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This is a continuation of application Ser. No. 07/952,875, filed as PCT/SE/00346 May 16, 1991, now U.S. Pat. No. 5,352,333. TECHNICAL FIELD The present invention relates to a process for partial combustion of cellulose spent liquors from the cellulose industry using a burner connected to a reactor, while supplying an oxygen containing gas as the oxidant. The burner comprises a liquor lance equipped with a nozzle at its downstream end which supplies liquor and the greater part of the non-fuel related oxygen required for the partial combustion, wherein or in which proximity the oxygen-containing gas is brought into contact with the spent liquor which then disintegrates into a divergent spray. The object of the present invention is to facilitate partial combustion of cellulose spent liquor through use of a burner creating a stable, self-igniting flame at low air/fuel ratios and elevated pressures. BACKGROUND OF THE INVENTION The cellulose industry generates spent liquors differing in composition according to the delignification process used. Within the sulphate pulping industry, spent liquor, commonly referred to as black liquor, contains valuable chemicals and energy in the form of combustible carbonaceous compounds. At the present time these chemicals and energy are normally recovered in a recovery boiler in which the black liquor is completely burned. Partial combustion of black liquor in a gasification reactor as in the present invention generates a combustible gas comprising H 2 , CO, CO 2 , and droplets of molten inorganic chemicals. In conjunction with pulp bleaching, a diluted liquor comprising organic matter and sodium salts is obtained. Mechanical and semi-chemical pulping processes also generate diluted liquors of different compositions. These as well as other waste and spent liquors generated in the cellulose industry can, after concentration, be used as a feedstock in the process of the present invention. Although the following description describes the present invention as it applies to black liquor it is not restricted only to this particular liquor in its application. The mechanisms related to partial combustion of black liquor are fairly well understood and are applied inter alia in the lower part of the soda recovery boiler. The difference between the present burner and a liquor burner in a soda recovery boiler is, however, great inter alia due to the low degree of liquor atomization in recovery boiler burners and the absence of a well-defined liquor flame. Another important difference between a recovery boiler burner and the burner of the present invention is that, the present burner is primarily intended for gasification at elevated pressures. A major difference between the burner of the present invention and conventional oil burners is that a stable flame has to be formed with the use of a considerably lower amount of air or oxygen carrier. As the exemplification below shows, black liquor as a fuel is characterized by a relatively low calorific value and high water and ash contents. ______________________________________Calorific value of 13 GJ/ton dry substance (DS)the dry substanceElementary composition C.sub.29 H.sub.34 O.sub.20 Na.sub.9 S.sub.2Dry solids content 65%Viscosity at 100° C. 100 cSt.______________________________________ The presence of sodium compounds in the black liquor and its inherently high oxygen content make it a very reactive fuel, which means, provided an adequate burner is at hand, that the carbon conversion already in the flame zone becomes high, in spite of the fact that the combustion is substoichiometric. The degree of atomization of the liquor is of great importance for obtaining a stable black liquor flame, the extension of the flame and high carbon conversion. The rheological properties of the black liquor are of significant importance to the degree of atomization which can be achieved in a given nozzle. The viscosity of the black liquor can be influenced by e.g. heating and/or the addition of additives. Normally the black liquor is being heated to above 100° C. for use in the present invention. The viscosity of the black liquor at the the moment of atomization should preferably be below 200 cSt. Atomization of the black liquor can be further enhanced by flashing the liquor into the reactor in which case the liquor is preheated to a temperature above its boiling point at the operating pressure of the reactor. Several types of atomizing nozzles are available but only a few varieties are suitable for atomizing cellulose spent liquors, such as black liquor, in the present invention. "Twin-fluid" nozzles are most suitable for use in the present burner. A common feature of "twin-fluid" nozzles is that a relatively high gas flow rate is necessary for the supply of energy for the atomization. Another important feature of these nozzles is that the resulting size of the droplets decrease with increasing density of the atomizing gas. Depending on how the two fluid phases are brought together several mechanisms for forming droplets, such as shearing between ligaments, combination and formation of spheres of liquor droplets and high turbulence decomposition of the liquor spray can be anticipated. DESCRIPTION OF THE PRESENT INVENTION The present invention describes a process for efficient substoichiometric combustion of cellulose spent liquors, using a burner connected to a reactor, while supplying an oxygen containing gas, which invention is characterized in that the weight ratio between the oxygen containing gas supplied through the burner and the spent liquor supplied through the burner is lower than 2:1, and that at least half of the oxygen which is required for the partial combustion of the spent liquor is supplied through the burner to the reactor as an oxygen containing gas, said gas being discharged into the reactor through the nozzle. Efficient atomization of the spent liquor is particularly important and is achieved in the burner of the present invention by direct contact between the spent liquor and the oxygen containing gas at elevated pressure in or directly adjacent to a nozzle designed specifically for that purpose. The spent liquor, which should be preheated to lower the viscosity before being fed to the burner, is supplied to the reactor through the liquor lance. At the downstream end of the liquor lance the liquor is brought into contact with an atomizing gas whereby the liquor flow velocity rapidly increases resulting in the formation of a divergent spray of atomized spent liquor. As is mentioned above the spent liquor is a fuel with unusual properties regarding reactivity and ash and water contents. The spent liquor solids contains a high level of bound oxygen which means that the amount of oxygen which can be supplied through the combustion air is relatively small, particularly for partial combustion. The oxygen supplied to the reactor corresponds to a stoichiometric ratio of between 0.3 and 0.6 relative to oxygen required for complete combustion of the spent liquor with a preferred ratio of between 0.35 and 0.5. The amount of air, oxygen-enriched air or oxygen to be supplied to the reactor is low in relation to the amount of spent liquor supplied. The weight ratio is lower than 2:1 when operating with air as oxidant and lower than 0.4:1 when operating with oxygen as oxidant. The greater part, and preferably more than 80% of the non-fuel bound oxygen which is required for partial combustion of the spent liquor is supplied to the reactor as an oxygen containing gas, which gas is discharged together with the liquor through the nozzle. The flow velocity of the oxygen containing gas in the nozzle should be between 40 m/s and 350 m/s. The nozzle can be designed with a circular gap or a circular opening for discharge of spent liquor, wherein it is contacted with the high velocity atomizing oxygen containing gas and disintegrates into small droplets forming of a divergent spray. In an alternative design of the nozzle the spent liquor is discharged together with the atomizing gas through three or more symmetrically arranged openings. Other aspects and advantages of the invention become apparent from the following more detailed description, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an axial sectional view of a first embodiment of the burner according to the invention comprising a nozzle and a liquor lance; FIG. 2 is a sectional view of the burner of FIG. 1 along line III--III in FIG. 1; FIG. 3 is an axial sectional view of a second embodiment of the burner according to the invention comprising a nozzle and a liquor lance; and FIG. 4 is a sectional view of the burner of FIG. 3 along line V--V in FIG. 3. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The burner 1 according to the invention shown in FIGS. 1 and 2 comprises a twin-fluid, substantially cylindrical liquor lance 26 and a nozzle 8 in which black liquor and gas are mixed. Nozzle 8 has the form of a Y-jet atomizer head of about rotationally symmetric shape. Its front face 2 is substantially flat and has a number of circular openings 3 equidistantly arranged along its chamfered circumferential front edge. From each opening 3 a bore 34 in nozzle 8 extends obliquely in respect of nozzle axis 23 in a way as to make their axes meet at a point on axis 23 inside of burner 1. At a distance from openings 3 each bore 34 splits into two channels designated 4 and 5 extending to the rear side of nozzle 8 which fits snugly to the liquor lance portion 26 of the burner in the way described below. The main portion of the liquor lance comprises an outer cylindric wall 10, an intermediate cylindric wall 18 and an inner cylindric wall 19 defining between them concentric spaces 6 and 7, respectively, extending over the entire length of the lance. Toward the end of the liquor lance portion 26 facing the rear side of nozzle 8 the radial width of concentric spaces 6 and 7 is reduced to about that of bores 4 and 5 at their respective rear side ends. By this arrangement and by making the front side of the liquor lance portion 26 and the rear side of the atomizer nozzle 8 fit each other snugly communication between concentric spaces 6 and 7 and, respectively, bores r and 5 is obtained. The atomizer nozzle 8 is held attached to the liquor lance portion 26 by an annular hood 9 fitted to outer liquor lance wall 10. At its rear end nozzle 1 is provided with black liquor and air inlet tubes 20, 21 communicating with concentric spaces 6 and 7, respectively. Black liquor and air fed into nozzle 8 will mix at the Y-junction of the Y-jet atomizing nozzles and then be forced under high pressure through the symmetrically arranged circular openings 3. FIGS. 3 and 4 show another embodiment of the burner 1' according to the invention having a liquor lance portion 26' with three concentric annular spaces 11 (outer), 12 (central), 13 (inner). Concentric spaces 11,12,13 are defined by cylindric walls 30,31 (11), 31,32 (12), and 32,33 (13). Through inlet pipes 20',21',22 arranged near the rear end of liquor lance portion 26', air (through pipes 21', 22) is fed into annular spaces 11 and 13, and black liquor (through pipe 20') is fed into annular space 12. The burner 1' of FIGS. 3 and 4 instead of a separate atomizer head has a downstream frontal atomizer portion 8' integral with the liquor lance portion 26'. Near its downstream end annular space 12 narrows to form a circular gap 16 while outermost and innermost annular spaces 11, 13 merge with two sets of narrow bores 14 and 15, respectively, the eighteen bores of the respective sets being arranged equidistantly from nozzle axis 23' and evenly spaced from each other, as seen in the sectional view of FIG. 4. Gap 16 and bores 14,15 open at the front side 2' of the substantially cylindric nozzle portion 8'. The frontal end portions of cylindric walls 30 and 31, respectively, are drawn inwardly in direction of axis 23' to form annular lips 17, 24. By lip 17 the black liquor fed through the narrow gap 16 as a thin film is forced inwards and atomized by meeting the air emerging from holes 15. This flow of primary air-black liquor mixture is met by additional air emerging from holes 14 and deflected inwards (towards the center axis of the nozzle) by lip 24, thereby creating a diverging jet of finely dispersed black liquor. When designing burners great attention has to be paid to the weight ratio between oxidant and fuel. Different fuels contain different amounts of chemically bound oxygen. Bitumenous coal usually contains between 4-10% of bound oxygen. Fuel oils contain less than 1% of bound oxygen. Black liquor dry solids contains about 35% by weight of bound oxygen calculated on dry, matter. This affects the design of burners for combustion of black liquor since a considerably lower amount of oxygen, air or oxygen enriched air has to be added to the reactor to obtain the desired level of combustion. The air/fuel ratio (by weight) for some fuels at stoichiometric combustion are exemplified below: ______________________________________Anthracite Air/fuel 10-12:1Ethyl alcohol Air/fuel 9:1Black liquor Air/fuel 4-5:1Diesel oil/heavy oil Air/fuel 13-15:1______________________________________ The burner designed in the present invention creates a stable flame in a reactor which preferably operates at pressures in the range of 0.1 to 150 bars above ambient and at temperatures in the range of 700° to 1400° C. Depending on factors such as temperature and flow velocities in the burner and the composition of the liquor, the burner nozzle can in addition to thermal effects be subjected to oxidation and reactions with sulphur which may have a detrimental effect on the degree of atomization. The burner nozzle of the present invention should therefore preferably be cooled by a circulating liquid. A preferred embodiment of the present invention is to use oxygen or oxygen enriched air as the oxidant. In such a preferred embodiment all or nearly all the the oxygen required for partial combustion is supplied through the nozzle to support atomization of the spent liquor. Part of the oxygen containing gas may be added to the reactor through a pipe arranged coaxially around the liquor lance or through one or several gates. To compensate for the low air/fuel ratios and to achieve reasonable gas velocities all of the oxygen containing gas should be preheated to at least 100° C., preferably to 300° C., and it should further be given a vortex movement which, i.a., can be achieved by passing the gas through vortex blading arranged in the coaxial pipe. The radial flow rate of the oxygen containing gas is thereby markedly affected with a maintained axial flow rate. The main principle of a vortex burner is to recirculate a portion of gases through an internal recirculation zone towards the liquor lance. This internal recirculation zone facilitates combustion and stabilizes the frame and the recirculated hot gases add energy for ignition of the liquor spray. The internal recirculation zone also serves as a depot for heat and reactive gas components.
The present invention is directed to a process for efficient combustion of cellulose spent liquors using a burner connected to a reactor, while supplying an oxygen containing gas, which invention is characterized in that more than 80% of the oxygen which is required for the partial combustion of the spent liquor is supplied through the lance of the burner to the reactor as an oxygen containing gas at a stoichiometric ratio of between 0.3 and 0.6 relative to complete combustion of the spent liquor.
2
BACKGROUND OF THE INVENTION Field of the Invention The invention relates to a device and the corresponding process for quantitative assessment of the orientation of two machines or machine parts relative to one another which are connected by a cardan shaft with two universal joints. A device of this type is known and is shown in FIG. 1 . Such a device requires a precise and relatively costly rotary joint 22 in order to keep a means 24 for sending and receiving a measurement light beam 28 from a source at distance from the machine shaft 10 which is to be measured. For this purpose, for example, an extender rail 20 and clamp devices 16 are used in addition. SUMMARY OF THE INVENTION A primary object of this invention is to devise a device that is comparable comparable to the known device but which is clearly more economical and does not adversely affect the ease of operation. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is perspective view of a known device. FIG. 2 is a perspective view showing alignment being performed with a device in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION The invention is based on the finding that it is often necessary, in practice, to determine the parallel axial offset of machines which are structurally connected by a cardan shaft with two universal joints. Generally, a cardan shaft is used when there is, in principle, a parallel axial offset and knowing the absolute magnitude of the offset is not critical. However, for reasons of rotational kinematics, it is especially important that the axes of the shafts of the machines which have been coupled to one another in this way are, for the most part, parallel in order to avoid even the smallest variations of angular accelerations on the rotating machine elements. Accordingly, in accordance with the invention, it is not necessary to provide a measurement system which, at the same time, can detect the parallel and angular offset of shafts. Rather, it is sufficient to provide a measurement system which can detect simply the angular offset of these shafts in a precise manner. With consideration of certain geometrical boundary conditions and relationships, it is thus possible to devise a measurement device and a process in which a conventional measurement rotary joint can be completely eliminated. Conclusions regarding the angular misalignment of these shafts and the corresponding machines can be drawn from the detectable amounts of offset which are detected in different rotary positions of the shafts which are to be measured by means of conventional sensors using simple formulas. Details of the invention are shown in FIG. 2 . There, a cardan shaft 62 and universal joints 60 , 64 are assumed to have been already removed for the measurement and therefore are schematically shown only by a broken line. As is apparent from the figure, the machines 30 , 31 may stand on bases 32 , 33 of different heights and thus have a parallel offset of their shafts. The extender 40 can be attached conventionally or by means of screws to the coupling support 36 and can carry an extra extender 42 ; but this is optional. In any case, either a light transmitter and/or receiver is mounted either directly on the extender directly or indirectly by means of the extra extender 42 . In this example, a receiving module 44 as is known in the prior art. In the illustrated measurement position, which is also called the “3 o'clock position,” the receiving module can determine the incidence site of the incident light beam 53 which is emitted by a light transmitter 52 . The light transmitter 52 is mounted on a second extender or a holding device 50 which is likewise mounted on the corresponding coupling support of the machine 31 . The measurement is taken such that the receiving module is operated in the conventional manner in one mode and that it allows determination of the incidence direction of an incident light beam by means of two photosensitive plates. In accordance with the invention, it is simplest to turn the extender by 180° to determine the measurement quantities of interest (therefore, to set, for example. the “9 o'clock position”), to move the corresponding module 44 such that it can also be hit by the light beam 53 in this position, and to take an additional measurement using the light transmitter and the receiving module in this position. (If the functions of the light transmitter and of the receiving module are combined in a single housing, it is also possible, in accordance with the invention, to provide this combination in interplay with a plane mirror, especially a large-area planar mirror). In this position, the two photosensitive plates of the receiving module thus see one direction of incidence of the light beam which, when the machines 30 , 31 are not aligned parallel, is distinguished from the direction of incidence in the “3 o'clock” position according to two detectable angle coordinates. Therefore, only the respective directions of incidence are measured and the position of the incident light beam is of subordinate importance in accordance with the invention. For this reason, it is therefore also possible and uncritical to move the light receiving or transmitting module ( 44 , optionally 52 , or both at the same time) relative to one another on the extender or extenders, and then, to fix it briefly thereon for an individual measurement. In principle, the invention makes do without the extra extender 42 if measurement positions can be set which lie rotated roughly 180° apart. If this is not the case, the extra extender 42 should be used, and instead of simply structured determination equations for determining the relative position of the machines, then ones should be used which take into account the corresponding projections (therefore the sine and cosine portions) of the angle of rotation of the extenders which differs from 180°. It is advantageous to take three or more measurements in additional measurement positions, i.e., rotational positions of the extenders and to combine them using statistical considerations or compensation computations into a more accurate measurement result than is possible with only two measurements. In another advantageous embodiment of the invention, it is provided that the extenders 40 and/or 50 be equipped with compensation weights (not shown) such that the torques applied to the shafts or mountings can be kept as small as possible. In this way, detection of the measurement values is facilitated, especially for smoothly running shafts.
A device for quantitative assessment of the orientation of two machines relative to one another has auxiliary devices in the form of extenders or holding devices ( 40, 50 ) on which displacement and/or mounting of light transmitting or receiving devices ( 44, 52 ) are mountable in a manner that makes the use of a precision pivot bearing unnecessary.
