced modulation formats while also reducing system cost by enabling the use of less expensive local oscillator lasers. SUMMARY In accordance with one embodiment, there is provided a method of signal processing in an optical communications receiver. The method includes receiving a modulated optical signal and coherently detecting the modulated optical signal and generating a first in-phase (I) component signal and a first quadrature (Q) component signal, converting the first I component signal and the first Q component signal into a first digital I signal and a first digital Q signal, adaptively equalizing the first digital I signal and the first digital Q signal to compensate for channel distortion introduced into the received modulated optical signal from a communication channel, and decoding the equalized first digital I signal and the first digital Q signal to generate an output signal. The method also includes compensating for phase distortion in the output signal caused by a local oscillator frequency offset (LOFO), the phase distortion introduced into the first I component signal and the first Q component signal by a local oscillator signal utilized during coherent detection of the modulated optical signal. In accordance with another embodiment of the present disclosure, there is provided an optical signal receiver including a coherent detector configured to receive a modulated optical signal and generate a first in-phase (I) component signal and a first quadrature (Q) component signal, an analog to digital converter (ADC) coupled to the coherent detector for converting the first I component signal and the first Q component signal into a first digital I signal and a first digital Q signal, an adaptive equalizer coupled to the ADC and configured to compensate for channel distortion introduced into the received modulated optical signal from a communication channel, and a decoder configured to decode the equalized first digital I signal and the first digital Q signal to generate an output signal. The receiver further includes a phase distortion compensator configured to compensate for a phase distortion in the output signal caused by a local oscillator frequency offset (LOFO), the phase distortion introduced into the first I component signal and the first Q component signal by a local oscillator signal utilized by the coherent detector. In still another embodiment, there is provided a wireless method for signal processing in an optical communications receiver. The method includes receiving a modulated optical signal and coherently detecting the modulated optical signal and generating a first channel in-phase (I) component, a first channel quadrature (Q) component, a second channel I component and a second channel Q component. The signals are converted into first digital I and Q signals second digital I and Q signals which are then adaptively equalized to compensate for channel distortion introduced into the received modulated optical signal from a communication channel. The equalized signals are differentially decoded to generate a first output signal and a second output signal. The method further includes compensating for phase distortion in the first output signal and the second output signal caused by a local oscillator frequency offset (LOFO), where the phase distortion is introduced into the first channel I and Q components and the second channel I and Q components by a local oscillator signal utilized during coherent detection of the modulated optical signal. BRIEF DESCRIPTION OF THE DRAWINGS For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like numbers designate like objects, and in which: FIG. 1 depicts a prior art DQPSK decoder (or analog interferometer); FIG. 2 depicts a prior art coherent detection system; FIG. 3 depicts a prior art carrier phase estimation or recovery system typically used with a coherent detection system; FIG. 4 is a block diagram illustrating an optical signal receiver in accordance with one embodiment of the present disclosure; FIG. 5 illustrates a change in phase of the received signal due to the local oscillator frequency offset (LOFO); and FIG. 6 is a block diagram illustrating a LOFO tracking and compensation circuit in accordance with one aspect of the present disclosure. DETAILED DESCRIPTION In general terms, the present disclosure describes and teaches methods and devices in an optical communications receiver for tracking and compensating for local oscillator frequency offset (LOFO) without using carrier phase estimation or recovery (CPR). Now turning to FIG. 4 , there is shown a block diagram of relevant components or elements of an optical communications receiver 400 . For purposes of clarity, not all elements within the optical receiver are shown or described, and only those elements necessary for an understanding of the present disclosure are shown. Other embodiments of the optical