6
FIELD OF THE INVENTION [0001] This invention relates generally to fabrics that have been napped to yield physical and aesthetic properties that were previously unavailable. More particularly, in a preferred embodiment, this invention relates to woven fabrics of specific constructions that have been hydraulically napped in accordance with the teachings herein. Such fabrics exhibit many highly desirable characteristics, such as relatively high strength, an exceptionally soft and compliant hand, and other qualities that make such fabrics particularly well suited to use in a variety of applications, including use as napery fabrics, with the additional important benefit that such qualities remain, and in some cases are significantly enhanced, after multiple washings. BACKGROUND OF THE INVENTION [0002] Practical methods for increasing the utility or desirability of textile fabrics are constantly sought by the textile industry. Of particular interest are fabrics and processes that are developed for end uses that share a common set of physical or aesthetic requirements. Through the use of creative fabric constructions and fabric processing techniques, fabrics that are especially well suited to specific end uses can be developed. [0003] For example, the use of fabrics made from cotton or linen in napery (tablecloths, napkins, and the like) and related culinary or restaurant applications (aprons, etc.) is well known—the combination of hand, absorbency, drape, and other characteristics made these natural fiber fabrics the traditional fabrics of choice. In recent years, however, fabrics made from synthetic fibers, with their durability, dimensional stability (resistance to wash shrinkage) and resistance to shade changes (due to staining or fading from repeated laundering), have developed a strong following in the marketplace. These new fabrics, however, have not always shown clear superiority in several performance areas that are of fundamental importance, such as hand, drape, resistance to pilling and snagging, and wicking (moisture transport). While such fabrics can be made soft and relatively pleasant to the touch, the necessary conventional processing usually involves mechanical napping or sanding processes that tend to cut or damage fibers and thereby degrade the structural integrity of the fabric yarns and, ultimately, the overall strength and durability of the fabric. Furthermore, such processes can decrease moisture absorption and increase the likelihood of snagging and pilling. Fabric constructions or finishing processes that can impart superior drape and a soft, long-lasting feel to fabrics containing synthetic fibers without these additional shortcomings have been long sought. [0004] Among the fabric processing techniques of the prior art that have been used in an attempt to achieve this result is the use of pressurized streams of water or other fluids. For example, commonly assigned U.S. Pat. No. 5,080,952 to Willbanks, the disclosure of which is hereby incorporated by reference, discloses a process for use with a polyester or polyester/cotton woven fabric by which a nap is raised primarily from warp yarns, and to a lesser extent from the fill yarns, by means of a hydraulic napping process in which discrete streams of high velocity water are directed onto the fabric as the fabric is held against a solid roll or other suitable support member. [0005] Advantages of this, and perhaps other hydraulic napping processes of the prior art, as compared to conventional wire napping or sanding processes in which wires or abrasives are used to raise a nap or pile from the surface yarns, include the following: (1) the individual yarns comprising the fabric are not cut or otherwise damaged, but instead are merely rearranged (e.g., tangled) and extended from the plane of the fabric; (2) because of the lack of yarn damage, the strength of the fabric is not significantly impaired; (3) the nap raised tends to be uniform in height and density on the fabric side facing the roll; (4) because no shearing operation is needed, as would routinely be used for conventionally napped fabrics, fabric weight (per unit area) is preserved and other properties such as cover (i.e., relative light opacity) and absorbency can be enhanced as compared with fabrics that require a shearing step; and (5) limited nap raising occurs on the opposite side of the fabric (that side facing the water streams), although not to the same extent as occurs on the side facing the roll, thereby imparting a napping effect to both sides of the fabric at the same time, even though the streams impact one side only. [0006] It has been found that, in spite of these advantages over conventional napping processes, these hydraulic processes of the prior art can affect the fabric in ways that are difficult to predict, resulting in non-uniform treatment and other processing shortcomings. [0007] When the specific hydraulic napping process as described herein is used in conjunction with a specifically engineered fabric, also as described herein, the result is a fabric that displays a variety of desirable characteristics including high strength, high wash durability, color fastness, a soft and pliant hand with excellent subjective “feel”, superior wicking, and high resistance to pilling and snagging. It is believed that hydraulically napped fabrics possessing this unique combination of properties may be particularly desirable in many textile market areas, including, but not limited to, indoor and outdoor apparel, home furnishings (including shades and draperies, bed and table linens, upholstery fabrics, and toweling), and their commercial hospitality counterparts. One specific application in the commercial hospitality area to which fabrics of this invention have been found to be particularly well suited is that of commercial napery. However, because of the high degree of superiority shown by the fabrics of this invention in a variety of important fabric performance parameters, it is contemplated that other market areas may also benefit from fabrics of the instant invention, even if one or more of the specific advantages listed above are not of paramount importance in those markets. DESCRIPTION OF THE DRAWINGS [0008] The foregoing advantages of this invention, as well as others, will be discussed further in the following detailed description of the invention, including the accompanying Figures, in which: [0009] [0009]FIG. 1 is a schematic side view of an apparatus for practicing the instant invention, wherein a continuous web of fabric is treated on a single side of the web by an array of liquid jets; [0010] [0010]FIG. 2 is a schematic side view of an apparatus for practicing the instant invention, wherein a continuous web of fabric is treated on both sides of the web by an array of liquid jets; [0011] [0011]FIG. 3 is a perspective view of the high pressure manifold assembly depicted in FIGS. 1 and 2; [0012] [0012]FIG. 4 is a cross-sectional view of the assembly of FIG. 3, showing the path of the high velocity fluid through the manifold, and the path of the substrate as it passes through the fluid stream being projected from the manifold assembly of FIG. 3; [0013] [0013]FIGS. 5A and 5B are scanning electron photomicrographs (normal orientation—i.e., perpendicular to the fabric plane, at 27× and 50×, respectively) of the surface of a fabric of this invention comprised of 100% synthetic fibers prior to treatment in accordance with the teachings herein; [0014] [0014]FIGS. 6A and 6B are scanning electron photomicrographs (normal orientation, 27× and 50×, respectively) of the surface of the fabric of FIGS. 5A and 5B following treatment in accordance with the teachings herein and a single wash; [0015] [0015]FIGS. 6Y and 6Z are scanning electron photomicrographs (normal orientation, 27× and 50×, respectively) of the surface of the treated fabric of FIGS. 6A and 6B, following 75 washes; [0016] [0016]FIGS. 7A and 7B are scanning electron photomicrographs (normal orientation, 28× and 50×, respectively) of the surface of a first competing fabric, representing one embodiment of the prior art, following a single wash; [0017] [0017]FIGS. 7Y and 7Z are scanning electron photomicrographs (normal orientation, 28× and 50×, respectively) of the surface of the fabric of FIGS. 7A and 7B, following 75 washes; [0018] [0018]FIGS. 8A and 8B are scanning electron photomicrographs (normal orientation, 28× and 50×, respectively) of the surface of a second competing fabric, representing another embodiment of the prior art, following a single wash; [0019] [0019]FIGS. 8Y and 8Z are scanning electron photomicrographs (normal orientation, 28× and 50×, respectively) of the surface of the fabric of FIGS. 8A and 8B, following 75 washes; [0020] [0020]FIGS. 9A and 9B are scanning electron photomicrographs (normal orientation, 27× and 50×, respectively) of the surface of a fabric of this invention comprised of synthetic and natural fibers, prior to hydraulic napping in accordance with the teachings herein; [0021] [0021]FIGS. 9C and 9D are scanning electron photomicrographs (normal orientation, 27× and 50×, respectively) of the surface of the fabrics of FIGS. 9A and 9B following treatment in accordance with the teachings herein and a single wash; and [0022] [0022]FIGS. 10A through 10C are graphs representing the results of a “co-occurrence” statistical analysis of the surfaces of the fabrics of FIGS. 5 through 8, quantifying the degree of nap (or the relative ratio of disordered to ordered fibers) before and after multiple launderings. DETAILED DESCRIPTION [0023] In the detailed discussion that follows, the following terms shall have the indicated meanings. The term “synthetic fiber” shall mean a man-made fiber, including, but not limited to, polyester, nylon, rayon, and acetate. The term “fiber loop” is intended to mean a segment of an individual fiber that is spaced apart from, but remains attached at both ends to, its associated yarn. The term “fiber tangle” is intended to mean a disordered arrangement of individual fiber loops, positioned above the surface of the fabric, that are associated with and connected to, but that are spaced apart from, a fiber bundle. A fiber tangle implies an arrangement in which the fiber loops are non-aligned and irregularly configured, but not necessarily entwined, interlocked or loosely knotted. A fiber tangle is primarily comprised of fiber loops, but may include free ends of fiber. The term “tangle cover” is intended to mean the extent to which the fiber tangle associated with a given surface yarn obscures from view the underlying fabric surface. The terms “napped” or “napping” as applied to fabric shall mean the raising of fibers from one or more surface yarns to form a plurality of fiber tangles that extend above the surface of the fabric and provide tangle cover. The term “surface yarn” is intended to mean that segment of a yarn comprising a fabric that forms a portion of the observed surface of the fabric, as viewed from a substantially normal (i.e., perpendicular to the plane of the fabric surface) perspective. The term “subsurface yarn” is intended to mean that segment of a yarn that is not a surface yarn (i.e., a subsurface yarn is hidden from view unless the fabric is reversed or seen in cross section). Using these definitions, a given warp or fill yarn in a woven fabric is considered to be comprised of a contiguous alternation of surface yarn segments and (where the yarn drops within or below the observed surface of the fabric) subsurface yarn segments. The term “observed surface fibers” is intended to mean those fibers comprising a surface yarn that are readily observable when viewed from a substantially normal (i.e., perpendicular to the plane of the fabric) perspective. The fabric side that faces the array of fluid streams shall be termed the array side of the fabric; the side that is nearest to the supporting surface shall be termed the support side of the fabric. [0024] Turning now to the drawings, FIG. 1 shows generally an apparatus that can be used to produce the fabric of this invention wherein a moving web of fabric is treated on a single side only. Source 10 of the desired working fluid, which shall hereinafter be assumed to be water, but which may be another suitable fluid as may be required or desired under the circumstances, is connected to high pressure pump 16 by means of conduit 12 . Use of a suitable filtering device 14 to remove particles and other undesirable matter from the water is recommended. From pump 16 , the pressurized water is directed, via conduit 12 , into stationary manifold assembly 50 , to be described in more detail below, in which the water is formed into a plurality of discrete parallel streams that are directed onto the surface of the moving web of fabric 30 to be treated. Fabric web 30 moves along a path that takes it into the region immediately adjacent to the stream-generating side of manifold assembly 50 and into contact with a suitable support member, such as smooth steel roll 22 , via roll 20 . This region between the manifold and the support member through which the parallel streams of water are directed shall be referred to as the treatment zone. [0025] Within the treatment zone, but immediately prior to being contacted by water streams from manifold assembly 50 , fabric web 30 is directed away from roll 22 , thereby providing a slight separation between the surface of support roll 22 and fabric web 30 as fabric web 30 is impacted by the streams from manifold assembly 50 . Specifically, the path of fabric web 30 elevates it off the surface of steel roll 22 just prior to treatment by the individual water streams. In the preferred embodiment depicted in FIGS. 1 and 2, the “thread up” path of fabric web 30 describes a substantially straight line from a point of tangency, where fabric web 30 contacts support roll 22 , at a location immediately upstream of the point of stream impingement, to the location downstream of the point of stream impingement where fabric web 30 is directed in front of manifold assembly 50 , although some deflection may occur during operation at the point of stream impingement. [0026] The significance of this separation between fabric web 30 and steel support roll 22 is in the role it plays in assisting in the efficient removal of water from the region within the treatment zone between fabric web 30 and the surface of support roll 22 , which shall be referred to as the roll impact zone. Support roll 22 preferably is made to turn in the same direction that the fabric web is traveling within the treatment zone, and the entire manifold/roll assembly preferably is oriented so as to allow gravity to assist in the removal of water from the roll impact zone. This zone serves two important functions: it provides a means by which water buildup can be relieved, yet also provides a robust means of support for the fabric web 30 at the location of impact by the individual water streams. By providing these two seemingly contradictory functions, a high degree of uniformity in fabric web treatment can be achieved. It should be understood that while use of a steel roll as a support member has been described, a smooth solid plate or other means could be used, as desired. [0027] It also frequently has been found advantageous to direct the individual streams of water at an angle that is slightly non-perpendicular, i.e., between about 1° and about 10° to the support roll surface, and in a generally downward direction (i.e., in the direction in which the spacing between the support roll and the moving fabric web is growing larger). In other words, as seen in FIG. 1, the plane containing the array of side-by side individual streams emanating from manifold assembly 50 preferably does not contain the rotational axis of support roll 22 . It is believed that this slight downward tilt to the water streams further minimizes the degree of water buildup between the fabric web and the roll, and further facilitates the removal of spent water from the roll impact zone. If left to accumulate within the treatment zone, such water buildup tends to interfere with the proper interaction between the impinging streams and the fabric surface. [0028] Where a single treatment zone and relatively high stream pressures are used, angles between about 2° and about 8° are preferred, and angles between about 4° and about 6° are particularly preferred. If a second treatment zone is used, as is discussed in detail below, the water streams in the first treatment zone need not be inclined to the same extent—angles between about 1° and about 50 may be used—because the lower water pressure associated with the second treatment zone results in reduced water flow, and therefore less water buildup. [0029] [0029]FIG. 2 shows the apparatus of FIG. 1 that has been adapted to treat both sides of a moving web of fabric web in a single pass. In FIG. 2, items corresponding to items in FIG. 1 carry similar identification or call-out numbers, with the letters “A” and “B” used merely to differentiate between that part of the apparatus used to treat one side of the fabric web (Side “A”), and the corresponding part used to treat the reverse side of the web (Side “B”). Water sources 10 A and 10 B supply water to separate high pressure pumps 16 A, 16 B via suitable filtering means 14 A, 14 B. Fabric web 30 moves into operative position in front of high pressure water jet manifolds 50 A, 50 B by means of various conventional roll means, as shown. Support members 22 A, 22 B are preferably rolls of steel or other suitable material having a smooth, solid surface. As discussed above, the point of water impingement coincides with that portion of the fabric web path during which the fabric web is in tangential relation to the surface of the support roll, i.e., the support roll is no longer contacting the fabric web, but rather is acting as a point from which fabric web 30 is held in moderate tension as web 30 is directed past water jet manifolds 50 A, 50 B and through the water jet streams. [0030] [0030]FIG. 3 is a cutaway view of manifold assembly 50 , which is used in the configurations of FIGS. 1 and 2, and shows the means by which an array of high pressure water streams may be formed and directed onto the moving web of fabric. High pressure water from the interior of manifold supply conduit 52 is directed through a plurality of passages 60 to reservoir gallery 66 , formed from juxtaposed reservoir chambers 64 and 65 machined into chamber assembly 58 and gallery assembly 56 , respectively (see FIG. 4). Cut into one of the mating surfaces of slotted chamber assembly 58 is a series of parallel slots or grooves 68 that, when chamber assembly 58 is mated to supply gallery assembly 56 by means of pressure bolts 70 , form an array of parallel orifices 69 , each having a substantially rectangular cross-section, from which an array of parallel streams of high pressure water can be directed on the moving web of fabric 30 . [0031] [0031]FIG. 4 shows reservoir gallery 66 and related structures and their relation to moving fabric web 30 . As indicated by the arrows, the working fluid passes through passages 60 in gallery assembly 56 into reservoir gallery 66 (FIG. 3) formed by reservoir chambers 64 and 65 , which serves as a local distribution manifold for the orifices 69 . As can be seen, fabric web 30 is guided, under tension, from support roll 22 (FIGS. 1 and 2) onto the lower forward portion of supply gallery assembly 56 to position web 30 tangential to and slightly separated from the surface of roll 22 . This allows the water to pass through the fabric web without significant water buildup in the roll impact zone, and is believed to enhance the formation of a napped surface on the support side of the fabric web (i.e., the side facing the roll). [0032] To treat a single side of fabric web, pump 16 delivers the water to manifold 50 at a pressure sufficient to generate a large number (perhaps several hundred or more) of discrete streams of water arranged in an array, each stream having a rectangular cross section ranging from about 0.010 in.×0.015 in. to about 0.020 in.×0.025 in., with adjacent stream-to-stream spacing within the range of about 0.025 in. to about 0.050 in. The manifold exit pressures depend upon the fabric web being treated and the desired effect. Pressures ranging from about 200 p.s.i.g. to about 3000 p.s.i.g. are contemplated, with pressures between about 500 p.s.i.g. and about 2000 p.s.i.g. most commonly employed, and pressures between about 1000 p.s.i.g. and about 1600 p.s.i.g. being favored for a wide variety of fabric web styles of the kind disclosed herein. The distance between the roll surface and the manifold may range from about 0.030 in. to about 0.250 in., depending upon the nature of the fabric and the effect desired. Generally, roll-to-manifold-distances of about 0.100 in. to about 0.200 in. are preferred. The fabric web is moved past manifold assembly 50 at a rate between about 10 yards per minute and about 80 yards per minute, and preferably between about 25 yards per minute and about 40 yards per minute, although speeds outside these ranges may be preferred with specific fabric webs and desired effects. [0033] Where treatment on both sides of the fabric web is desired—a technique that has been found to generate a remarkably uniform layer of fiber tangles, in roughly equal amounts, on both sides of the fabric web—the web should pass through a second treatment zone wherein pressurized water streams are directed at the opposite side of the fabric web, substantially as described above. The manifold exit pressures associated with the second treatment zone, however, are preferably lower than the pressures associated with the first treatment zone. Specifically, second treatment zone manifold pressures of about 0.2 to about 0.8 times the pressures associated with the first treatment zone have been found effective, with values between about 0.3 and about 0.7 being preferred, and values between about 0.4 and about 0.6 being most preferred. Although these ratios may be modified somewhat if the water pressures in the first treatment zone are extreme, it has been found that where second treatment zone manifold pressures fall outside these ratios, the side-over-side (i.e., array side vs. support side) uniformity of the napped surface is significantly degraded. It is theorized that fiber tangles that are generated within the first treatment zone are partially re-distributed through the fabric web within the second treatment zone, and relatively few additional fiber tangles are generated within the second treatment zone. Accordingly, second treatment zone pressures that are too low appear to distribute insufficient fibers to the reverse side, and second treatment zone pressures that are too high appear to distribute too many fibers to the reverse side. [0034] The various photomicrographs of FIGS. 5 through 9 show the surface of various fabric webs and graphically demonstrate the effects and advantages of the instant invention. As summarized in Table 1, FIGS. 5A, 5B show an untreated portion of the subject fabric of the invention. This fabric is subsequently treated and washed as described in Example 1 and the accompanying FIGS. 6A, 6B. FIGS. 7A, 7B and 8 A, 8 B show first and second fabrics, respectively, that are representative of currently available competitive napery fabrics, following one wash cycle as described in Examples 2 and 3. FIGS. 6Y, 6Z; FIGS. 7Y, 7Z and FIGS. 8Y, 8Z show, respectively, these same fabrics following 75 wash cycles, as described in the respective Examples 5 through 7 below. FIGS. 9A through 9D show the results of processing a blended fabric in accordance with the teachings herein. EXAMPLE 1 [0035] The following example describes how a superior napery fabric is created using a combination of fabric construction techniques and high-pressure water treatment. This particular fabric is 100% polyester and is made of spun warp yarns and filament fill yarns. The fabric is constructed as a plain weave and has 55 ends per inch and 44 picks per inch in the greige state. The warp yarn is an open end spun 12/1 (i.e. a 12 singles cotton count yarn) with a twist multiple of 3.6, and the filament filling yarn is a 2/150/34 (i.e. 2 plies of 150 denier yarn, each ply containing 34 filaments) and is an inherently low-shrinkage filling yarn. The greige fabric without size weighs about 5.65 ounces per square yard. Prior to hydraulic processing, the fabric is shown in FIGS. 5A and 5B. The above fabric is subjected to the following processing. One side of the fabric is subjected to high-pressure water at about 1400 p.s.i.g. (manifold exit pressure) The water originates from a linear series of nozzles which are rectangular (0.015 inches wide (filling direction)×0.010 inches high (warp direction)) in shape and are equally spaced along the treatment zone. There are 40 nozzles per inch along the width of the manifold. The fabric travels over a smooth stainless steel roll that is positioned 0.110 inches from the nozzles. The nozzles are directed downward about five degrees from perpendicular, and the water streams intersect the fabric path as the fabric is moving away from the surface of the roll. The tension in the fabric within the first treatment zone is set at about 35 pounds. [0036] In the second treatment zone, the opposite side of the fabric is treated with high-pressure water that originates from a similar series of nozzles as described above. In this zone the water pressure is about 700 p.s.i.g., the gap between the nozzles and the treatment roll is 0.160 inches, and the nozzles are directed downward about three degrees from perpendicular. As before, the water streams intersect the fabric path as the fabric is moving away from the surface of the roll. The fabric tension between the treatment zones is set at about 60 pounds, and the fabric exit tension is set at about 60 pounds. Maintenance of these specific tension levels is preferred, but is not necessarily critical to achieve an acceptable result. [0037] The fabric is dried and then subjected to a variety of finishing chemicals. It is pulled to the desired width in a tenter frame, and the finished weight is about 6.25 ounces per square yard. Fabrics having finished weights between about 5 ounces per square yard and about 9 ounces per square yard, and preferably between about 6 ounces per square yard and about 8 ounces per square yard, and most preferably between about 6 ounces per square yard and about 7 ounces per square yard, have been found to be particularly suitable in napery uses. [0038] The fabric is then subjected to a single standard industrial wash, in accordance with the following procedure: [0039] The fabric was loaded into an industrial washer (extractor Model 30015 ) manufactured by Pellorin Milner Corp., of Kenner, La. The equipment was verified to be free of burrs and sharp edges, to have properly functioning water level, temperature controls, and chemical delivery systems. Suggested Wash Formulas & Chemical Supplies for Milliken Napery WATER TEMPERATURE TIME CHEMICALS/ CYCLE LEVEL ° F. (Min.) 100 lbs. Flush High 120 3 Break Low 160 12  24 oz. Alkali 30 oz. Surfactant Carry-over Low 160 6 Rinse High 145 2 Rinse High 130 2 Rinse High 115 2 Sour Low 90-100 8 2 oz. Sour Extract 5 [0040] The extraction time should be sufficient to permit the fabric to be ironed without tumble drying. The fabric was removed from the laundering unit and pressed (using a Model AE Air Edge Press, manufactured by New York Pressing Machinery Co. of New York, N.Y.) for a total press cycle time of 20 seconds, consisting of 5 seconds of steam, 10 seconds of bake (at 380° F.) and 5 seconds of vacuum. [0041] The following wash chemicals were supplied by U.N.X. Incorporated of Greenville, N.C.: [0042] Alkali—Super Flo Kon NP [0043] Surfactant—Flo SOL [0044] Sour—Flo NEW [0045] The results are as shown in FIGS. 6A and 6B and as described in Table 1. (Only one side of the fabric is shown; both sides of the fabric are substantially identical in terms of fiber entanglement, etc.) The fabric surface shows a plurality of fiber tangles, each comprised of fibers that are essentially intact and undamaged, i.e., the individual fibers show no nicks, dents, fibrillations, or other surface irregularities or deformities. The tangle cover is, in some cases, sufficiently dense so as to obscure from view the underlying fiber bundle to a significant degree. EXAMPLE 2 [0046] A first competitive fabric is 100% polyester and has a spun warp and a spun filling. The fabric is constructed as a plain weave and has 63 ends per inch and 47 picks per inch in the finished state. The warp yarn is an air spun 151 made of type T 510 polyester fiber (1.2 denier per filament×1.5 inches in length), and the filling yarn is an air spun 151 made of type T 510 polyester (1.2 denier per filament×1.5 inches in length). The finished fabric weighs 5.8 ounces per square yard. [0047] The fabric is subjected to a single standard industrial wash, in accordance with the wash procedure of Example 1. The result is as shown in FIGS. 7A and 7B and described in Table 1. EXAMPLE 3 [0048] A second competitive fabric is 100% polyester and has a spun warp and a spun filling. The fabric is constructed as a plain weave and has 67 ends per inch and 44 picks per inch in the finished state. The warp yarn is an air spun 11/1 made of type T 510 polyester fiber (1.2 denier per filament×1.5 inches in length), and the filling yarn is an air spun 12/1 made of type T510 polyester (1.2 denier per filament×1.5 inches in length). The finished fabric weighs 7.2 ounces per square yard. [0049] The fabric is subjected to a single standard industrial wash, in accordance with the wash procedure of Example 1. The result is as shown in FIGS. 8A and 8B and described in Table 1. [0050] Although the Examples above have discussed only fabrics comprised exclusively of synthetic fibers, it is contemplated that treated fabrics comprised of blends of synthetic and natural fibers should be included as part of the instant invention. The following specific, non-limiting example involves the use of a polyester and cotton blend in the warp of a blended woven fabric, with either a blended or wholly synthetic fill yarn. EXAMPLE 4 [0051] A blended fabric is comprised of a 65/35 blend of polyester and cotton made with a spun warp and a spun filling. The fabric is constructed as a plain weave and has 102 ends per inch and 53 picks per inch in the finished state. The warp yarn is an open end spun 26/1, 65/35 poly/cotton blend with a twist multiple of 3.69. The filling yarn is a ring spun 25/1, 65/35 poly/cotton blend with a twist multiple of 3.80. The finished fabric weighs 4.25 ounces per square yard. FIGS. 9A and 9B show the fabric surface prior to a hydraulic napping step as described below. [0052] The fabric is hydraulically napped as set forth in Example 1, above, except that the water pressure within the first treatment zone is 1200 p.s.i.g., the spacing between the manifold and the support roll in the first treatment zone is 0.120 inches, the speed of the fabric web is 30 yards per minute, and the relative angle of the water jets is 0°. [0053] The result is as shown in FIGS. 9C and 9D and described in Table 1. As can be seen, a profusion of fiber tangles has been created above the surface yarns that appear to be well distributed laterally, and the observed fiber tangles are not readily associated with warp yarns or fill yarns. [0054] It is believed that the hydraulic napping action as described herein is most effective, but not exclusively so, when the target fabric contains yarns with staple fibers in significant quantities. The napping action is also most effective when those yarns are held within the target fabric structure in a way that allows the energy in the individual water streams to displace, without damage or complete removal, segments of the staple fibers, thereby forming a plurality of fiber tangles comprised of disordered, but undamaged, staple fiber segments that remain attached at both ends to their respective yarns or fiber bundles. Generally, this has been found to occur most reliably in woven fabrics where the staple fibers are contained in the warp yarns, or contained in both the warp and fill yarns. [0055] An important characteristic and advantage of this invention is the relative durability, following repeated washings, of the napped surface that is formed. This is believed to be due to the number of fiber tangles that are generated initially, as well as the extent to which the fibers are disordered within the fiber tangles, and the effects that mechanical washing actions have on the fabric. This combination of characteristics is believed to form a robust nap structure that not only successfully resists the rigors of repeated launderings, but that tends to improve with such launderings—the degree of distributional uniformity (i.e. lateral cover) and degree of disorder of the observed fiber tangles both appear to increase dramatically as a result of repeated laundering, as compared with the nap surface immediately following the hydraulic napping operation. [0056] As a means to gauge the extent of this characteristic and assess the magnitude of this advantage, the subject fabric of this invention as seen in FIGS. 6A, 6B and the commercially available competing napery fabrics of FIGS. 7A, 7B and 8 A, 8 B were each subjected to 75 standard launderings and then examined by photomicrography. The details and results of this comparison are the subject of Examples 5 through 7, below. EXAMPLE 5 [0057] The fabric of Example 1 and shown in FIGS. 6A and 6B is washed (as described in Example 1) 75 times in succession. The surface of the fabric is as seen in FIGS. 6Y and 6Z, and as described in Table 1. EXAMPLE 6 [0058] The fabric of Example 2 and shown in FIGS. 7A and 7B is washed (as described in Example 1) 75 times in succession. The surface of the fabric is as seen in FIGS. 7Y and 7Z, and as described in Table 1. EXAMPLE 7 [0059] The fabric of Example 3 and shown in FIGS. 8A and 8B is washed (as described in Example 1) 75 times in succession. The surface of the fabric is as seen in FIGS. 8Y and 8Z, and as described in Table 1. [0060] It should be noted that attempts to subject fabrics having a high cotton content typically do not survive 75 washes, due to degradation of the cotton fibers. [0061] The following table summarizes some principal observations and comments based upon the above-referenced photomicrographs. TABLE 1 (PHOTOMICROGRAPH SUMMARY) Subject of FIG. Nos. Photomicrograph Description Comments 5A, 5B Untreated subject fabric; Spun polyester warp is No fiber tangles outside normal (perpendicular) substantially confined to yarn bundles view yarn bundle; filament fill is in orderly bundles 6A, 6B Treated subject fabric (1 Many localized fiber Treatment has partially wash); normal view tangles; distinct dislocated significant checkerboard pattern numbers of staple fibers indicates primary from warp yarn bundles involvement of warp yarns 6Y, 6Z Treated subject fabric Dramatically increased Multiple washings have (75 washes); normal number of fiber tangles enhanced treatment view obliterating checkerboard effect 7A, 7B First competitive fabric Little entanglement; no Fiber entanglements (1 wash); normal view distinct checkerboarding quite isolated compared with treated subject fabric 7Y, 7Z First competitive fabric Yarn bundles appear Multiple washings have (75 washes); normal more ordered; visible compacted or removed view entangled fibers appear fiber tangles much more localized than after 1 wash 8A, 8B Second competitive Limited fiber Fewer entanglements fabric (1 wash); normal entanglement; no distinct than subject fabric (FIG. view checkerboarding 6A, 6B) 8Y, 8Z Second competitive Slightly more Fiber entanglements fabric (75 washes); entanglement than after somewhat compacted normal view 1 st wash; no checkerboarding 9A, 9B Treated subject blended Nominal occurrence of Individual fiber tangles fabric prior to hydraulic fiber tangles and are sparse napping; normal view unattached fiber ends 9C, 9D Treated subject blended Widespread occurrence Treatment has partially fabric following hydraulic of fiber tangles, well dislocated significant napping distributed laterally; numbers of staple fibers tangles not readily from surface yarn associated with specific bundles warp or fill surface yarns [0062] In an effort to quantify some of the distinctions and advantages of the instant invention, a statistical technique generally referred to as “co-occurrence” analysis was performed, using the scanning electron microscope images of FIGS. 5A, 6A, 6 Y, 7 A, 7 Y, 8 A, and 8 Y. These statistics are derived from a “co-occurrence matrix.” The matrix is sometimes called a concurrence matrix or second order histogram (Jain 1989). The advantage of using this approach is the objective quantification-of texture or degree of nap with a single number. [0063] There is good correlation between the statistic referred to as “energy” in the References (see below) and the degree of nap. “Energy” is a general statistic for analyzing texture, and its value changes when the regularity of a texture changes. It is an unweighted average of the squares of fundamental co-occurrence matrix values, and is therefore not biased for any particular application. For convenience, this statistic shall be referred to as the “nap index” in FIGS. 10A through 10C. [0064] The nap formed by the fiber tangles discussed herein covers up the regular weave structure of the fabric, thereby essentially randomizing the image. This leads to an decrease in the statistic, reflecting an increase in the degree of nap. The sign of the statistic was changed for convenience, so that an increase in the degree of nap results in an increase in the value of the nap index. [0065] The statistic was calculated for each sample from four SEM images, formed by dividing the respective FIGS. 5A, 6A, 7 A, and 8 A each into quadrants, and treating each as a separate image. These repeat calculations provide a measure of statistical variation. This variation is used as an estimate of statistical confidence. A 90% confidence level (two standard deviations) was used for the range of variation of the four measurements for each sample. The two competitor samples did not include control samples (untreated fabric), and although all samples were plain weaves, the weave structures did not match exactly the control sample of the subject fabric. Therefore, it is not possible to make statistically meaningful comparisons among the various products. [0066] The results of the measurements are graphically depicted in FIGS. 10A through 10C. These results are fully consistent with subjective assessments made from visual examination of the photomicrographs, and are believed to support several conclusions. The subject fabric shows significant nap following one wash. The degree of nap is substantially increased after 75 washes, with a high degree of statistical confidence. This effect is totally absent from the results involving the first and second competitive fabric. The first competitive fabric shows, with a high degree of statistical confidence, a dramatic reduction in the degree of nap following 75 washes. The second competitive fabric shows, at best, no statistically significant increase in the degree of nap following 75 washes. For a more thorough discussion of this technique, see one or more of the following References: (1) Robert M. Haralick, K. Shanmugam, Its'hak Dinstein, “Textural Features for Image Classification,” IEEE Trans. Syst., Man, Cybernn. , Vol. SMC-3, No. 6 (1973), 610-621; (2) Robert M. Haralick, “Statistical and Structural Approaches to Texture,” Proc. IEEE, Vol. 67, No. 5 (1979), 786-804; (3) Steven W. Zucker, Demetri Terzopoulos, “Finding Structure in Co-Occurrence”; (4) “Matrices for Texture Analysis,” Comput. Graph. Image Processing , Vol. 12 (1980), 286-308; (5) Anil K. Jain, “Fundamentals of Digital Image Processing,” Prentice Hall (1989), 394-400. [0067] In an effort to quantify further some of the aesthetic advantages of the instant invention, selected measurements were made using the Kawabata Evaluation System (“Kawabata System”). The Kawabata System was developed by Dr. Sueo Kawabata, Professor of Polymer Chemistry at Kyoto University in Japan, as a scientific means to measure, in an objective and reproducible way, the “hand” of textile fabrics. This is achieved by measuring basic mechanical properties that have been correlated with aesthetic properties relating to hand (e.g., smoothness, fullness, stiffness, softness, flexibility, and crispness), using a set of four highly specialized measuring devices that were developed specifically for use with the Kawabata System. These devices are as follows: [0068] Kawabata Tensile and Shear Tester (KES FB1) [0069] Kawabata Pure Bending Tester (KES FB2) [0070] Kawabata Compression Tester (KES FB3) [0071] Kawabata Surface Tester (KES FB4) [0072] KES FB 1 through 3 are manufactured by the Kato Iron Works Co., Ltd., Div. of Instrumentation, Kyoto, Japan. KES FB 4 (Kawabata Surface Tester) is manufactured by the Kato Tekko Co., Ltd., Div. of Instrumentation, Kyoto, Japan. The results reported herein required only the use of KES FB 2 through 4. [0073] The mechanical properties that have been associated with these aesthetic properties can be grouped into five basic categories for purposes of Kawabata analysis: bending properties, surface properties (friction and roughness), compression properties, shearing properties, and tensile properties. Each of these categories, in turn, is comprised of a group of related properties that can be separately measured. For the testing described herein, only parameters relating to the properties of surface, compression, and bending were used, as indicated in Table 2, below. TABLE 2 KAWABATA PARAMETERS AND UNITS Kawabata Test Group Kawabata Property and Definition Property Units Bending 2HB = Moment of Hysteresis Gms (force) cm/cm per unit length at 0.5 cm −1 (is the opposite of recovery) Surface MIU = Coefficient of friction Dimensionless Compression LC = Linearity (ease of Dimensionless compressional deformation; similar to compressional modulus) DEN 50 = Density in g/cm 3 based on Grams (force)/cm 3 thickness at 50 gf/cm 2 COMP = Percent compressibility Percent based on difference in thickness divided by low pressure thickness [0074] The complete Kawabata Evaluation System is installed and is available for fabric evaluations at several locations throughout the world, including the following institutions in the U.S.A.: [0075] North Carolina State University [0076] College of Textiles [0077] Dep't. of Textile Engineering Chemistry and Science [0078] Centennial Campus [0079] Raleigh, N.C. [0080] Georgia Institute of Technology [0081] School of Textile and Fiber Engineering [0082] Atlanta, Ga. [0083] The Philadelphia College of Textiles and Science [0084] School of Textiles and Materials Science [0085] Schoolhouse Lane and Henry Avenue [0086] Philadelphia, Pa. 19144 [0087] Additional sites worldwide include The Textile Technology Center (Sainte-Hyacinthe, QC, Canada); The Swedish Institute for Fiber and Polymer Research (Mölndal, Sweden); and the University of Manchester Institute of Science and Technology (Manchester, England). [0088] The Kawabata Evaluation System installed at the Textile Testing Laboratory at the Milliken Research Corporation, Spartanburg, S.C. was used as a means to quantify some of the characteristics of the invention disclosed herein, and compare those characteristics with those of the first and second competing fabrics, as well as a cotton fabric representative of fabrics commonly used in napery applications. [0089] In each case, Kawabata testing was done following one industrial wash. The following fabrics were tested: First and Second Competitive Fabrics: As described in Examples 2 and 3, respectively. 100% Cotton Fabric: A commercially available napery fabric having 74 ends and 58 picks and a weight of 5.5 ounces per square yard Subject Fabrics 1-3: 100% polyester spun warp napery fabrics having weights between 6.0 and 7.0 ounces and various constructions, following hydraulic napping in accordance with the teachings herein. Subject Fabrics 4 and 5: Two examples of the fabrics of Example 1, following hydraulic napping in accordance with the teachings herein. Kawabata Compression Test Procedure [0090] An 8 inch×8 inch sample was cut from the web of fabric to be tested. Care was taken to avoid folding, wrinkling, stressing, or otherwise handling the sample in a way that would deform the sample. The die used to cut the sample was aligned with the yarns in the fabric to improve the accuracy of the measurements. Multiple samples of each type of fabric were tested to improve the accuracy of the data. [0091] The testing equipment was set-up according to the instructions in the Kawabata Manual. The Kawabata Compression Tester (KES FB3) was allowed to warm-up for at least 15 minutes before use. The gap interval was set according to the instructions in the Manual. Each sample was placed in the Compression Tester, and the plunger was lowered. The data was automatically recorded on an XY plotter. The values of LC, DEN50, and COMP were extracted and averaged. The results are as indicated in Table 3. Kawabata Surface Test Procedure [0092] An 8-inch×8-inch sample was cut from the web of fabric to be tested. Care was taken to avoid folding, wrinkling, stressing, or otherwise handling the sample in a way that would deform the sample. The die used to cut the sample was aligned with the yarns in the fabric to improve the accuracy of the measurements. Multiple samples of each type of fabric were tested to improve the accuracy of the data. [0093] The testing equipment was set-up according to the instructions in the Kawabata Manual. The Kawabata Surface Tester (KES FB4) was allowed to warm-up for at least 15 minutes before use. The proper weight was selected for testing the samples. The samples were placed in the Tester and locked in place. Each sample was tested for friction, and the data was printed as well as plotted on an XY recorder. The values of MIU were determined from the printed data and averaged. The results are as indicated in Table 3. Kawabata Bending Test Procedure [0094] An 8 inch×8 inch sample was cut from the web of fabric to be tested. Care was taken to avoid folding, wrinkling, stressing, or otherwise handling the sample in a way that would deform the sample. The die used to cut the sample was aligned with the yarns in the fabric to improve the accuracy of the measurements. Multiple samples of each type of fabric were tested to improve the accuracy of the data. [0095] The testing equipment was set-up according to the instructions in the Kawabata Manual. The machine was allowed to wann-up for at least 15 minutes before samples were tested. The amplifier sensitivity was calibrated and zeroed as indicated in the Manual. The sample was mounted in the Kawabata Pure Bending Tester (KES FB2) so that the cloth showed some resistance but was not too tight. The fabric was tested in both the warp and fill directions, and the data was automatically recorded on an XY plotter. The value of 2HB for each sample was extracted from the chart and averaged. The results are as indicated in Table 3. [0096] A table summarizing selected results of the KAWABATA testing is given below: TABLE 3 KAWABATA RESULTS LC DEN 50 COMP MIU 2HB Description (Compression) (Compression) (Compression) (Friction) (Bending) First competitive fabric 0.316 0.473 36.63 0.178 0.160 Second competitive fabric 0.251 0.498 40.20 0.179 0.229 100% Cotton 0.304 0.400 42.29 0.181 0.147 Subject fabric (Sample 1) 0.359 0.394 37.49 0.185 0.190 Subject fabric (Sample 2) 0.375 0.443 34.88 0.204 0.178 Subject fabric (Sample 3) 0.387 0.407 33.10 0.200 0.171 Subject fabric (Sample 4) 0.425 0.375 46.27 0.226 0.106 Subject fabric (Sample 5) 0.437 0.370 45.21 0.219 0.094 [0097] As may be seen from the results of Table 3, the five subject fabrics of the instant invention, and particularly those indicated as “Sample 4” and “Sample 5,” are indicated as being quantitatively superior in several aesthetically important ways to the other listed fabrics. Specifically, it has been determined that the uniqueness of the fabrics of this invention may be characterized in accordance with the following individual Kawabata parameter values as follows: LC values greater than 0.31, preferably greater than 0.375, more preferably greater than 0.390, and most preferably greater than 0.410; DEN 50 values less than 0.400, and preferably less than 0.390, and most preferably less than 0.380; MIU values greater than 0.195, and preferably greater than 0.200, and most preferably greater than 0.215; COMP values greater than 42.5, and preferably greater than 44.0, and most preferably greater than 45.0; and, lastly, 2HB values that are less than 0.200, and preferably less than 0.140, more preferably less than 0.130, and most preferably less than 0.120. It should be understood that, because of the tendency for some properties of the fabrics of this invention to be mutually exclusive, the fabrics of this invention are not always characterized by values of any single Kawabata measurement, but rather by the combination of values of two or more Kawabata measurements. [0098] Having described the principles of my invention in the form of the foregoing exemplary embodiments and non-limiting Examples, it should be understood by those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles, and that all such modifications falling within the spirit and scope of the following claims are intended to be protected hereunder.
A fabric having at least one hydraulically napped surface comprised of tangled fibers is disclosed. Because the fiber tangles are created from intact, undamaged fibers, fabric strength is not adversely affected by treatment. In addition, laundering enhances entanglement and the aesthetic qualities attributed to this fabric property: surface texture (hand), resistance to pilling, drapeability, and the like. These subjective characteristics have been quantified using values from the Kawabata Evaluation System. A process for creating such fabrics has also been disclosed. The fabric passes through one or two treatment zones in which high pressure fluids (e.g., water) are directed at the fabric surface as the fabric moves away from a support member. IN the case of dual treatment zones, a substantially lower pressure is used in the second treatment zone.