receiver 400 may be used without departing from the scope of this disclosure. Any reference to “standards” in the following text is meant to encompass existing and future versions of the referenced standards, as well as standards encompassing the principles of the invention disclosed and claimed herein. In this example, the optical receiver 400 is part of (or communicates with) a larger optical communication system or network (not shown) or other devices or modules. The optical signal receiver 400 includes an optical coherent receiver 410 , an analog to digital converter (ADC) 420 , an adaptive equalizer 430 , a digital delay interferometer 440 , and a local oscillator frequency offset (LOFO) tracking and compensation module 450 . As illustrated, in one embodiment, the elements 410 , 420 , 430 and 440 (those within the dotted lines) are configured as or in (or form) a digital signal processing (DSP) engine, module or processor 490 (hereinafter simply referred to as the DSP 490 ). The coherent receiver 410 performs coherent detection (or decoding) of a received optical signal 402 and generates four electrical output signals 412 a thru 412 d (X I X Q Y I Y Q ). The X and Y signals represent two polarized signals, and each X and Y signal has both in-phase (I) and quadrature (Q) components. A local oscillator (LO) laser signal 404 generated by a LO laser (not shown) is input to the coherent receiver 410 . As will be appreciated, the phase and/or frequency of the LO laser signal 404 is usually slightly different than the phase and frequency of transmitter oscillator laser (not shown) used to generate the transmitted optical signal received by the receiver 400 . Each of the four signals 412 a - d are converted to digital signals by the ADC 420 and input to the adaptive equalizer 430 where distortions present in the received signals caused by the communications channel/line and hardware are removed/reduced (i.e., compensated). Such distortions may include dispersion, polarization rotation, etc. The adaptive equalizer 430 outputs complex signals 432 a and 432 b (S X S Y ) which are relatively distortion free. Within (or prior to) the equalizer 430 , the I and Q components of each channel (X channel, Y channel) are combined and form channels of complex signals (e.g., I+jQ) and the equalization is performed mathematically based on the complex numbers. As will be appreciated, the recovered output signals 412 a thru 412 d from the coherent receiver 410 can be written as: V X,Y ( t )=[ D X,Y ( t ) H link ]·e j·(2·π·Δf·t+φ(t))   Equation 1 D X,Y (t) is the differential coded information bits on the X and Y polarization signals, H link is the combined transfer function of the link and hardware, Δf is the LOFO as compared to the transmitter carrier frequency, and φ(t) is the random phase noise introduced by laser and link propagation. The distortions from the communication channel/line and hardware impairments are compensated for in the adaptive equalizer 430 . After the equalizer 430 , the output signals S X and S Y pass through the digital delay interferometer 440 which generates output signals 442 a and 442 b (U X U Y ). The output of the digital interferometers 440 is: U X,Y ( nT )= S ( nT )· S *( nT+T )· e j(2·π·Δf·T+φ(nT)−φ(nT+T))   Equation 2 where T is the baud duration of one symbol. As mentioned above, with the DQPSK format, information bits are coded as transient between adjacent symbols. S(nT)S*(nT+T) in Equation 2 represents a differential decoding operation, which extracts the information bits which were differentially coded. It will be understood from Equation 2 that, in addition to the decoded information bits, there exists an extra phase term φ. This phase term can cause performance degradation. In an optical communication system, the phase noise φ(t) usually has a much narrower bandwidth than the baud rate which is at 10 GHz or above, corresponding to T<100 pa in Equation 2. Within this short duration, the phase noise φ(nT)−φ(nT+T) is negligible. This leaves the local oscillator frequency offset (LOFO) as the only significant source of performance impairment (e.g., phase distortion) which could be up to 3 GHz (as defined in ITU standard). On the recovered signals, the LOFO adds a constant phase rotation, as shown in FIG. 5 . With knowledge of this impact on the recovered signals, a phase de-rotation with a value calculated based on the LOFO can be used to eliminate/reduce (i.e., compensate for) the LOFO injected phase distortion. Now turning to FIG. 6 , there is illustrated in more detail a relevant portion of the LOFO tracking and compensation module 450 . FIG. 6 shows only shows the processing in one polarization branch (X branch), and it will be understood that another similar polarization branch (Y branch) is included in the module 450 (though not shown). After passing through the equalizer 440 and the digital interferometer 