3
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT The Government has rights in this invention pursuant to Contract DASG60-85-C-0072 awarded by the Department of Army. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to optical systems. More specifically, the present invention relates to mechanical systems and apparatus used to stabilize an optical line-of-sight. While the present invention is described herein with reference to an illustrative embodiment in a particular application, it is understood that the invention is not limited thereto. Those of ordinary skill in the art and access to the teachings of the present invention will recognize additional modifications and embodiments within the scope thereof. 2. Description of the Related Art The current state of the art is such that guided missiles may be equipped with an onboard tracking and guidance system that provides a `fire and forget` capability. Such capability is desirable in that it permits a launch platform to either launch the missile and move to another tactical position or acquire a second target. Missiles with an onboard tracking and guidance capability can also effectively meet mission objectives when merely launched into an area within which the target is expected to enter or exist. In this application, the missile acquires and tracks the target while guiding itself to the area or point of contact. This allows for an accurate system which permits a number of missiles to be launched at targets which would not otherwise be within range. There are numerous missile guidance technologies which provide some or all of these capabilities. Of these, radar guided and optically guided systems are most commonly used. For the purpose of this application, optically guided systems are deemed to include active and passive systems using infrared, laser, and visual targeting and guidance techniques. The accuracy of most, if not all, of the optical systems is dependent in some measure on the extent to which the line-of-sight on the target is maintained stable on a photodetector or sensor. That is, the incoming optical beam or image must be maintained on the sensor with good acuity and resolution, viz., minimal distortion and/or smear. This is problematic inasmuch as a missile in flight typically experiences substantial disturbance forces. These forces may be due to atmospheric conditions or torques generated by the onboard guidance system. In any event, the forces tend to jitter components in the optical train causing distortion, smear, image offsets, and other problems. To stabilize the optical train of missiles in flight, one prior approach has been to mount the sensor on gimbals in the line-of-sight of the input image. However, due to the mass properties of the sensor, this direct approach has been found to be limited. That is, the weight and size of the sensor make it difficult to stabilize the gimbals within the limited space available in a missile nose cone. The additional mass associated with any nuclear shielding would further exacerbate the problem. Thus, a more common solution has been to place a mirror on a gimbal in the optical line-of-sight which deflects the input image to an off-axis sensor. The mirror is mounted on the inner gimbal and initially stabilized with respect to inertial space. The mirror deflects the input image to an off axis sensor. However, because of the 2 to 1 angular relationship between perturbations in the line-of-sight and perturbations in the reflected image, merely stabilizing the mirror with respect to inertial space is not enough. To compensate for the mirror effect, many systems endeavor to measure a number of parameters including the missile rotation rate, the instantaneous gimbal angle relative to the sensor and the gimbal angle rotation rate relative to the sensor. These measurements are then used to calculate the mirror correction. This approach thus provides indirect stabilization in that the correction is provided by calculation, not by a mechanical stabilization on the gimbal per se. However, such indirect stabilization systems cannot always adequately decouple the line-of-sight. That is, the mirror is not stabilized relative to the input image, and only indirectly with respect to an inertial frame of reference. As such, the accuracy of such systems is limited by the performance of the overall system. Consequently, such systems frequently have insufficient servo bandwidth to achieve a high degree of line-of-sight stability. That is, the accuracy of the overall system is dependent on the accuracy of the least accurate component on the measurement and computational chain. In addition, hardware for making the measurements and corrective calculations adds to system weight, cost, complexity and failure risk. Thus there is a general need for a simple, low cost mirror stabilization scheme which offers improved stability relative to those illustrated by the related art. SUMMARY The shortcomings of pointing systems illustrated by the related art are addressed by the mirror pointing apparatus and method of the present invention which stabilizes a mirror relative to the line-of-sight of the input image. The invention includes an outer gimbal pivotally mounted on a pedestal which is in turn attached to the missile body. An inner gimbal is pivotally mounted on the outer gimbal and the mirror is separately pivotally mounted on the outer gimbal. A linkage is provided between the inner gimbal and the mirror to stabilize the mirror relative to the line-of-sight of the input image. In a more specific embodiment, the outer gimbal and the inner gimbal are stabilized. That is, a rate detector, servos and resolvers are provided for detecting angular turning rates of the inner and outer gimbals and compensating therefor as is known in the art. Line-of-sight stability is accomplished by sizing the linkage to provide a 2 to 1 angular reduction of the mirror relative to the inner gimbal. Optical line-of-sight stability is preserved in the presence of body motions about the inner gimbal axis so long as the inner gimbal remains inertially fixed. Thus, incident radiation remains substantially directed along a body fixed optical axis in the presence of disturbances which would otherwise cause distortion and smear. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a simplified schematic diagram of an illustrative embodiment of the present invention in an illustrative application. FIG. 2 is a simplified schematic diagram of an illustrative embodiment of the present invention in an illustrative application where the outer gimbal is shown in section. FIG. 3 is a view in section of the inner gimbal and mirror assembly of the illustrative embodiment of the present invention. FIG. 4 is a perspective view of an illustrative embodiment of the present invention. FIG. 5 is a perspective sectional view of an illustrative embodiment of the present invention. FIG. 6 is a side view of an illustrative embodiment of the present invention disposed in the environment of an illustrative application. FIG. 7 is a top view of the illustrative embodiment of FIG. 6. FIG. 8 is a rear view of the illustrative embodiment of FIG. 6. DESCRIPTION OF THE INVENTION The present invention provides a method and apparatus for stabilizing a mirror relative to a line-of-sight using a 2 to 1 linkage between a stabilized inner gimbal and a mirror pivotally mounted on an outer gimbal. The linkage articulated mirror 10 of the present invention is shown in a schematic diagram in FIG. 1. The invention 10 includes an outer gimbal 12,an inner gimbal 14, a mirror 18 and a floating link 20. The outer gimbal 12is mounted on a pedestal 22 which is attached to an inertial frame of reference (not shown). The inner gimbal 14 is mounted on the outer gimbal 12. The mirror 18 is pivotally mounted at one end on the outer gimbal structure (not shown) at a pivot or bearing 24 and at the opposite end to the inner gimbal 14 via the floating link 20. Hence, the gimbals 12 and 14provide a two axis platform for the mirror 18. Schematically, the floating link 20 is connected to the mirror leg 21 by a hinge 25. The floating link 20 is also pivotally attached to the inner gimbal 14 by a second hinge 27. Those of ordinary skill in the art will recognize additional means for driving the mirror from the inner gimbal 14within the scope of the present invention. Thus, the mirror 18 has a first line-of-sight 13 when it is positioned at `A` in the counter-clockwise extreme of the two positions depicted in FIG.1, and a second line-of-sight 15 when the mirror 18 is positioned at point `B`. Actuation is accomplished by rotating the inner gimbal 14 about the inner gimbal axis 26. This drives the link 20 as established by the geometry. A force is developed in the link 20 which is applied to the mirror 18 at thelink-to-mirror pivot 25 which produces rotation about the outer gimbal bearing 24. Each position of the mirror 18 at or between the extreme angular positions A and B directs optical energy of the input image, entering through the input aperture 9, along the sensor axis 17 to a sensor 30. The simple linkage shown will not produce a mathematically perfect or true 2 to 1 angular relation between the inner gimbal 14 and the mirror 18 although this is desired. However, by adjusting in combination, the lengthof the link 20, the length of mirror member 21, the mirror length from attachment to mirror member 21 to outer gimbal bearing 24, the length of the inner gimbal 14 and the spacing between the bearing 24 and the inner gimbal axis 26, an approximation of a 2 to 1 angular reduction with sufficient accuracy or fidelity for practical utilization over a limited angle can be achieved. Note that the outer gimbal axis 32 is parallel to the sensor axis 17 thus yielding a 1 to 1 gimbal angle to line-of-sight angle requiring no corrective stratagem. The sectional view of FIG. 2 shows a practical realization of the schematicembodiment of FIG. 1. Again the outer gimbal axis 32 is parallel to sensor axis 17 and incident radiation from extreme line-of-sight directions 19 and 16 are reflected by the mirror 18 along the sensor axis 17. The mirror18 is supported at outer gimbal bearing 24 and actuated at pivot 25 by the link 20. The pivot 27, as part of the inner gimbal 14, is constrained to rotate about the inner gimbal axis 26. A two axis rate sensor or gyro 33 is attached to the inner gimbal 14 and oriented such that its insensitive axis, typically the spin axis is parallel to the momentary line-of-sight. Thus, the sensitive axes of the gyro 33 are aligned to measure angular motion of the inner gimbal 14 about two axes perpendicular to the line-of-sight. The outer gimbal 12 includes a structure 40 that provides pivotal inner gimbal support at the inner gimbal axis 26 and mirror support at the outergimbal bearing 24. The structure 40 is pivotally mounted on shafts 34 and 42. Shafts 34 and 42 are fitted into bearings 46, defining the outer gimbal axis 32. Protrusion 47 retains the stator 43 of the outer gimbal resolver 36 and the stator 37 of the outer gimbal torquer 38. The rotors 35 and 39 complete the outer gimbal resolver 36 and torquer 38 respectively. The rotors 35 and 39 are support structure integrated or associated with the pedestal 22 and as such are non-gimballed. The torquer38 induces motion in the outer gimbal 12 while the resolver 36 senses the instantaneous angular position of the structure 40. The rate detector 33, torquer 38, resolver 36 and a control system (not shown) provide for angular positioning and stabilization of the outer gimbal 12 about the outer gimbal axis 32 as is known in the art. FIG. 3 provides a sectional view through the inner gimbal 14. The outer gimbal structure 40 provides pivotal support for the mirror 18 at bearing 24 and for the inner gimbal 14 at axis 26. The inner gimbal 14 supports the rate detector 33. The inner gimbal is suspended within the structure 40 by two sets of ball bearings 48. The inner gimbal to outer gimbal interface includes a torquer 56 and a resolver 58. The torquer 56 and the resolver 58, each having a stator 57 and 61 respectively and a rotor 59 and 63 respectively, are mounted in a manner similar to that described forthe outer gimbal 12. The rate detector 33, torquer 56, resolver 58 and a control system (not shown) provide for angular positioning and stabilization of the inner gimbal 14 about the inner gimbal axis 26 as is known in the art. FIG. 4 shows a perspective view of an illustrative embodiment of a linkage articulated mirror 10 constructed in accordance with the teachings of the present invention. FIG. 5 shows another sectional perspective view of the linkage articulated mirror 10 of FIG. 4. In FIG. 5, the outer gimbal 12 isshown mounted within a pedestal 22. FIGS. 6, 7, and 8 show an application of the invention 10 within a missile nose cone 11. FIG. 6 is a side view looking into the outer axis 32. The pedestal 23 attaches to and is supported by the missile bulkhead 22 with the optical line-of-sight 13 directed through a transparent window or aperture 9. FIG. 7 shows a top view looking along the inner gimbal axis 26. FIG. 8 is a rear view showing the rate detector 33, the optical sensor30 and the optical sensor axis 17 folded by the fixed mirror 60. In operation, light entering along the optical line-of-sight 13 is reflected off mirror 18 to the detector 30 either directly as shown in FIG. 1 or indirectly via the optional stationary folding mirror 60 as shown in FIG. 8. Any perturbations of the gimbals along the outer gimbal axis 32 and the inner gimbal axis 26 are detected by the angular rate detector 33. Signals from the detector 33 are provided to a control system(not shown) which returns control signals to the torquers 38 and 56 to stabilize the gimbals relative to an inertial frame of reference. Pointingof the mirror 18 is controlled by the torquers 38 and 56 and the resolvers 36 and 58. The present invention decouples the perturbations of the gimbals from the optical line-of-sight. This is accomplished by mounting the mirror 18 on the outer gimbal 12 instead of the inner gimbal 14 as is known in the art.The mirror 18 is thereby destabilized relative to the inertial frame of reference. The mirror 18 is stabilized about the inner axis relative to the optical line-of-sight 13 by the 2 to 1 linkage to the inertially stabilized inner gimbal 14. That is, ordinarily, a one degree perturbation, for example, in the pointing angle of the mirror 18 would translate to a two degree perturbation with respect to the position of thereflected image. The provision of a 2 to 1 linkage by the teaching of the present invention requires a two degree change in the angular position of the inner gimbal 14 to cause a one degree change in the pointing angle of the mirror 18. Stated alternatively, the mirror angle changes a mere 1/2 degree for each degree of rotation of the inner gimbal 14 about its axis 26. Thus, for each degree of perturbation of the inner gimbal 14, the reflected image moves by an amount corresponding to a one degree change inazimuth position of the reflected image. Stabilization of the image therebybecomes directly related to the stabilization of the inner gimbal 14. Thus the present invention has been described with reference to an illustrative embodiment for a particular application. Those of ordinary skill in the art and access to the teachings of the present invention willrecognize additional applications, modifications and embodiments within thescope thereof. For example, the invention is not limited to use in missile systems. The invention could be used in any targeting system or other system where line-of-sight accuracy and stability is desired. For an appropriate application, a linkage ratio of other than 2 to 1 may be used.Further, the mechanical linkage may be replaced with a band drive or other suitable mechanism. In addition, the invention is not limited to any particular arrangement of the gimbals. It is intended by the appended claims to cover any and all such applications, modifications and embodiments.
An improved mirror pointing method and apparatus which stabilizes a mirror relative to the line-of-sight of the input image. The invention includes an outer gimbal pivotally mounted on a pedestal which is in turn attached to a reference frame. An inner gimbal is pivotally mounted on the outer gimbal and the mirror is separately pivotally mounted on the outer gimbal. A linkage is provided between the inner gimbal and the mirror to stabilize the mirror relative to the line-of-sight of the input image. In a more specific embodiment, the outer gimbal and the inner gimbal are stabilized. Thus, a rate detector is provided for detecting angular turning rates of the inner and outer gimbals in conjunction with torquers and resolvers as is known in the art.
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FIELD OF THE INVENTION The invention relates to solar concentrators, and more particularly to the shape and manufacture of solar reflectors for concentrating sunlight onto photovoltaic or thermal absorption devices. BACKGROUND OF THE INVENTION Solar concentrators are used to collect energy emitted by the sun in the form of radiation. Known solar concentrators are shaped so as to direct sunlight incident on a large area spanned by the solar concentrator into a much smaller target area occupied by a device which converts the sun's radiation in the form of light and/or heat into usable energy. Generally the configurations of solar concentrators include a combination of reflectors, lenses, and radiation diffusers. Typical known solar concentrators often utilize a large single or compound reflector for concentrating sunlight incident upon a relatively large area into a smaller target area at which location further reflectors, lenses and/or diffusers are used to further focus and/or diffuse the incident radiation prior to its falling incident upon the target device for conversion into usable energy. One known base shape that is often used for solar concentrators is the parabola. A two-dimensional parabola has the property that, at any point on the parabola, the angle between a line passing through the point parallel with the axis of symmetry of the parabola, and the normal of the curve at that point on the parabola, is the same as the angle between the normal and a line passing through the point and what is known as the focus of the parabola. Consequently, parallel rays from infinity are focused into a single point or a relatively small area located at the focus. Two widely used types of parabolic reflectors, having a three-dimensional form based on the parabola, are the parabolic trough and the parabaloid or parabolic dish reflector. A parabolic trough is a trough shaped reflector which has, in any plane perpendicular to its length, a two-dimensional profile in the shape of a parabola, and hence has a three-dimensional shape of that parabola extruded along the length of the trough. This kind of reflector has a focal line running the length of the trough and passing through the foci of the parabolas in the planes perpendicular to its length. A parabolic dish reflector is a parabaloid shaped reflector which has, in any plane parallel with and intersecting the reflector's axis of rotational symmetry, a two-dimensional profile in the shape of a parabola, and hence has a three-dimensional shape of that parabola rotated about its axis of symmetry. This kind of reflector has a focal point located along the axis of symmetry and at the foci of all the rotationally symmetric parabolas in the planes parallel with and intersecting the axis. FIG. 1 is a two-dimensional cross-sectional view of a known parabolic concentrator 100 which view is illustrative of both a parabolic trough and a parabolic dish reflector. For simplicity the parabola of the two-dimensional profile of the parabolic reflector of the parabolic concentrator 100 is simply referred to as the parabola 110 . Incoming radiation 105 i from infinity or the sun which is parallel to the axis of symmetry 102 of the parabola 110 is reflected by the parabola 110 as reflected radiation 105 r , which converges at focus 103 . Known systems which collect solar radiation and convert it into thermal energy, typically use a reservoir or conduit such as a pipe containing a liquid which is heated up by the radiation focused by the parabola 110 , the thermal energy of which is used ultimately for the generation of electrical energy. FIG. 1 depicts a cross-section of a pipe 122 which is for conducting fluid to be heated near the focus 103 of the parabola 110 . The pipe 122 is located at a distance 101 b from the parabola 110 which is substantially at the focus 103 of the parabola 110 such that most or all of the reflected radiation 105 r of the parabola 110 is incident upon the surface of the pipe 122 . The materials used for the pipe 122 , or other reservoir or conduit, at least in the region substantially at the focus 103 of the parabola 110 , are such that they are capable of withstanding the intensity of the reflected radiation 105 r focused by the parabolic reflector 100 and are ideal for converting the reflected radiation 105 r into thermal energy and transferring that energy in the form of heat to the fluid passing therethrough. Known systems which collect solar energy by converting light directly into electricity typically utilize photovoltaic (PV) cells arranged in a PV panel or unit to collect the light focused by the parabola 110 and convert it into electrical current. Typically, PV units are of finite dimensions, having a finite area spanned by a number of PV cells, and have maximal efficiency when the radiation incident upon the photovoltaic cells of the PV unit have the same intensity i.e. when the incident radiation upon the active area of the PV unit is homogeneous. In general a PV unit's efficiency is limited by the lowest intensities incident upon its radiation collecting surface, and consequently, localized shadows or minima in the incident radiation are a concern whereas localized bright areas or maxima are generally not. Additionally, there are limits to the intensity of the radiation to which any portion of a PV unit may be subjected without it malfunctioning or undergoing permanent irreparable damage. Hence, a PV unit is typically positioned either between the focus 103 and the parabola 110 such as a PV unit 120 a at a distance 101 a from the parabola 110 , or at a distance beyond the focus 103 from the parabola 110 , such as a PV unit 120 b at a distance 101 c from the parabola 110 . Due to the finite area of the PV unit, not all of the incident radiation 105 i near the axis of symmetry 102 will be incident upon the parabola 110 . Specifically, a shadow is cast by the PV unit 120 a , 120 b which is reflected as a shadow 108 within the reflected radiation 105 r. In some known systems utilizing PV units, a radiation diffuser in the form of a substantially transparent plate or lens (not shown for clarity) is positioned so as to intercept and diffuse the radiation reflected by the parabola 110 prior to its falling incident upon the photovoltaic cells of the PV unit 120 a , 120 b . Although this technique improves homogeneity of the intensity of the radiation incident upon the PV unit 120 a , 120 b , efficiency is sacrificed due to the energy lost in the form of the radiation reflected or refracted away from the PV unit 120 a , 120 b by the plate or lens and/or the radiation absorbed by the plate or lens and converted into heat at the plate or lens which is lost to the surrounding environment. As is discussed hereinbelow, the smaller the proportion of the reflected radiation which is diffused with use of a diffuser, the higher the efficiency of the parabolic concentrator 100 . The foregoing applies equally to known parabolic concentrators of both the parabolic trough and parabolic dish types, the difference between them being only that the parabolic dish is rotationally symmetric about a single axis and the parabolic trough is bilaterally symmetric in a plane passing through the axes of the parabolas of the trough. SUMMARY OF THE INVENTION According to one aspect, an embodiment of the invention provides for a quasi-parabolic reflector for a solar concentrator comprising: a concave reflective surface, the concave reflective surface comprising a cross-section substantially symmetric about an axis of symmetry, wherein the cross-section comprises: a first reflective portion on a first side of the axis of symmetry, the first reflective portion having a first focal area, the first focal area located on a concave side of the concave reflective surface and on the first side of the axis of symmetry and at a first distance away from the axis of symmetry; and a second reflective portion on a second side of the axis of symmetry, the second side of the axis of symmetry opposite the first side of the axis of symmetry, the second reflective portion having a second focal area, the second focal area located on the concave side of the concave reflective surface and on the second side of the axis of symmetry and at a second distance away from the axis of symmetry; and wherein the first focal area and the second focal area are substantially at a focal distance away from the concave side of the concave reflective surface, and wherein incident radiation which is incident upon the concave side of the concave reflective surface and propagating in a direction substantially parallel to the axis of symmetry is reflected from the concave reflective surface as reflected radiation such that reflected radiation reflected from the first reflective portion and reflected radiation reflected from the second reflective portion propagate to a radiation absorbing target. According to another aspect, an embodiment of the invention provides for a method of processing petals for a solar concentrator comprising: performing an iterative procedure comprising: stamping the petal with a stamping apparatus comprising stamping surfaces having a greater curvature than a target curvature of a reference petal; determining at least one of a quality and an accuracy of the petal by taking multiple measurements with use of a laser beam reflected from the petal upon a target; and determining deviations of the multiple measurements from a reference set of measurements which would have been obtained with a reference petal; during each iteration of the iterative procedure, determining whether the deviations of the multiple measurements meet at least one of a quality and an accuracy criteria threshold, and if the deviations of the multiple measurements meet at least one of a quality and an accuracy criteria threshold, passing the petal as a finished petal and stopping the iterative procedure, and if the deviations of the multiple measurements do not meet at least one of a quality and an accuracy criteria threshold: determining if either the deviations of the multiple measurements exceed an absolute threshold or if the iterative procedure has been performed more times than a predetermined number, and performing one of: failing the petal and stopping the iterative procedure if either the deviations of the multiple measurements exceed an absolute threshold or if the iterative procedure has been performed more times than a predetermined number; and performing another iteration of the iterative procedure if the deviations of the multiple measurements do not exceed the absolute threshold and the iterative procedure has not been performed more times than the predetermined number. BRIEF DESCRIPTION OF THE DRAWINGS The features and advantages of the invention will become more apparent from the following detailed description of the preferred embodiment(s) with reference to the attached figures, wherein: FIG. 1 is a diagram illustrating a known parabolic concentrator having a known parabolic reflector; FIG. 2 is a diagram illustrating a quasi-parabolic reflector for quasi-parabolic concentrators according to an embodiment of the invention; FIG. 3 is a diagram of a quasi-parabolic concentrator according to an embodiment of the invention; FIG. 4 is a diagram of the reflected radiation from a quasi-parabolic reflector according to an embodiment of the invention; FIG. 5 is a diagram of the reflected radiation from a quasi-parabolic reflector according to an embodiment of the invention illustrating sensitivity to changes in distance; FIG. 6 is a diagram of the reflected radiation from a parabolic reflector illustrating sensitivity to changes in distance; FIG. 7 is a diagram further comparing the reflected radiation from a parabolic reflector and a quasi-parabolic reflector according to an embodiment of the invention; FIG. 8 is a diagram further comparing the reflected radiation from a parabolic reflector and a quasi-parabolic reflector according to an embodiment of the invention; FIG. 9A is a graph depicting a magnitude of intensity across a PV unit of a known parabolic concentrator; FIG. 9B is a graph depicting a magnitude of intensities across a PV unit of a quasi-parabolic concentrator at various distances; FIG. 10 is a diagram of a stamping apparatus for use in forming a petal of a quasi-parabolic dish reflector according to an embodiment of the invention; FIG. 11 is a diagram of a testing apparatus for use in testing a petal of a quasi-parabolic dish reflector according to an embodiment of the invention; and FIG. 12 is a functional block diagram of a process for forming and testing a petal of a quasi-parabolic dish reflector according to an embodiment of the invention. It is noted that in the attached figures, like features bear similar labels. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 2 , a cross-section of a quasi-parabolic reflector 200 in accordance with a first embodiment of the invention will now be discussed in terms of its structure. The shape of the cross-section of the quasi-parabolic reflector 200 is a quasi-parabola 211 which comprises two partial parabolas 211 a and 211 b each of which is shifted a distance R f away from the axis of symmetry 202 of the quasi-parabola 211 . For simplicity of description, and for comparison with the known parabolic concentrator 100 depicted in FIG. 1 , each partial parabola of the quasi-parabola 211 , namely the left partial parabola 211 a and the right partial parabola 211 b have the same shape as respectively the left-half and the right-half of the parabola 110 of FIG. 1 . Consequently, the left partial parabola 211 a has a focal point 207 a a distance R f to the left of the axis of symmetry 202 , while the right partial parabola 211 b has a focal point 207 b a distance R f to the right of the axis of symmetry 202 . The left partial parabola 211 a and the right partial parabola 211 b are either separated by a gap or void, or joined by a portion of the quasi-parabola 211 which need not serve to reflect any of the incident radiation 205 i in any meaningful way. The interaction between the incident radiation 205 i and the quasi-parabola 211 provides reflected radiation 205 r which differs significantly from reflected radiation 105 r of the known parabola 110 of FIG. 1 . The foci 207 a , 207 b respectively of the left partial parabola 211 a and the right partial parabola 211 b are at a focal distance 206 a away from quasi-parabola 211 . As can be seen in FIG. 2 , the reflected radiation 205 r reflected from the outer portions of the left partial parabola and the right partial parabola crossover to become the inner portions of the reflected radiation 205 r at a distance just greater than focal distance 206 a . Reflected radiation 205 r reflected from the inner portions of the left partial parabola and the right partial parabola crossover to become the outer portions of the reflected radiation 205 r at a distance just greater than the focal distance 206 a. The overall nature of the radiation pattern reflected by the quasi-parabola 211 will now be described. Between the quasi-parabola 211 and the foci 207 a , 207 b of the left and right partial parabolas, the radiation pattern comprises two converging sections on either side of the axis of symmetry 202 separated by a gap equal to twice the distance R f . Between the focal distance 206 a and an initial crossover distance 206 b , the reflected radiation 205 r from each focus 207 a , 207 b diverges such that the gap, which is twice the distance R f at the focal distance 206 a , reduces to 0 at the initial crossover distance 206 b , while the outer edge of the radiation pattern in this region maintains a generally constant radius R f from the axis of symmetry 202 . At the initial crossover distance 206 b from the quasi-parabola 211 , reflected radiation 205 r reflected from the outer portions of the left partial parabola and the right partial parabola just begin to intersect. At distances between the initial crossover distance 206 b and a complete crossover distance 206 c from the quasi-parabola 211 , the portion of overlap between the reflected radiation 205 r of the left partial parabola and the right partial parabola at the center of the radiation pattern increases from an infinitesimal amount at the initial crossover distance 206 b to a complete overlap at the complete crossover distance 206 c . At the complete crossover distance 206 c , reflected radiation 205 r reflected from the left partial parabola and the right partial parabola completely overlap with each other. At distances beyond the complete crossover distance 206 c , the reflected radiation 205 r reflected from the outer portions of the left partial parabola and the right partial parabola diverge such that they progressively overlap less and less with reflected radiation 205 r from the other of the left partial parabola and the right partial parabola. Referring now to FIG. 3 , a quasi-parabolic concentrator 300 in accordance with an embodiment of the invention will now be described. The quasi-parabolic concentrator 300 comprises a quasi-parabolic dish reflector 311 which is rotationally symmetric about the axis of symmetry 302 , and has a two-dimensional profile in any plane parallel to and intersecting the axis of symmetry 302 similar to the quasi-parabola 211 depicted in FIG. 2 . The quasi-parabolic dish reflector 311 is made up of petals 315 arranged in a rotationally symmetric and periodic pattern. The quasi-parabolic dish reflector 311 of FIG. 3 is made up of a total of 16 petals 315 , only one of which is shown for clarity. Incident radiation 305 i from the sun is reflected by the quasi-parabolic dish reflector 311 as reflected radiation 305 r . As can be seen in FIG. 3 , the resulting radiation pattern formed by the reflected radiation 305 r is a converging cone shaped pattern with a cylindrical gap of radius R f . The reflected radiation 305 r focuses at a focal distance 306 a from the quasi-parabolic dish reflector 311 to form a focal ring 307 having a radius R f . Between the focal distance 306 a and an initial crossover distance 306 b , the reflected radiation 305 r from the focal ring 307 diverges such that the resulting radiation pattern is a cylinder roughly of radius R f with a cone shaped gap having a radius of R f at the focal distance 306 a and converging to a point at the initial crossover distance 306 b . At the initial crossover distance 306 b from the quasi-parabolic dish reflector 311 , reflected radiation 305 r reflected from the outer portions of quasi-parabolic dish reflector 311 just begin to overlap in the center at the axis of symmetry 302 . At distances between the initial crossover distance 306 b and a complete crossover distance 306 c from the quasi-parabolic dish reflector 311 , the resulting radiation pattern is made up of a cylinder roughly of radius R f having reflected radiation 305 r with no overlap and a cone of overlapping reflected radiation 305 r growing from a point at the initial crossover distance 306 b to a radius of R f at the complete crossover distance 306 c . At the complete crossover distance 306 c , the reflected radiation 305 r reflected from the left partial parabola and the right partial parabola of any cross section of the quasi-parabolic dish reflector 311 completely overlap with one another. As distances increase beyond the complete crossover distance 306 c , the reflected radiation 305 r reflected from the quasi-parabolic dish reflector 311 diverges such that it progressively overlaps proportionally less with itself. The resulting radiation pattern in this region is a conical section of non overlapping radiation having an initial radius of about R f at the complete crossover distance 306 c to an infinite radius at infinity, with a core of overlapping radiation generally in the shape of a cylinder of radius R f , which makes-up proportionally 100% of the radiation pattern at the complete crossover distance and proportionally 0% of the radiation pattern at infinity. For completeness, a circular PV unit 326 of the quasi-parabolic concentrator 300 having a radius R f and located at the initial crossover distance 306 b is shown in FIG. 3 . Referring to FIG. 4 , a configuration of the target devices in a radiation pattern produced by the quasi-parabolic dish reflector 311 of FIG. 3 will now be discussed. A single two dimensional cross-section taken through the axis of rotational symmetry is shown. Reflected radiation 405 r converges at a focal ring 407 at a focal distance 406 a from the quasi-parabolic dish reflector. A PV unit having a radius roughly the same as R f is generally placed between an initial crossover distance 406 b from the quasi-parabolic dish reflector as illustrated by PV unit 426 a , and a complete crossover distance 406 c from the quasi-parabolic dish reflector as illustrated by PV unit 426 b . Due to the finite angular size of the sun in the sky, and with use of further lenses or diffusers, the PV unit 426 a may be placed at a distance just closer to or just farther from the quasi-parabolic dish reflector than the initial crossover distance 406 b . This is made possible due to a smoothing out of the gap or the overlap that otherwise would be sharply defined near the center at the axis of symmetry. As can be seen in FIG. 4 , substantially all of the reflected radiation 405 r is spread over the entire area of the PV unit 426 a , at the initial crossover distance 406 b such that there is singular coverage, and at the complete crossover distance 406 c substantially all of the reflected radiation 405 r is spread over the entire area of the PV unit 426 b such that there is double coverage. The consequences of the radiation pattern having singular coverage and double coverage will be discussed in more detail hereinbelow. To convert solar energy into thermal energy a reservoir or conduit such as pipe 422 or large pipe 423 is used. As with the PV units, a pipe sufficiently large may be located at distances around and between the initial crossover distance 406 b and the complete crossover distance 406 c , although if the pipe has a radius smaller than R f as is the case for pipe 422 , it may be placed at a distance such that the overlapping cone of double coverage is incident upon the pipe 422 to ensure a large proportion of the entire reflected radiation is incident upon the surface of the pipe 422 . A large pipe 423 may also be placed at a distance within the cylinder of double coverage beyond the complete crossover distance 406 c , and may be mounted permanently in association with a non-permanently mounted PV unit 426 a , 426 b . In such embodiments, the quasi-parabolic concentrator has dual modes of operation, thermal and photo-voltaic. Referring now to FIG. 5 and FIG. 6 , the effects of a variation in distance of a PV unit from the quasi-parabolic reflector of a quasi-parabolic concentrator and the effects of a variation of a distance of a PV unit from a known parabolic concentrator will now be compared. FIG. 5 depicts the radiation pattern 500 of a quasi-parabolic dish reflector such as that illustrated in FIG. 3 . Reflected radiation 505 r converges into a focal ring 507 at a focal distance from the quasi-parabolic dish reflector which has a vertical axis of symmetry 502 . A PV unit 520 of radius R 0 is located between the initial crossover distance and the focal distance, at a distance D 0 such that the radius to the outer edge of the reflected radiation 505 r is also R 0 . The total amount of reflected radiation 505 r is incident upon the PV unit 520 and has an area of πR 0 2 −πR 1 2 =π(R 0 2 −R 1 2 ). If the PV unit 520 were to shift by ΔD to a distance D 0 ′, the total amount of reflected radiation 505 r would be incident upon the PV unit 520 and would have an area of πR 0 2 −R 2 2 =π(R 0 2 −R 2 2 ). Designating the absolute value of the slope of the reflected radiation 505 r from the outside of the quasi-parabolic dish reflector as m, the magnitude of the change in radius ΔR is ΔD/m, hence R 2 =R 1 +ΔD/m. The change in area due to the shift is ΔA=−π(2R 1 ΔD/m+(ΔD/m) 2 ). The reduction in area in shifting from D 0 to D 0 ′ is reflected in an increase in intensity. The closer the set position of the PV unit 520 is to the location of interest at which it would have complete singular coverage, namely the initial crossover distance, the closer R 1 is to 0, and small shifts in distance result in a change in area having one term proportional to the square of the change in distance (πΔD 2 /m 2 ) and another term proportional to R 1 (π2R 1 ΔD/m) which vanishes at the initial crossover distance. FIG. 6 depicts the radiation pattern 600 of a parabolic dish reflector. For comparison to the radiation pattern 500 of FIG. 5 it should be kept in mind that the slope of the reflected radiation 505 r from the outside portions of the quasi-parabolic dish reflector is substantially the same as the slope of the reflected radiation 605 r from the outside portions of the parabolic dish reflector (not shown) generating the radiation pattern 600 in FIG. 6 . Reflected radiation 605 r converges into a focal point 603 at a focal distance from the parabolic dish reflector which has a vertical axis of symmetry 602 . A PV unit 620 of radius R 0 is located at a distance D 1 such that the radius if the outer edge of the reflected radiation 605 r is also R 0 . The total amount of reflected radiation 605 r is incident upon the PV unit 620 , and has an area of πR 0 2 . If the PV unit 620 were to shift by ΔD to a distance D 1 ′, the total amount of reflected radiation 605 r would be incident upon the PV unit 620 and would have an area of πR 0 ′ 2 . The absolute value of the slope of the reflected radiation 605 r from the outside of the parabolic dish reflector is m, the same as that of the quasi-parabolic dish reflector of FIG. 5 , and hence the magnitude of the change in radius ΔR is ΔD/m, and therefore R 0 =R 0 ′+ΔD/m. The change in area due to the shift is ΔA=−π(2R 0 ′ΔD/m+(ΔD/m) 2 ). The reduction in area in shifting from D 1 to D 1 ′ is reflected in an increase in intensity. At the set position of interest for the PV unit 620 , at which it would have complete singular coverage, namely at distance D 1 from the focus 603 , small shifts in distance result in a change in area having one term proportional to the square of the change in distance (πΔD 2 /m 2 ) and another term proportional to R 0 ′ (π2R 0 ′ΔD/m) which approaches the non-zero value R 0 for smaller and smaller shifts in position. As such a change in area and hence intensity due to a shift in the position of a PV unit for a quasi-parabolic dish reflector is smaller than a change in area and intensity due to a shift in the position of a PV unit for the parabolic dish reflector. The performance, stability, and behavior of the quasi-parabolic concentrator thus is less susceptible to changes in the distance of the PV unit from the reflector. Referring now to FIG. 7 , radiation patterns 700 of reflected radiation from a quasi-parabolic dish reflector 710 and a parabolic dish reflector 711 are shown superimposed for direct comparison. As discussed above, the quasi-parabolic dish reflector 710 comprises, in any cross section a left partial parabola and a right partial parabola, each of which is shifted a distance R f and each similar in shape to a respective half of a known parabola. The quasi-parabolic dish reflector therefore has a gap (which may or may not be reflective or even spanned by the dish structure) having a radius of R f . The known parabolic dish reflector 711 has a focus 703 a focal distance 706 a away from the parabolic dish reflector 711 . A PV unit 720 a or 720 b is ideally positioned at a distance less than or greater than the focal distance 701 b such that the outer radius of the radiation pattern is the same size as the radius of the PV unit 720 a or 720 b . At either distance 701 a , 701 c , the PV unit 720 a , 720 b encounters its own shadow 708 which forms a circle centered on the axis of symmetry 702 which is absent reflected radiation. Such a local minimum of radiation intensity would greatly harm the efficiency of the PV unit 720 a , 720 b and hence diffusers and/or lenses are often used in an attempt to scatter the radiation, otherwise incident outside of the shadow and evenly over a relatively large area, so as to redirect it into the central area of the shadow. As described hereinabove techniques utilizing diffusers and/or lenses have their limits and some energy of radiation will be lost due to reflection, refraction, or absorption at the diffusers and/or lenses. For clarity, incident radiation from the source, only out to a radius of Rd is depicted in FIG. 7 . The quasi-parabolic dish reflector 710 has a focal ring 707 a focal distance 701 b away from the quasi-parabolic dish reflector 710 . A PV unit 726 a or 726 b is ideally positioned at the complete crossover distance 706 c or at the initial crossover distance 706 b or anywhere between, such that the outer radius of the radiation pattern is substantially the same size as the radius of the PV unit 726 a or 726 b . Since the PV unit 726 a , 726 b has a radius substantially the same as the focal ring 707 , and the radius of the gap, no shadow is cast by the PV unit 726 a , 726 b onto reflecting portions of the quasi-parabolic dish reflector, and hence at distances between the initial crossover distance 706 b and the complete crossover distance 706 c , no shadow or extreme local minima in intensity exists. Beyond the initial crossover distance 706 b , there is an increasingly growing central area of double coverage as discussed above, which does not serve to limit the efficiently of the PV unit 726 a , 726 b . However, if the central hotspot encountered just beyond the initial crossover distance 706 b would otherwise cause damage to the PV unit 726 a , a small diffuser and/or lens may be used to spread or redirect the hotspot outward. Since the hotspot is relatively small, the likewise small diffuser and/or lens would have a minimal footprint. Generally, utilizing diffusers and/or lenses to spread out a small hotspot is less disruptive than attempting to evenly gather radiation from a larger area to fill in a hole in the radiation pattern (i.e. a shadow). It is clear that no matter what distance the PV unit 720 a , 720 b is located at, reflected radiation from any one point Q of the parabolic dish reflector 711 is incident upon the PV unit 720 a , 720 b at one spot on the active surface of the PV unit 720 a , 720 b , and that spot on the active surface of the PV unit 720 a , 720 b has radiation incident upon it from only that one point Q of the parabolic dish reflector 711 . In a case that the PV unit 726 b is located at the complete crossover distance 706 c , it is clear that every spot on the active surface of the PV unit 726 b has radiation incident upon it from two points of the quasi-parabolic dish reflector 710 , radiation from one point of the left partial parabola and radiation from one point of the right partial parabola. For example, spot P on the PV unit 726 b surface is illuminated by point P′ of the left partial parabola of the quasi-parabolic dish reflector 710 , as well as being illuminated by point P″ of the right partial parabola of the quasi-parabolic dish reflector 710 . It is due to the illumination by two distinct points of the quasi-parabolic dish reflector 710 that the PV unit 726 b is referred to as subject to double coverage at the complete crossover distance 706 c. A consequence of the partial double coverage on the PV unit 726 b between the initial crossover distance 706 b and the complete crossover distance 706 c , and the complete double coverage at the complete crossover distance 706 c , is that a quasi-parabolic concentrator is much more robust in the face of surface defects such as post-installation localized damage, blemishes, dirt or interfering matter such as bird feces than a known parabolic concentrator subject to the same surface defect. For the same reason, the quasi-parabolic concentrator is more robust than the known parabolic concentrator in the face of pre-installation damage and or any other surface defect which could arise during manufacture, assembly, or during shipment. Referring now to FIG. 8 , a qualitative illustration of relative intensity across a PV unit 826 a is discussed. It is known that a known parabolic concentrator reflecting incident radiation from a distant object illuminates a flat PV unit with a circularly symmetric pattern having an intensity maximum near the center (outside of any shadow) and monotonically decreasing to a minimum at the edges. As such, in FIG. 8 , the reflected radiation from point p 1 on the parabola 811 passing through the focus 803 and falling on the PV unit 826 a at spot q 1 , has a higher intensity than that from point p 2 on the parabola 811 passing through the focus 803 and falling on the PV unit 826 a at spot q 2 . An equivalent point to p 1 , on the left partial portion of the quasi-parabola 810 , p 1 ′, is shifted a distance R f away from p 1 and away from the axis of symmetry 802 . The point p 1 ′ reflects radiation from the quasi-parabola 810 at the same angle as that reflected from p 1 of the parabola 811 , to pass through the focal ring 807 and fall on the PV unit 826 a at a spot q 1 ′ at the same angle that the incident radiation falls on q 1 after being reflected by the parabola 811 . An equivalent point to p 2 , on the left partial portion of the quasi-parabola 811 , p 2 ′, is shifted a distance R f away from p 2 and away from the axis of symmetry 802 . The point p 2 ′ reflects radiation from the quasi-parabola 810 at the same angle as that reflected from p 2 of the parabola 811 , to pass through the focal ring 807 and fall on the PV unit 826 a at a spot q 2 ′ at the same angle that the incident radiation falls on q 2 after being reflected by the parabola 811 . It is to be noted that the pattern reflected by the parabola 811 is such that radiation from the relatively central areas of the reflector, such as from point p 1 , is reflected to the relatively central area of the PV unit 826 a , such as at spot q 1 , and radiation from the relatively outer areas of the reflector, such as from point p 2 , is reflected to the relatively outer areas of the PV unit 826 a , such as at spot q 2 . In contrast to the pattern reflected by the parabola 811 , the pattern reflected by the quasi-parabola 810 is such that radiation from the relatively central areas of the reflector, such as from point p 1 ′, is reflected to the relatively outer areas of the PV unit 826 a , such as at spot q 1 ′, and radiation from the relatively outer areas of the reflector, such as from point p 2 ′, is reflected to the relatively central area of the PV unit 826 a , such as at spot q 2 ′. This reversal of inner and outer intensity plays a role in the generally homogeneous intensity resulting from solar radiation reflecting from the quasi-parabolic concentrator of the invention. With reference to FIG. 9A and FIG. 9B intensities of the radiation patterns of a known parabolic reflector and a quasi-parabolic reflector are discussed. Each graph shows a plot of intensity I against position X across a PV unit. FIG. 9A shows an intensity plot of a radiation pattern from a known parabola falling incident on a PV unit as discussed above. As can be seen, intensity is largest in the center of the PV unit (position X=0) and falls off to zero intensity on either side of the axis of symmetry. For clarity, FIG. 9A does not show the shadow or the correction applied to it by a diffuser or lens. FIG. 9B shows a number of intensity plots of a radiation pattern from a quasi-parabolic reflector according to the invention falling incident on a PV unit as discussed above. Each plot shows the intensities resulting for a specific distance between the PV unit and the quasi-parabolic reflector. Intensity plot 930 shows intensities when the distance is just beyond the initial crossover distance. Each of intensity plots 910 , 915 , 920 , 925 , 935 , 940 , 945 , 950 correspond to the intensities across a PV unit at respectively distances offset from the initial crossover distance of: −50 mm; −25 mm; −12.5 mm; −5 mm; +25 mm; +50 mm; +75 mm; +100 mm. Clearly intensities near the initial crossover distance, indicated by 930 , are generally homogenous over a large area of the PV unit. Also of note is the intense concentration at the central areas at distances beyond the initial crossover distance, allowing for thermal applications to sit behind the PV applications, and since the intensities at the central area are relatively concentrated for a large range (up to 75 mm), tolerances of thermal applications are improved and hence so are efficiencies. With reference to FIGS. 10 , 11 , and 12 a system and method of manufacturing and testing a petal of the quasi-parabolic reflector will now be discussed. Although many different methods may be utilized to construct a petal of the quasi-parabolic reflector discussed above, a person skilled in the art will understand different methods will be appropriate for different materials from which the petal is made. In the manufacturing embodiment depicted in FIG. 10 , each petal is constructed from a lightweight metal such as aluminum with a hard reflective coating deposited thereon. In some embodiments the reflective material is anodized and laminated to