440 , the signal 442 a passes through a Look-Up-Table (LUT) 600 , in which the complex signal is mapped to a corresponding phase angle signal 602 (θ X ). In this embodiment using this mapping, all of the subsequent signal processing (digital) can be done with simple real number addition, instead of complex multiplication, and the corresponding implementation complexity is reduced. The phase angle signal 602 (θ X ) is corrected/compensated by being added to a LOFO-based phase angle offset signal 604 (Δθ X ) to generate a post-correction phase signal 606 ({circumflex over (θ)} X ) which is input to a symbols slicer 620 and a residual error calculator 630 . In the symbols slicer 620 , the corrected phase signal 606 ({circumflex over (θ)} X ) is decoded into information bits D X as {1,0}. The signal 604 is sometimes referred to as an adaptive phase offset correction. A residual error signal 608 (e x ) is calculated as the difference between phase before and after the symbol slicer 620 . In other words, the residual error signal 608 (e x ) is calculated as the difference between the post correction phase signal 606 ({circumflex over (θ)} X ) and a symbol slicer output signal 610 (D X ). This residual error indicates the accuracy of an initial LOFO estimation which is reflected in the LOFO-based phase angle offset signal 604 (Δθ X ). The post correction phase signal 606 ({circumflex over (θ)} X ) in the form of symbols is sliced and decoded by the symbol slicer 620 to recover the data information bits (Output X, Output Y) contained therein (the slicer output signal 610 ). These output signals may be further processed by the receiver 400 (not shown). As will be appreciated, the symbols slicer 620 may be separate from the module 450 . As noted above, FIG. 6 only shows processing in one polarization branch. There is a similar processing module in the Y branch. A second residual error signal 614 (e y ) can be used with the residual error signal 608 (e x ) to improve the accuracy of error estimation, which can be impacted by optical noise. The detected phase error is used to update the phase angle offset signal 604 (Δθ X ) which will be applied to correct phase error in the following symbols, and so on and so forth. This updating process, with the residual error signal 608 (e x ) (used as feedback) forms a digital Phase Lock Loop (PLL). This step may be necessary because of laser frequency wandering in a real application scenario. The bandwidth of this PLL can be controlled through a user defined step size μ, to reach optimum balance between tracking speed and noise impact. To further improve overall optical receiver 400 and system stability, the LOFO-based adaptive phase angle offset signal 604 (Δθ X ) can be used to generate a control signal 616 operable for controlling the local oscillator laser (not shown). This signal may be fed back to the laser to move it to the right frequency grid and operably adjust the LO signal. As will be understood, the functionality (and algorithms described above) of the LOFO tracking and compensation module 450 may be implemented within the DSP 490 . In addition, the functionality (and algorithms described above) of the equalizer 430 and/or digital interferometer 440 may also be implemented by the DSP 490 . In some embodiments, some or all of the functions or processes of the one or more of the devices are implemented or supported by a computer program that is formed from computer readable program code and that is embodied in a computer readable medium. The phrase “computer readable program code” includes any type of computer code, including source code, object code, and executable code. The phrase “computer readable medium” includes any type of medium capable of being accessed by a computer, such as read only memory (ROM), random access memory (RAM), a hard disk drive, a compact disc (CD), a digital video disc (DVD), or any other type of memory. It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. The term “controller” means any device, system or part thereof that controls at least one operation. A controller may be implemented in hardware, firmware, software, or some combination of at least two of the same. The functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.
An optical signal receiver tracks local oscillator frequency offset (LOFO) and compensates for the phase distortion introduced in the received signals as a result of utilizing the local oscillator within a coherent detection scheme. This phase distortion is basically a constant phase rotation caused by the LOFO and implementation of the receiver using coherent detection and a digital interferometer instead of a conventional (yet complex) carrier phase estimation or recovery scheme. With an optical receiver implemented in this manner, the requirement of using a precise local oscillator laser with low frequency offset is less important.
7