the aluminum base material and may be nonmetallic such as a hard plastic-based material. Rather than being die cast or machined, the aluminum base material, in the form of a plate or sheet, is cut to roughly the same shape as, although a little larger than, the finished petal but having no appreciable curvature. This petal is treated so that the reflective coating is deposited thereon, and then the composite material petal is stamped. FIG. 10 depicts a stamping apparatus 1000 for stamping the composite material petal into a shape for use in a reflector of a solar concentrator. The stamping apparatus 1000 includes an upper stamping portion 1020 and a lower stamping portion 1030 , the upper stamping portion 1020 having an upper stamping surface 1025 and the lower stamping portion 1030 having a lower stamping surface 1035 . The shape of the upper stamping surface 1025 and the lower stamping surface 1035 are substantially the same as each other, which is a modified version of the desired petal shape. Specifically, in the embodiment depicted in FIG. 10 , the upper and lower stamping surfaces 1025 , 1035 have curvatures whose magnitudes are greater than the magnitudes of the curvature of the final petal, for example, the magnitude of the convex curvature of the upper stamping surface 1025 is greater than a magnitude of the concave curvature of a desired petal, and the magnitude of the concave curvature of the lower stamping surface 1035 is greater than a magnitude of the convex curvature of a desired petal. By stamping with magnitudes of curvatures which are greater than what is desired in the produced stamped petal, this stamping process takes into account the rigid nature of the composite material petal which will exhibit a certain amount of spring back once stamped. In order to prevent the hard reflector material from peeling-off or cracking, the level of overcompensation of the curvature (the amount by which the stamp curvature is greater than a curvature of a desired petal) of the upper and lower stamping portions does not exceed the limit ratio of the curvature of the petal at which the reflector material would be damaged. Although this may require a greater number of multiple stampings, the quality and durability of the final product is greatly enhanced. Referring now also to FIG. 11 , a testing apparatus 1100 for testing and refining a petal 1130 will now be described. After each stamping cycle through the stamping apparatus 1000 depicted in FIG. 10 , the stamped composite material petal is subjected to testing in the testing apparatus 1100 . The testing apparatus 1100 includes a frame 1110 for supporting and holding in place the stamped composite material petal 1130 , a laser light source 1150 , and a target 1160 . To facilitate loading of the petal 1130 , which is of considerable weight, a platform 1112 is provided in front of the support structure 1111 on which the composite material petal 1130 is mounted for testing. The laser light source 1150 is mounted such that it provides a beam of light 1152 in a direction which, relative to the composite material petal 1130 , is parallel to the direction light rays would travel from the sun when the quasi-parabolic concentrator in which the petal 1130 is installed is aligned with the sun. The laser light source 1150 is mounted on a first translating mount 1114 for translating the laser light source 1150 in a first direction within a plane substantially perpendicular to the beam of light 1152 , and is also mounted on a second translating mount 1113 for translating the laser light source 1150 in a second direction within a plane substantially perpendicular to the beam of light 1152 and also substantially perpendicular to the first direction. This enables laser light source 1150 to target various points on the stamped composite material petal 1130 for testing, such as point 1135 . The beam of light 1152 from the laser light source 1150 reflects from the composite material petal 1130 as reflected beam 1154 which strikes the target 1160 at a point of incidence 1165 . In some embodiments the target 1160 is placed at a distance substantially equal to the distance which would exist between the focal area and the petal of a parabolic reflector. In the embodiment depicted in FIG. 11 , the laser light source 1150 is positioned at various predetermined locations at different first direction and second direction coordinates. In one embodiment of the invention the laser light source 1150 is located at 16 different predetermined locations during testing of a petal. The target area 1160 is either marked, or monitored by light scanning apparatus (not shown for clarity) in order to compare the actual point of incidence 1165 with the calculated point of incidence for an ideal petal. Depending upon the level of accuracy or inaccuracy of each of the points of actual incidence, the composite material petal 1130 may be sent back for additional stamping, may be discarded, or may be determined to be within quality and accuracy tolerances meeting the standard of a final finished composite material petal. In some embodiments each point of incidence upon the target area is also inspected for quality by inspecting the spread and/or shape of the incident light on the target. In some embodiments an average of the deviations is determinative of an overall accuracy which is measured against an overall accuracy threshold. In other embodiments a deviation exceeding a maximum threshold is determinative of a failed petal which should be discarded, and in other embodiments a weighted average of deviations is compared to a maximum weighted average deviation threshold. Referring now to FIG. 12 , a method of iteratively stamping and testing of a composite material petal will now be described. At 1200 a composite material petal is first stamped in accordance with an assumed number of stampings required to bring an average composite material petal to its proper shape. At 1220 the petal is mounted on the testing apparatus and multiple measurements are taken with the laser light source at multiple locations. The resulting incident locations on the target as well as the quality of the incident radiation are recorded and a determination is made as to how much these deviate from the ideal petal in 1230 . The next step is to determine if the petal meets the quality/accuracy threshold at 1240 . The quality of the incident beam is determined with use of the spread and/or shape of the incident light on the target, while in general accuracy may be determined by determining the difference between the location of the center of an incident beam on the target area and the location where the beam would have been incident upon the target had it been reflected by a reference petal having an ideal or target curvature. If the petal meets the quality and accuracy criteria thresholds it is passed as a finished petal for use in a parabolic concentrator in step 1250 and then the process ends. If the petal does not meet the quality and accuracy criteria, at step 1260 it is determined whether the petal either has deviations which exceed an absolute threshold level or has been stamped more times than is acceptable. If either of these conditions exist, the petal is determined in step 1270 to be a failure and unsuitable for use in a quasi-parabolic concentrator. If neither of these conditions exist, the petal is determined to be worth attempting to rectify through further processing and the process returns to a further step of stamping 1200 . The process of FIG. 12 allows for multiple stamping of petals based on a measurement of the actual quality and accuracy of the petal. This allows early identification of petals which are unsuitable, and also early identification of petals which are suitable after relatively few stamping cycles. This reduces stresses on the reflective material and the risk of cracking or peeling due to stamping, by eliminating unnecessary stamping cycles. Although embodiments of the quasi-parabolic concentrator discussed above have been described in the context of a circularly or rotationally symmetric dish reflector, elliptical variations of the quasi-parabolic concentrator and linear extruded variations of the quasi-parabolic concentrator are also contemplated by the invention. In such embodiments, instead of a focal ring, a focal ellipse or two parallel focal lines result. Although embodiments of the quasi-parabolic concentrator discussed above have been described as comprising two separated partial parabolas on either side of an axis or plane of symmetry, other shapes may be utilized to give rise to the equivalent radiation patterns to those disclosed above such as parabolas which are separated and rotated toward or away from the axis or plane of symmetry, or parabolas which are not separated but are rotated, compound parabolas, or other forms substantially forming and having two focal areas on either side of the axis of symmetry. In these embodiments, cross sections of the reflector possess two separate foci, such that there is overlap or double coverage within the radiation pattern. As long as there exist areas within the radiation pattern in which there is double coverage, the concentrator provides robust performance in the face of surface defects whether due to post-installation or pre-installation activities and/or incidents. Although embodiments of the quasi-parabolic concentrator discussed above have been described as comprising two distinct foci, other embodiments may utilize partial parabolas or other shapes to give rise to areas of radiation which are nearly focal referred to as focal areas. In such embodiments there would exist crossover of radiation but the areas of crossover would not necessarily be restricted to a point, ring or line, but instead could be a surface, such as a cylinder, or a volume, such as a torus. As long as the nearly focal regions are such that the radiation pattern has areas of double coverage, the concentrator will still remain robust in the face of surface defects. Also, as long as the quasi-parabolic reflector generates a radiation pattern in which radiation from the central areas of the reflecting surface are reflected to the outer areas of a PV unit and radiation from the outer areas of the reflecting surface are reflected to the central areas of the PV unit, improvements to the homogeneity of the radiation on the PV unit may be obtained. Although, the embodiments described above include a straight trough of constant width and a circular or elliptical dish, the invention applies also to non-straight troughs and/or troughs having varying widths, as well as non-rotationally symmetric dishes which nonetheless are symmetric at each angle through a single axis. Other forms such as troughs which are contiguous and having no ends such as a trough which describes a circle or an ellipse in a horizontal plane are also contemplated. Skilled persons in the art will understand that various forms utilizing reflective cross-sections with two focal areas in accordance with the teachings hereinabove are in accordance with the invention. The embodiments presented are exemplary only and persons skilled in the art would appreciate that variations to the embodiments described above may be made without departing from the scope of the invention. The scope of the invention is solely defined by the appended claims.
A quasi-parabolic reflector and method are provided for a solar concentrator which produces a unique radiation pattern which is less susceptible to surface defects, less sensitive to target distance irregularities, and having greater uniformity of intensity for PV applications in comparison to that produced by true parabolic reflectors. Cross-sections of the quasi-parabolic reflector include spaced reflective surfaces which have focal areas spaced one from the other about an axis of symmetry. A method for forming petals of a quasi-parabolic reflector includes stamping them into shape using a stamping apparatus with a higher radius of curvature than the finished petal and iteratively testing and stamping the petal until the petal passes or fails a quality and accuracy threshold.
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CROSS REFERENCES TO RELATED APPLICATIONS The Present Application claims priority to U.S. Provisional Patent Application No. 60/827,384, filed on Sep. 28, 2006. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not Applicable BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an ink for printing on a game ball. More specifically, the present invention relates to an ink for dispensing from an inkjet printing machine onto a surface of a game ball. 2. Description of the Related Art Inks that are used in inkjet printing commonly are water-based resins which contain dye as a coloring agent. Other types of inks, such as solvent-based (i.e., non-aqueous) formulations and ultraviolet (“UV”) curable inks, could be useful in ink jet printing if an appropriate viscosity and surface tension of the ink could be achieved as to be compatible with both the inkjet printing system and the golf ball surface. UV curable inks are quick-curing inks and therefore are advantageous for use in continuous-type processes in which subsequent treatment of an ink-printed substrate is involved. A number of UV curable inks are known. For example, U.S. Pat. No. 4,271,258 discloses a photopolymerizable ink composition containing acrylate resin, methacrylate monomer or oligomer, acrylate monomer or oligomer, photoinitator, and a particular type of an epoxy resin. U.S. Pat. No. 5,391,685 discloses a UV curable ink having an isocyanate compound added thereto. U.S. Pat. No. 5,391,685 contends that the ink disclosed therein is particularly well suited for printing on slightly adhesive plastic bases, such as those made of polyoxymethylenes and polypropylenes. Screen printing on spherical surfaces such as golf balls can be difficult. As a result, pad printing customarily is used for marking golf ball surfaces. However, many of the known UV curable inks are not well suited for pad printing due to difficulties in transferring the ink from a pad to a substrate. Furthermore, UV curable inks that can be pad printed have not been found suitable for use on golf balls. More specifically, when applied to a golf ball, these inks are not sufficiently durable (impact resistant) to withstand multiple blows by a golf club. It would be useful to obtain a highly durable UV curable ink which has favorable pad transfer properties when used for printing an indicia on a surface such as a curved and dimpled surface of a golf ball, and which provides an image having good durability. Ink jet printing is commonly used to form multicolor images on paper for use in advertising materials, computer-generated photographs, etc. There are two fundamental types of ink jet printing: continuous and drop on demand. U.S. Pat. No. 5,623,001 describes the distinction between continuous and drop on demand ink jet printing. In continuous ink jet printing, a stream of ink drops is electrically charged and then deflected by an electrical field either directly or indirectly onto the substrate. In drop on demand ink jet printing, the ink supply is regulated by an actuator such as a piezoelectric actuator. The pressure produced by the actuation forces a droplet through a nozzle or nozzles onto the substrate. It is known to print directly on a game ball surface using a continuous ink jet printer which relies on an electric charge to deliver droplets of ink to the game ball surface. (See JP 8322967-A published Dec. 10, 1996 (Bridgestone) and JP 2128774-A published May 17, 1990 (Bridgestone)). Normally inkjet inks are composed of all monomers due to the need for a low viscosity such as 30 centipoise or less. However, monomers do not provide the necessary durability if the indicia is printed over the top surface of a game ball. The use of oligomers would give more durability, however, the viscosity of oligomers is in the thousands of centipoises. BRIEF SUMMARY OF THE INVENTION The present invention resolves the need for a more durable low viscosity ink jet ink by providing an ink with at least one oligomer and other components which reduce the viscosity. One of the component is a thinning agent, however, the amount of thinning agent can not be too great. The game ball surface may also be plasma treated to provide better adhesion. Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention. DETAILED DESCRIPTION OF THE INVENTION The ink of the present invention is directly inkjet printed on a surface of a game ball using an ink jet printer. An indicia is ink jet printed directly onto the top surface of the game ball. After the image has been applied, the ink is preferably cured with ultraviolet energy. The ink of the invention can be used on curved surfaces of game balls such as golf balls, basketballs, baseballs, softballs, and the like, and is particularly useful on golf balls. It can be difficult to print on the curved and dimpled surface of a golf ball because the dimples tend to distort an image printed thereon and because the plastic cover of a golf ball, which typically is made of ionomer, balata, or polyurethane, has a low surface energy. The low surface energy of the ionomer cover makes adhesion difficult and also causes ink to form into beads when placed on the cover, thereby blurring the printed image. One way in which the present invention overcomes the beading problem is by applying the indicia on the top coat layer of the game ball, which requires that the indicia have good durability. Inks contemplated to be suitable for ink jet printing typically have a viscosity of from about 1 to about 20 cps measured at the temperature of application. The ink is preferably a UV curable ink. To facilitate flow through the ink jet printer, a UV ink suitable for an ink jet printer should incorporate very finely divided pigments (about 0.1 micron or alternatively less than 100 Angstroms), dissolved dyes, or combinations of dyes and finely divided pigments. Flow additives, surface tension modifiers, extra solvent, etc. may be added to the ink formula to improve ink jet printability and prevent clogging of the ink jet printer. The adhesion between the ink and the top coat and/or substrate is contemplated to be sufficiently strong so that the indicia remains substantially intact when the golf ball is used. Standards for image retention vary depending upon the intended use of the golf ball and the degree and frequency of impact that the image is required to withstand. When applied to a golf ball, the ink durability desirably is sufficient that after the ball is subjected to the wet barrel durability test procedure described below, at least about 50% of the surface area of the original image remains, optionally at least about 70%, optionally at least about 80%. Excellent durability results when more than about 85% of the image remains. Although any ink jet printer may be used, two types of ink jet printers specifically contemplated for printing on golf balls are continuous ink jet printers and drop on demand ink jet printers. In a continuous ink jet printer, a stream of ink drops is electrically charged and then deflected by an electronic field either directly or indirectly onto the substrate. In a drop on demand ink jet printer, the ink supply is regulated by an actuator such as a piezoelectric actuator. The pressure produced by the actuation forces a droplet through a nozzle or nozzles onto the substrate. The UV curable ink of the present invention can be used for printing indicia on golf balls, softballs, baseballs, other game balls, as well as other sporting good including, but not limited to, softball and baseball bats, tennis and racquetball rackets, and golf clubs. The ink also can be applied to a variety of materials including, but not limited to, ionomers, polybutadiene, composite materials, metals, etc. As indicated above, the ink comprises a UV curable resin, a coloring agent, such as a pigment or a dye, one or more photoinitiators, and possibly a solvent. A thinning agent that includes a monomer and/or a solvent can be added. A wetting agent also can be included. The coloring agent can be any type of pigment, dye or the like which will withstand UV treatment, i.e., which is not UV labile. Furthermore, the coloring agent is contemplated to permit sufficient passage of UV light through the ink, by any combination of transmission, reflection, or refraction mechanisms, to initiate photocrosslinking. Liquids or powders can be used. One non-limiting example of an ink is a powder which is dispersed in a liquid monomer. Carbon black and iron oxide black are non-limiting examples of suitable pigments for making black inks. Red lake and quinacrydones are non-limiting examples of suitable pigments for making red inks. Blends of different pigments and/or dyes can be used. The uncured ink can contain about 2-60 wt % colorant, alternatively about 5-30 wt % colorant, alternatively about 5-10 wt % colorant. The photoinitiator is selected to respond to the wavelength of UV radiation to be used for photoinitiation. It is also important to consider the color of the ink in selecting the photoinitiator because, as indicated above, it is necessary to the UV light to penetrate the ink composition to initiate the cure. More specifically, penetration is sometimes required in order to cure the portion of the ink which is beneath the surface. Penetration typically is most difficult when black or white pigments are used. Non-limiting examples of photoinitiators to be used in conjunction with black pigment include sulfur-type photoinitiators such as isopropyl thioxanthone, and benzophenone and its derivatives including acetophenone types and thioxanthones. Photoactivators can be used in conjunction with one or more photoinitiators. Non-limiting examples of suitable photoactivators are amine-type photoactivators such as ethyl 4-dimethylamino benzoate. The uncured ink may contain about 0.3-5 wt % photoinitiator, alternatively about 1-4 wt % photoinitiator, alternatively about 3-4 wt % photoinitiator. Blends of different photoinitiators, or photoinitiators and photoactivators can be used. A thinning agent can be added to lower the viscosity of the uncured ink composition or to contribute to impact resistance or flexibility. When a monomer is used as a thinning agent, it optionally can be a photopolymerizable monomer that forms a polymeric structure upon irradiation. In contrast, when solvents are used as thinning agents, they evaporate during curing. The monomer can be a monofunctional, difunctional or multifunctional acrylate. Non-limiting examples of suitable monomers include 1,6 hexanediol diacrylate, butanediol diacrylate, trimethylol propane diacrylate, tripropylene glycol diacrylate and tetraethylene glycol diacrylate. When a solvent is used in the UV curable ink, it typically is a liquid with a fast to moderate evaporation rate which, upon partial evaporation causes the ink to be tacky, and thereby promotes transfer onto and off an ink pad. A solvent also can be the medium in which a photoinitiator is dissolved. The cured ink is contemplated to be sufficiently flexible to exhibit good impact resistance. It is advantageous for the top coat to react with the ink to hold the ink in place, or to have adhesion by hydrogen bonding and/or van der Waals forces. As a non-limiting example, the ink can be used in conjunction with a two-component polyurethane top coat, such as a top coat based on polyester or acrylic polyols and aliphatic isocyanates such as hexamethylene diisocyanate or isophorone diisocyanate trimers. The conditions of UV exposure which are appropriate to cure the ink can be ascertained by one having ordinary skill in the art. For example, it has been found that when a golf ball passes through a UV treatment apparatus at a rate of about 10 ft./min. (about 3 m/min.) at a distance of about 1¼-1¾ inches (about 3.2-4.4 cm) from a UW light source which has an intensity of e.g. 200-300 watts/in 2 (31-47 watts/cm 2 ), (or alternatively 600 millijoules per square centimeter) the indicia may be exposed to UV radiation for no more than a few seconds, optionally no more than about 1 second, optionally no more than about 0.7 seconds. Higher and lower UV lamp intensities, distances, and exposure times may be used as long as the cured ink meets the applicable durability requirements. Excess UV exposure is avoided to prevent degradation of the substrate. The ink of the invention provides for durability sufficient to meet stringent durability standards required for commercial grade golf balls. The durability of the ink can be determined by testing stamped golf balls in a variety of ways, including using the wet barrel durability test procedure. Durability according to the wet barrel durability test procedure is determined by firing a golf ball at 135 ft/sec (at 72° F.) (41 m/s (at 22° C.)) into 5-sided steel pentagonal container, the walls of which are steel plates. The container has a 19½ inch (49.5 cm) long insert plate mounted therein, the central portion of which has horizontally extending square grooves on it which are intended to simulate a square grooved face of a golf club. The grooves have a width f 0.033 inch (0.084 cm), a depth of 0.100 inch (0.25 cm), and are spaced apart from one another by land areas having a width of 0.130 inches (0.330 cm). The five walls of the pentagonal container reach have a length of 14½ inches (36.8 cm). The inlet wall is vertical and the insert plate is mounted such that it inclines upward 30° relative to a horizontal plane away from opening in container. The ball travels 15½-15¾ inches (39.4-40 cm) horizontally from its point of entry into the container until it hits the square-grooved central portion of insert plate. The angle between the line of trajectory of the ball and the insert plate is 30°. The balls are subjected to 70 or more blows (firings) and are inspected at regular intervals for breakage i.e., any signs of cover cracking or delamination). If a microcrack forms in a ball, it speed will change and the operator is alerted. The operator then visually inspects the ball. If the microcrack cannot yet be observed, the ball is returned to the test until a crack can be visually detected. The balls are then examined for adhesion of the ink. The following examples are included to further describe the invention. TABLE ONE parts by wt. Amine modified epoxy diacrylate oligomer 1 30.0 Cyclic trimethyolpropane acrylate monomer 2 25.0 Pentaerythritol triacrylate monomer 3 20.0 Tetrahydrofurfuryl acrylate monomer 4 5.0 Phosphine oxide and alpha hydroxyl ketone 5 7.0 Black pigment in oligomer/monomer 6 10.0 Trimethylbenzophenone and 2.0 methylbenzophenone 7 Defoamer 8 0.5 Surface Additive 9 0.5 Resin Solid Component Total 100.00 Methyl Acetate Ketone 50.0 1 Ebecryl 3703 (2650 cps @ 25° C.). 2 SR531 (15 cps @ 25° C.). 3 SR444 (520 cps @ 25° C.). 4 SR285 (6 cps @ 25° C.). 5 ESACURE KT046. 6 Black Dispersion 9B1076 (30 cps @ 25° C.). 7 ESACURE TZT. 8 BYK-088. 9 BYK-UV3500. From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.
An ink, method of inkjet printing the ink and game ball utilizing the ink are disclosed. The ink preferably comprises a diacrylate oligomer. The ink more preferably comprises an acrylate monomer in an amount ranging from 15 to 40 parts of a solid component of the ink, a diacrylate oligomer in an amount of 20 to 40 parts of a solid component of the ink, a pigment in an amount of 5 to 15 parts of a solid component, and a thinning agent.
2
BACKGROUND [0001] The present invention relates to tools, and in particular relates to a tool having an adjustable handle adapted for positioning in different orientations for comfort, function, and preference. The illustrated tools are hand tools such as for gardening and yard work, but the present inventive concepts are not believed to be limited to only such uses and tools. [0002] Serious gardeners, landscapers, and outdoor yard workers want hand tools that are comfortable. They also want tools that are adjustable for individual preferences and for multiple functions, and further that are ergonomically designed to minimize stress and injury to arms, wrists, and hands. Many hand tools are not designed this way. For example, many trowels and transplanters for planting and maintaining plants are designed so that the blade aligns with the handle. As a result, the worker must awkwardly bend his/her wrist and raise his/her elbow and upper arm when driving the blade into the ground. This causes the user's awkwardly-bent wrist and arm to position his/her bones, muscles, and tendons in a non-aligned and unnatural position, where the stress from digging is unbalanced, poorly directed, and unhealthy. As a result, this can cause arthritis and soreness in the arm, wrist, and hand, particularly where the gardener is not a young person or is not used to substantial physical labor. According to The American College of Rheumatology, “The most common cause of tendonitis and bursitis includes injury . . . due to bad posture, or uses of the affected limb in an awkward position.” (website “www.rheumatology.org”, ©2000 American College of Rheumatology.) Compounding this problem is the fact that many handles are not ergonomically designed for grasping, but instead are designed using traditional cylinder shapes and sizes that are not easily grasped, are not optimally suited to assist in holding onto the tool when driving the head into the ground or when wet, and are not designed for optimal ergonomic use. [0003] Though optimal alignment and positioning of the wrist is important, the optimal handle position on a hand tool may vary for different users and/or for different jobs. However, it is not economical for the retailer to carry multiple versions of the same tool, nor for the homeowner to purchase a different tool for each job. Hence, it is desirable to provide a tool that can be adjusted to an optimal position to meet different user preferences, different user needs, and different jobs. [0004] Though adjustability is important, so is the ease of adjustment. Any adjustment should preferably be easily made, so that the user does not have to struggle to accomplish it. Further, the adjustment preferably should not require separate parts and pieces, since the parts and pieces can get lost. Also, the adjustment should be able to be done without the need for other tools, and should not take much time, since the worker wants to get at his/her task, and not spend considerable “getting ready to get started” time. Another problem with hand tools, particularly those used in gardening and yard work, is that the tools quickly become dirty and corroded, with dirt and debris being packed into crevices and clearances needed for allowing the adjustment. [0005] The tool industry is highly competitive, and accordingly, any tool design must be cost-competitive to manufacture and assemble, durable and long-lasting in use, and ergonomically designed for optimal user comfort. [0006] Accordingly, a hand tool is desired solving the aforementioned problems, and having the aforementioned advantages. SUMMARY OF THE PRESENT INVENTION [0007] One aspect of the present invention includes an adjustable tool comprising a tool head configured for doing at least one particular task, a handle, and an internally-positioned adjustment mechanism adjustably connecting the tool head to the handle. The adjustment mechanism is configured to support selective angular adjustment of the tool head relative to the handle between at least two different use positions and to hold the tool head in a selected one of said two different use positions. [0008] Another aspect of the present invention includes a garden hand tool comprising an elongated handle adapted to receive a person's hand. A tool head extends substantially in-line with the handle and is connected to the handle. The tool head has an active surface shaped for effective use and also has a back surface. The handle defines a direction extending at an angle of at least about 15° away from the active surface toward the back surface to promote an ergonomic wrist position when using the tool. [0009] Another aspect of the present invention includes an adjustable tool comprising a tool head. A handle is adjustably connected to the tool head, the handle including a recess adapted to ergonomically receive and support a user's thumb and fingers so that pressure can be readily communicated through the handle to the tool head while using the tool. A release button is movable between a released position and a latched position for fixing the tool head to the handle in a selected adjusted position. The release button is located near the recess where the release button is easily operated by the user to adjust the tool head. [0010] Another aspect of the present invention includes an adjustable tool comprising a tool head, and a handle adjustably connected to the tool head. The tool head is adjustable, at least, between a first position where the tool head extends generally parallel to the handle but is offset laterally from being directly in line with the handle, and a second position where the tool head extends at an angle to the handle but is supported generally in line with the handle whereby when the tool head is in the first position is usable in a forward motion to dig into and lift, and when in the second position is usable in a pulling motion to scratch and claw. [0011] It is an object of the present invention to provide a tool that is easily and readily adjustable, so that the tool's working end can be used for many different functions. For example, a tine can be arranged parallel a handle for use as a fork, or can be arranged at an angle to be useful by dragging as a cultivator. Also, for example, a trowel can be arranged parallel a handle for use as a shovel-like digger, or can be arranged at an angle for use as a V-hoe. Also, for example, a transplanter blade can be arranged parallel a handle for transplanting, or arranged at an angle for bulb planting. In each of these different uses, the handle can be positioned at an ergonomic angle to reduce stress on a user's wrist and forearm. [0012] These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. BRIEF DESCRIPTION OF DRAWINGS [0013] FIGS. 1-1B are perspective, plan, and side views of a hand tool embodying the present invention, FIG. 1 showing the handle adjusted to an approximate 30° angled position (solid lines), and showing various adjusted positions of the handle (in dashed lines); [0014] FIG. 2 is an exploded view of a kit including the handle of the tool of FIG. 1 , and including three tool heads (including the tool head shown in FIG. 1 ); [0015] FIGS. 3-4 are side and plan views of the tool head shown in FIG. 1 ; [0016] FIGS. 5-6 are fragmentary perspective views of the handle-connecting end of the tool head of FIG. 3 ; [0017] FIGS. 7-9 are top, side, and end views of the handle internal structure of FIG. 1 ; [0018] FIG. 10 is a cross section taken along the line X-X in FIG. 7 ; [0019] FIGS. 11 and 11 A are left and right perspective views of the tool-connecting end of the handle structure of FIG. 7 ; [0020] FIG. 12 is an exploded view of the handle, showing the handle internal structure of FIG. 7 and also the sock-like resilient handle covering; [0021] FIGS. 13-14 are longitudinal and transverse cross sections taken through an assembly of the handle components of FIG. 12 , FIG. 14 being taken about midway along the handle; [0022] FIGS. 15-19 are right perspective, left perspective, end, side, and top views of the release button shown in FIG. 2 ; [0023] FIGS. 20-21 are perspective views showing an ergonomic best use ( FIG. 20 ) and an ergonomically “less-preferable” use ( FIG. 21 ) of the present tool; [0024] FIGS. 22-24 are perspective, side, and plan views of the second tool head shown in FIG. 2 ; [0025] FIGS. 25-27 are perspective, side, and plan views of the third tool head shown in FIG. 2 ; and [0026] FIGS. 28-29 are perspective views of the hand tool including the third tool head shown in FIG. 25 , the tool head in FIG. 28 being adjusted to have tines oriented generally parallel the elongated handle but where they are offset laterally from being aligned with the elongated handle (for jabbing and digging into the ground), and the tool head in FIG. 29 being adjusted to have its tines extend at an angle to the elongated handle but where they are supported generally in line with an end of the elongated handle (for scratching, clawing and cultivating the ground). [0027] FIGS. 30-31 are side views showing use of the tine in FIG. 28 as a fork ( FIG. 30 ) to dig and as a dragged cultivator ( FIG. 31 ); and [0028] FIGS. 32-33 are side views showing use of the transplanter blade in FIG. 22 as a transplanter tool ( FIG. 32 ), or as a dragged cultivator ( FIG. 33 , solid lines) or as a bulb planter ( FIG. 33 , dashed lines). DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0029] A hand tool 30 ( FIG. 1 ) includes a trowel/V-hoe tool head 31 , and an angularly adjustable handle 32 . The handle 32 comfortably receives a user's hand, with the user's thumb or forefinger located at an adjustment mechanism comprising a release button 33 with teeth thereon. The release button 33 is biased with a spring 34 ( FIG. 2 ) and includes teeth 35 that inter-engage with teeth 36 on the tool head 31 to provide a positive latching mechanism to hold a selected angular position. A water-impermeable resilient cover 37 covers the handle internal structure 38 and the release button 33 in a glove-like manner, preventing dirt from entering the button area to prevent jamming of the latching mechanism. Different tool heads can be provided, such as the illustrated transplanter/bulb planter tool head 31 A and the cultivator/garden fork tool head 31 B, to make a reconfigurable tool kit. [0030] The trowel/V-hoe tool head 31 ( FIGS. 3-6 ) is preferably made of aluminum or similar durable material suitable for the intended use. The trowel/V-hoe tool head 31 includes a working end 40 that is generally elongated, triangularly-shaped, and relatively flat, but with a transverse cross section that is slightly dished. The working end 40 has curvilinear edges 41 forming a point 42 . Further, indicia such as depth markings 43 are formed into the working end to facilitate its accurate use. The “front surface” (i.e. the surface having the depth markings 43 ) is referred to as the “active surface” herein, because it is the surface most actively used to carry dirt and material. Also, it is readily visible to a user, such as a gardener, while he/she is doing yard and outdoor work. The relation of the plane of the active surface to the handle is very important. When this angle is about 30°, it aligns the bones in a user's forearm 90 so as to minimize and reduce stress on the user's wrist 91 , when digging while working on one's hands and knees for doing yard work. Surprisingly and unexpectedly, I have not found garden tools with this angle as defined. Angles other than 30° may be beneficial for some yard work/tasks, but 30° appears to work best for digging,“jabbing”, and similar work. [0031] The handle-connected end 44 includes a stem 45 and a disk-shaped flange 46 with flat sides that extend parallel the stem 45 , and that define a thickness. The disk-shaped flange 46 has a thickness and includes an arcuate edge flange 47 that comprises about 20%-25% of its thickness, a row of teeth 36 that form about 50%-60% of the thickness along an outer edge on one side of the flange 46 , and an arcuate channel 48 forming about 20%-25% of the thickness along an outer edge of the other side of the disk-shaped flange 46 opposite the teeth 36 . The illustrated teeth 36 have an angled outer corner surface 49 so that the mating teeth 35 on the release button 33 do not have to move transversely as great of a distance in order to disengage the teeth 36 . The illustrated teeth 36 are seven in number, although more or less can be used. In the illustrated teeth 36 , one is located approximately at a center line of the tool head 31 , two teeth 36 are located above the center tooth and four teeth are formed below the center tooth. However, it is contemplated that more or less teeth can be constructed, and further, that different shapes of teeth can be utilized. [0032] The handle internal structure 38 ( FIGS. 7-10 ) includes a frame portion 51 with channels 52 formed therein to reduce a mass of the frame portion 51 . Further, the channels 52 facilitate cooling and die-casting by eliminating large, thick sections of material. The handle portion 51 is designed for optimal ergonomics and includes a reduced section or circumferential recess 53 at its tool-engaging end for comfortably receiving a person's thumb and first finger. Further, an enlarged section 54 is located at the tool-receiving end and includes an outwardly-extending surface leading to a ball-shaped end 55 of the handle internal structure 38 . The ball-shaped end 55 includes a pair of space-apart flanges 56 and 57 defining a cavity 58 therebetween with the lip 59 extending around opposing ends of the cavity 58 . The cavity 58 is shaped to receive the disk-shaped flange 46 and includes holes 60 and 61 in flanges 56 and 57 that align with a hole 62 in the flange 46 for receiving a pivot pin 64 ( FIG. 2 ). When the tool head 31 is assembled to the handle internal structure 38 by the pivot pin 64 , the lip sections 59 ′ and 59 ″ ( FIG. 10 ) limit the angular adjustment of the handle on the tool head 31 . A hole 66 is formed at the base of the flange 56 and extends transversely for receiving the release button 33 . A second hole 67 is formed overlapping with the hole 66 for receiving the spring 34 ( FIG. 2 ) (see FIG. 10 ). One or more recesses or channels 68 and/or 68 ′ are formed around the flanges 56 and 57 outboard of the holes 60 and 61 for providing a lip along with the end surfaces on the flanges 56 and 57 for more securely receiving the cover material of the cover 37 as described below. [0033] The cover 37 ( FIG. 12 ) is a thick-textured flexible cover (such as vinyl or PVC) having a varied thickness of about 0.03 inches to 0.180 inches wall thickness. (It is noted that the cover is generally thinner around its button area.) The cover 37 is flexible and configured to slip onto the handle's internal structure 38 with a glove-like or sock-like motion. The cover 37 ( FIG. 13 ) includes an annular lip 70 with a tip 71 shaped to fit into the channel 68 and further includes a flexible tip 72 shaped to flex and be stretched tight against the outer surfaces of flanges 56 and 57 ( FIG. 12 ) and into channel 68 ′ for good sealing to prevent dirt, debris, and moisture from entering the adjustment structure area. The cover 37 includes ribs 74 ( FIG. 14 ) that engage the handle internal structure 38 , such as in recesses 52 to orient the handle cover 37 in a particular rotational position. The handle cover 37 includes lines (formed by a recession or a protruding ridge) 76 ( FIG. 12 ) that correspond to the button 33 . However, the handle cover 37 is continuous and there is no break in the material around the button cover area 77 . [0034] The release button 33 ( FIGS. 15-19 ) (sometimes called a “latch member” herein) includes a button head 78 with a top surface 79 that generally matches the recess 53 formed around the tool-engaging end of the handle internal structure 38 . However, it is noted that the outer surface of button 33 does not have a circumferential radius, but instead is linear when viewed from a side as shown in FIG. 18 . This provides a little relief above the button 33 relative to a user's hand, which helps prevent inadvertent pressure on the button 33 , which could cause inadvertent release of teeth 35 from teeth 36 . The release button 33 further includes a shaft 80 shaped to fit mateably within the hole 66 . A side of the shaft 80 ( FIG. 16 ) includes a channel 81 shaped to receive the spring 34 , with the spring 34 being positioned in the hole 67 at the same time as the release button 33 is positioned in the hole 66 . A step 84 ( FIG. 18 ) limits a depth that the release button 33 can be depressed by engagement of the step 84 and compressed spring 34 with a bottom of the hole 66 in the handle internal structure 38 . As shown in FIG. 18 , the release button 33 includes teeth 35 with an angled surface 86 formed by a cutaway corner. The angled surface 86 corresponds with the angled surface 49 on the teeth 36 to reduce a distance that the release button 33 must be moved to release the teeth 35 from the teeth 36 . Three teeth 35 are shown on the release button 33 , however, more or less teeth can be used. Further, it is contemplated that other engagement and latching mechanisms can be used such as undulating or roughened surfaces, saw-teeth-type arrangements, pin-to-hole arrangements, and the like. [0035] The location of the button 33 is believed to be novel and patentable-both in its forward location in the handle 32 , and in its location in recess 53 (which is where a user is grasping while using the tool). I spent significant time trying to design away from this location and position, until I realized the advantages and usefulness at this location . . . and realized that it did not have to result in inadvertent and/or accidental release of the latching adjustment mechanism. [0036] To assemble the present construction, the release button 33 and spring 34 are arranged within the handle internal structure 38 and depressed sufficiently enough to allow the tool head 31 to be positioned. Thereafter, the pivot pin 64 is engaged in the holes 60 , 62 , and 61 . If desired, the pivot pin can be frictionally, permanently press-fit into position. Alternatively, it is contemplated that the pin 64 can be made removable such as by providing a threaded end and screwdriver-receiving head. Thereafter, the cover 37 is pulled onto the handle internal structure 38 , with the lip 70 / 71 / 72 being pulled into position on the enlarged section 54 / 56 / 57 . This assembly allows manufactures an optimal sequence where one handle can be assembled to any one of several different tool heads, thus reducing inventory. [0037] In use, an operator can press on the button cover area 77 , which is aligned with the release button 33 to depress the release button and cause the teeth 35 on the release button to disengage from the teeth 36 on the tool head 31 . This allows the tool head 31 to be angularly adjusted about pivot pin 64 until the ends of the channel 48 engage mating portions of the release button 33 to limit angular position. As shown in FIGS. 1 and 1 B, the illustrated hand tool 30 is angularly adjustable between six different positions, one being a centered position, three being above center at 15° increments, and two being below center at 15° increments. It is contemplated that the different positions may be equal angular spacings or can be different spacings such as at particularly ergonomic positions for specific tasks. For example, note FIG. 20 where the tool head 31 is adjusted to an angle of about 30° relative to the handle 32 , in which case, the bones in the user's forearm 90 is generally aligned with the tool head 31 for reducing stress on the user's wrist 91 . As shown in FIG. 21 , a linear arrangement where the tool head 31 is aligned with the handle may not position the wrist 91 at an acceptably straight position. On the other hand, if the tool 30 is being used to pry, the arrangement in FIG. 21 may be acceptable. [0038] A transplanter/bulb planter tool head 31 A ( FIGS. 2 and 22 - 24 ) is not totally dissimilar to the trowel/V-hoe head 31 . However, the transplanter/bulb planter tool head 31 B includes a narrower, longer body, and a relatively sharper tip. Further, the tool 31 A ( FIG. 22 ) includes a serrated edge 95 , which is useful for cutting roots and small branches, or for outlining flower beds. Other optimal shapes of the tool head can be constructed for shoveling and digging in different soils. The illustrated tool head 31 A is particularly useful for planting bulbs because of the inch-depth markings, which allow the user to easily see a digging depth ( FIG. 33 ). Also, the angularly-adjustable handle allows for a more natural hand position to be selected. [0039] A cultivator/garden fork tool head 31 B ( FIGS. 2 and 25 - 27 ) includes a stem 100 leading to three tines 101 . Each tine 101 includes a root section 102 that extends from the stem 100 in generally a same vertical plane as the stem 100 . The outer end 103 of each tine extends at about a 35°-45° angle to the root section 102 . (See FIG. 26 .) By adjusting the angle of the handle, the tines 101 can be positioned at different angles optimally suited for different uses. In particular, in the adjustment shown in FIGS. 28 and 30 , the tine outer ends 103 extend generally parallel the handle internal structure 38 (see lines 106 and 107 ), but the outer ends 103 of tines 101 are offset from the handle 32 B. This creates an optimal ergonomic condition well-suited to allow a user to dig into and lift the soil with minimal stress to the tendons and muscle in a user's wrist and forearm. It is noted that all of the outer ends 103 of tines 101 are located in the same plane, and further they include a pointed tip facilitating the jabbing and digging action. Contrastingly, by adjusting the tines 101 in an opposite direction ( FIGS. 29 and 31 ), the outer ends 103 of tines 101 can be positioned at an angle to the handle internal structure 38 . This lets the user ergonomically use the tool to scratch, claw, and cultivate soil. [0040] It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
A tool includes different tool heads, and an angularly adjustable handle. The angular adjustability allows better ergonomic body posture during use, thus reducing stress and injury, and also allows multiple functions for each tool. The handle comfortably receives a user's hand, with the user's thumb or forefinger located at a release button. The release button is spring-biased and includes teeth that inter-engage with teeth on the tool head to latchingly hold a selected angular position. A resilient cover encases the handle and the release button, preventing dirt from entering the button area to prevent jamming. The covering slips onto the handle and includes an annular lip that stretches over an end surface to retain the covering on the handle. The cultivator includes tines that, by adjusting an angle of the handle, extend in a direction parallel the handle but offset therefrom, or that extend at an angle to the handle.
1
PRIORITY [0001] This application is a non-provisional application which claims the priority date from the provisional application entitled FlexStayK Two-Piece Damage Resistant Marking Stake filed by Scott A. Morton, Naomi Morton-Knight and Craig Knight on Jan. 27, 2005 with application Ser. No. 60/647,527, the disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention generally relates to an improved marking stake and more particularly, to a two-piece damage resistant marking stake for effectively marking a location even when damaged or partially removed from the ground. [0004] 2. Background Information [0005] Wooden stakes ranging from 12 inches to 48 inches in length are currently used in the majority of survey and location marking applications. Some plastic stakes are available as a direct replacement for wooden stakes. The higher cost of the plastic stakes frequently prevents or limits their use. Surveys for roads, pipelines and other such facilities are frequently carried out in harsh environments with considerable effort taken to effectively mark a position. In order to be effective, the stakes must remain positioned so that the marked position and attached information may be referenced in subsequent activities. [0006] In many cases, surveying activities are done in areas where livestock is present or where other activities are taking place. Animals such as cows and horses frequently uproot or displace the stakes by chewing on, stepping on or rubbing on them. This problem is particularly acute in areas where cattle are present. Because cattle are used to contact and interaction with humans, they regularly follow behind a survey crew, breaking and/or pulling up survey stakes almost as soon as they are placed. The cattle chew on marking stakes and ribbons, pull them from the ground and rub on the stakes, thereby breaking them and/or obliterating the survey marking. In some cases, the stakes may simply be trampled resulting in the location sensitive marker being moved, broken or otherwise rendered unreadable. When stakes, ribbons, or other markers are broken, the survey staking must be repeated multiple times for a single project, incurring considerable additional expense. [0007] There is a need in the art for a marking stake that will continue to mark a location despite being abused, broken, displaced, removed, or otherwise damaged as described above. [0008] Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. SUMMARY OF THE INVENTION [0009] One embodiment of the present invention is a device for marking a location. The device coming in two separate pieces, namely a ground stake and a marking post. The ground stake configured for insertion into a ground surface. The marking post configured for attachment to the ground stake. The post is preferably removable from the stake so that when livestock are present, if they uproot or displace the marking post portion of the device, the ground stake remains in the ground still marking the location. If a survey crew or other individual is at the marking location after the post has been removed, they can replace the post (or insert a replacement post) to return the device to its full functionality. [0010] The preferred ground stake having an abutment collar configured for abutting the ground surface, the abutment collar configured for allowing the stake to be driven into the ground surface but remaining clearly visible. The abutment collar further having a planar surface with a hole defined there through, this hole aligned with an internal passageway into a connection body. It is preferred that that abutment collar's upper facing surface have at least one planar writing surface for allowing marking information and data to be written thereupon. [0011] The connection body having an open end (cooperating with the hole) extending to a closed end thereby defining a passageway there-between. Within the passageway is preferably a plurality of protrusions/flanges/tabs/teeth/ridges/etc., configured for grasping the marking post (when inserted therein). It is further preferred that at least one orifice extending from the passageway to an exterior surface of the body for allowing air to escape from the passageway when a first end of a post is inserted into the passageway be provided. [0012] The ground stake further comprising a ground engagement portion connecting to one or both of the abutment collar/connection body. This ground engagement portion comprising at least one pointed distal end for insertion into a ground surface. Preferably, the ground engagement portion comprises at least one retaining ridge extending there-from for fixing the ground engagement portion within the ground surface. [0013] The marking post having a first end extending to a second end. The first end configured for insertion into the passageway through the passageway open end and the hole in the abutment collar. It is preferred that the post has an exterior surface configured for being grasped by the passageway's interior protrusions. It is also preferred that the post have at least one planar writing surface for allowing marking information and data to be written thereupon. [0014] The purpose of the foregoing Abstract is to enable the United States Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. [0015] Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description wherein we have shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by carrying out our invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the drawings and description of the preferred embodiment are to be regarded as illustrative in nature, and not as restrictive in nature. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIG. 1 is an exploded, perspective (partial cut-away) view of one embodiment of the present invention. [0017] FIG. 2 is an un-exploded, perspective (partial cut-away) view of the embodiment of FIG. 1 . [0018] FIG. 3 is a cross-sectional view of a second embodiment of a ground stake/socket of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0019] While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims. [0020] The present invention relates to an improved marking device (marking stake) and more particularly, to a two-piece damage resistant marking stake for marking a location despite damage or partial removal from the ground. The present invention allows for a location to be effectively marked despite damage or removal as described above. [0021] FIGS. 1 and 2 show cut-away views of a first embodiment of the present invention (marking stake 100 ). FIG. 1 showing an exploded state, whereas FIG. 2 shows an unexploded (in-use) state. In the preferred embodiment, the present invention comprises these two main components: the ground stake (“ground socket”) 102 and the marking post (“elastomeric shaft”) 104 . FIG. 3 shows a cross-sectional view of a second embodiment of a ground stake 202 of the present invention. [0022] The first component of the present invention 100 is the ground stake 102 . The ground stake 102 having a ground engaging portion 136 configured for being driven into the ground until (preferably) the abutment collar (top flange) 115 is generally flush with the ground surface. Being flush with the ground surface, the flange 115 visually demarks the location of the ground stake 102 attached there-to. Additionally, because the flange 115 is generally flush with the ground it is not easily removed by an animal, the elements and/or passing machinery. Because the diameter or shape of the flange 115 is larger than the diameter or shape of the ground engagement portion extending there below, the flange 115 prevents the ground stake 102 from being driven into the ground so far that it is no longer visible. [0023] The ground stake 102 would most likely be molded of an impact resistance plastic material such as acrylonitrile-butadiene-styrene copolomers (ABS) or a polycarbonate/ABS alloy and would be colored a fluorescent orange, yellow, blue, red, etc., color similar to current survey marking paint and flagging. While these are the preferred materials of manufacture, obviously other materials would likewise be suitable. [0024] The ground stake 102 has an upper portion connecting to the aforementioned flange 115 . A pointed distal end (tip) 120 is provided at an end opposite the flange 115 of the ground stake 102 . The tip 120 is formed and/or shaped to a point to more easily allow the ground stake 102 to be inserted, screwed, vibrated, pressed and/or driven into the ground. [0025] The ground stake 102 having a connection body 110 configured for connecting with the marking post 104 . The outer surface of the ground stake may be smooth (as shown in FIG. 3 ) if soil friction conditions are sufficient to resist extraction by livestock, or may define ground retaining ridges 140 (as shown in FIGS. 1 and 2 ) for preventing the ground stake 102 from being easily removed once inserted into the ground. The ground retaining ridges 140 are preferably one-way ridges or notches so that it is not difficult to pound, drive or otherwise insert the socket into the ground. Other such mechanisms known in the prior art could likewise be used to accomplish this same purpose including but not limited to threading, ring shanks, etc. [0026] Installation of the ground stake 102 (insertion into the ground) may be accomplished in various manners. One installation method allows a special slide hammer designed with a pin to fit into a passageway (“socket cavity”) 130 defined within the connection body 110 . The passageway 130 having an internal passageway open end 116 and an internal passageway closed end 114 . Hammering this slide hammer resulting in the ground stake 102 being driven into the ground. When the desired depth is reached, the pin would thus be removed from the passageway. The ground stake 102 may also be inserted by manually pushing it into the ground or by hammering the flange end of the ground stake 102 . [0027] In the preferred embodiment of the present invention, the flange 115 of the ground stake 102 is preferably large enough in shape/diameter to legibly write generally used survey marking information/data upon, for instance upon a planar surface 112 . [0028] Other manners of applying such data could likewise be provided, from stickers, to stamps, to RFID, etc. In one example, the top surface of the flange itself comprises a planar writing surface upon which a user could write using a permanent marker. The benefit of doing so is that if the marking post (which traditionally is the location of such data) is ever removed from the ground stake, data marked upon the planar writing surface allows a subsequent user to obtain useful marking information from the ground stake 102 itself. [0029] The second component of the present invention 100 is the marking post 104 . The marking post having an elastomeric shaft 150 that is configured for insertion into the socket cavity 130 of the ground stake 102 . The shaft 150 is preferably flexible so that it will not break if driven over, stepped on, or in the event of other abuse. The shaft 150 would most likely be molded from polyurethane or polypropylene with a durometer A rating in the 80 to 95 range. [0030] The socket cavity (“passageway”) 130 of the ground stake 102 is preferably cylindrically shaped or tapered for allowing for increasing tightness as the shaft 150 is inserted further within the socket cavity 130 . The ground stake 102 preferably further defines one-way retaining ridges (or other protrusions, flanges, etc) 160 , 260 within the socket cavity 130 that grasps the shaft and thus prevent the shaft 150 from being easily extracted once inserted. These retaining ridges 260 may take the form of a tapered buttress screw thread as shown in FIG. 3 to facilitate removal of the molding core for the socket and to allow adjustment of the removal pull-out force for the elastomeric shaft 150 by how far the shaft 150 is screwed into the socket threads, may take the form of concentric ridges 160 as shown in FIGS. 1-2 , etc. [0031] Threaded retaining ridges 260 effectively allow a user to select a shaft 150 removal force by screwing the shaft against the retaining ridges 260 based on elements such as soil quality, animals present, and other environmental and external conditions. In the embodiment shown in FIGS. 1 and 2 , the one-way retaining ridges 160 are ribbed ridges defining the edges of the socket cavity 130 . Other types of connections are likewise envisioned. [0032] The ground stake 102 may also define one or more slits 180 that extend from the socket cavity 130 to the outer surface of the ground stake 102 . This allows air within the socket cavity 130 to be displaced to outside the ground stake 102 so that air is not compressed within the ground stake 102 creating a rebounding force that would tend to push the shaft 150 out of the ground stake 102 as a user inserts the shaft into the socket. Additionally, this allows the outer surface area of the ground stake 102 and the shaft 150 to be more closely matched creating a much tighter fit. The elastomeric shaft 150 may also be tapered to match the taper of the tapered buttress screw threads of the retaining ridges 160 in the socket allowing for a much tighter fit when a user determines that conditions warrant. The marking post 104 is preferably installed by pushing the end of the shaft 150 into the passageway 130 by hand and turning the shaft to engage the buttress screw thread retaining ridges. [0033] The elastomeric shaft 150 preferably comprises or connects with a planar writing surface 170 . In the embodiment shown in FIGS. 1 and 2 , this writing surface being a paddle. The paddle having a flat shaped writing area or planar surface on which survey marking information may be written. In one embodiment, the entire elastomeric shaft 150 would be molded from the same fluorescent orange, yellow, blue, red, etc., colors as the ground stake 102 . Different colors of shafts 150 and sockets 110 could be mixed and matched for specific applications as decided by a user. [0034] In the preferred embodiment, the extraction force needed to remove the shaft 150 of the marking post 104 from the ground stake 102 is preferably less than the extraction force of the ground stake 102 from the ground, so that if the shaft 150 is removed, the ground stake 102 remains in the ground to mark the survey point. It is preferred that the ground stake 102 be brightly colored to allow the ground stake 102 to be more easily located if the elastomeric shaft 150 is removed from the socket. Additionally, the elastomeric shaft 150 is more easily retrieved because of its bright color. [0035] FIG. 3 showing a second embodiment of the present invention, this figure showing a second embodiment of a ground stake 202 . This embodiment having the same general features as the embodiment of FIGS. 1-2 (i.e., abutment collar (top flange) 215 , pointed distal end (tip) 220 , connection body 210 , internal passageway (“socket cavity”) 230 , internal passageway open end 216 , planar surface 212 , internal passageway closed end 214 , ground engaging portion 236 , retaining ridges 260 ). Of note in this embodiment is that the retaining ridges 260 are a screw threading style (for allowing the shaft to be screwed therein vs. the concentric flanges 160 shown in FIGS. 1-2 for grasping the shaft. Further, in this embodiment the exterior surface is smooth and does not have the retaining ridges 140 shown in FIGS. 1-2 . [0036] Radio frequency identification (RFID) tags may be attached to the ground stake 102 and/or the marking post 104 to aid in locating these parts if they do get separated, and to store survey or other information. Additionally, a user could program information into the RFID tags while in the field or at a base location. This information could include any information relating to the survey point, name and individual assigned to the project, contact information, etc. [0037] The invented marking stake 100 can be used for many different applications and in many different manners. In one example installation, once a user has found a specific location that he needs to mark, he selects a color of his choice. He then drives the flanged socket into the ground at the desired location. The manner the flanged socket is driven into the ground will depend on the soil type and user preference. The socket is preferably driven into the ground until the flange is flush with the ground. At this point, or later, the user may elect to write survey, location, or other information/data on the flange of the socket. [0038] The user then selects a marking post. At this point, or later, the user may elect to write survey, location and/or other information/data upon the paddle (planar writing surface) of the marking post. The user would then decide what he would like the shaft extraction force to be. The farther the user twists the elastomeric shaft into the shaft cavity and corresponding buttress screw thread the greater the shaft extraction force will be. The user will likely elect to choose an extraction force that is less than the socket extraction force so that if an animal were to pull on the shaft, it would come free before the socket would come free from the ground. However, a user could make the shaft extraction force anything he chooses. When a user needs to remove the elastomeric shaft from the socket, he will simply twist it in the opposite direction to remove it from the socket. [0039] Once a user has connected the socket and the elastomeric shaft, he may return at anytime to gather more information or alter or move the marking stake as needed. In some cases, animals may have tugged the elastomeric shaft from the socket. In that instance, a user may visually scan the general location to find the fluorescent shaft and flange wherever they may be. Sometimes the shaft and socket will not be readily visible because of plants, weeds, dirt, rocks and other visual obstructions. In those instances, the user can use the RFID tags to find the parts of the marking stake. Additionally, at any point during the marking process, the RFIDs of the shaft and socket can be programmed with information or used to gather the preprogrammed information as needed. [0040] The present invention may further include an admixture treatment on at least a portion of the exterior surface of the ground stake/socket for increasing the holding power of the stake in the ground. This would be very similar to cement coated nails, where the coating “melts” under the influence of friction during insertion and “glues” the nail into the wood. A ground stake with an admixture coating would function similarly with the coating “gluing” the stake within the soil. To apply a coating to the stake, it (preferably the ground engagement portion) would be dipped, sprayed, or brushed with a coating such as rosin, shellac, or a synthetic resin, for example, vinyl or acrylic. Other types of coatings are envisioned. When the stake is driven into the ground, the heat from friction softens the thin film of resin on the stake shaft, which then adheres to soil particles and significantly increases the extraction force of the stake. [0041] While there is shown and described the present preferred embodiment of the invention, it is to be distinctly understood that this invention is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the invention as defined by the following claims.
A device for marking a location. The device coming in two separate pieces, namely a ground stake and a marking post. The ground stake configured for insertion into a ground surface. The marking post configured for attachment to the ground stake. The post is preferably removable from the stake so that when livestock are present, if they uproot or displace the marking post portion of the device, the ground stake remains in the ground still marking the location. If a survey crew or other individual is at the marking location after the post has been removed, they can replace the post (or insert a replacement post) to return the device to its full functionality.
6
BACKGROUND OF THE INVENTION Benzaldehyde is an important starting material in various chemical syntheses, including those relating to the synthesis of scents and flavors. In these applications the benzaldehyde is often required to have a high degree of purity, but unfortunately crude benzaldehyde, and especially benzaldehyde prepared by the oxidation of toluene with a gas containing molecular oxygen will contain certain impurities that are very difficult to remove. One very significant problem presented by these impurities is that it is particularly difficult to obtain a product from such crude benzaldehyde that will satisfy olfactory specifications. Furthermore, the presence of such impurities also causes a quite rapid discoloration of the benzaldehyde during storage. Such discoloration will occur even at very low concentrations of the impurities, such as a few p.p.m. by weight. It is of interest to note that benzyl hydroperoxide is not normally present in the crude benzaldehyde in any significant quantities. One suggested solution which appears in Japanese Pat. Publication No. 24,467/74 is to purify the crude benzaldehyde by treating it with an aqueous solution of sodium hydroxide. However, this method of purification does not give satisfactory results, as shown, by the fact that benzaldehyde treated in this manner is still found to discolor quite rapidly. One method which does give satisfactory results is that disclosed in U.S. Pat. application Ser. No. 952,609 filed Oct. 18, 1978. The process disclosed in that application employs an oxidizing agent and a distillation step to accomplish the purification. Still another method is disclosed in a sister application to the present application filed on the same date in the United States Patent Office. In that application, the difficulty was in trying to purify an impure benzaldehyde in the presence of water. That problem was overcome by treating the impure benzaldehyde simultaneously with water and a metal less noble than hydrogen followed by a distillation step. DESCRIPTION OF THE INVENTION The present invention provides an additional process for purifying the crude benzaldehyde. According to the process of the present invention, pure benzaldehyde is obtained by treating impure benzaldehyde, which contains no significant quantities of benzyl hydroperoxide, with hydrogen in the presence of a suitable hydrogenation catalyst to achieve hydrogenation of the impurities without significant hydrogenation of benzaldehyde. This is followed by a distillation step. One advantage of the process of the present invention is that the loss of benzaldehyde is relatively small, usually in the range of about 1 to 5% by weight, while still producing benzaldehyde with satisfactory olfactory characteristics even if the crude benzaldehyde was prepared by the oxidation of toluene. Hydrogenation catalysts which are suitable for use in the process of the present invention are the known hydrogenation catalysts such as the metals of Group VIII of the periodic table of elements, e.g., palladium, nickel, platinum, irdium or rhodium. The catalyst may be placed on a typical carrier such as carbon, aluminum oxide, silicon or titanium oxide. Catalyst which are particularly suitable for use in the process of the present invention are Raney nickel and palladium on carbon. Preferably, the catalyst employed will be used in quantities varying from about 0.5 to about 200 mgat of active substance per kg of benzaldehyde. In particular, quantities of catalyst in the range of from about 1.0 mgat to about 100 mgat of active substance per kg of benzaldehyde may be advantageously used in the present process. Normally, the amount of hydrogen taken up in purification of the impure benzaldehyde will range from about 1 to about 100 liters of hydrogen (N.T.P.) per kg of benzaldehyde per hour. Often, the amount of hydrogen taken up will be in the range of about 3 to about 40 liters of hydrogen (N.T.P.) per kg of benzaldehyde per hour. The contacting of hydrogen with the impure benzaldehyde can be done in a number of ways including, for example, by stirring the benzaldehyde in a hydrogen atmosphere or by bubbling hydrogen through or over the impure benzaldehyde. The duration of the hydrogenation process is usually between about 0.25 and about 4 hours and is preferably in the range of from about 0.5 to 2 hours. The use of larger quantities of catalyst and/or of larger excesses of hydrogen eventually during longer treatment periods is acceptable but offer no significant advantages. Treatment of the impure benzaldehyde with hydrogen in the presence of a suitable hydrogenation catalyst is preferably, effected at a moderate temperature in order to suppress hydrogenation of the benzaldehyde. A suitable temperature range is between about 270 and about 400 K. Particularly suitable are temperatures between about 285 and about 340 K. The reaction pressure should be such that the liquid phase is maintained. A suitable reaction pressure is, for example, between about 100 and about 1000 Kpa. A particularly suitable reaction pressure is in the range of about 100 and about 500 kPa. The distillation subsequent to the hydrogenation treatment may be carried out at atmospheric or elevated pressure, but is preferably conducted at a reduced pressure, for instance, a pressure in the range of between about 2kPa and about 35 kPa. U.S. Pat. No. 3,387,036 discloses that an oxidation product of toluene, consisting of a mixture of toluene, benzyl hydroperoxide, benzaldehyde, benzoic acid and some other by-products, may be processed in such a manner that the benzyl hydroperoxide is converted, for instance, by catalytic hydrogenation of the benzylhydroperoxide. However, such a "deperoxidation" is completely different from the method of the present invention. The invention will be elucidated by means of the following non-restrictive examples and comparative experiment. The color value in degrees Hazen (°H) was determined by ASTM D 1209/62. EXAMPLES EXAMPLE I A sample of benzaldehyde, prepared by oxidation of toluene in the liquid phase by means of a gas containing molecular oxygen with the use of a homogeneous cobalt catalyst, was treated with hydrogen for 2 hours at 295 K. and a pressure of 350 KPa in the presence of 0.5% by wt. Raney nickel, dring which treatment 10 liters hydrogen (N.T.P.) per kg benzaldehyde per hour was taken up. Subsequently, the mixture was distilled in a sieve-tray column with 30 trays at a top pressure of 20 kPa and with a reflux ratio of 1:3. The color value of the main fraction was 10° H. This main fraction was divided into two portions. One portion was heated for 1 hour under a nitrogen atmosphere. The color value rose to 25° H. The other portion was stored for 30 days in a dark bottle under a nitrogen atmosphere. At the end of this period, the color value had risen to 20° H. EXAMPLE II A sample of the same liquid crude benzaldehyde as used in Example I was treated with hydrogen for 0.5 hour at 305 K. and a pressure of 300 kPa in the presence of 0.5% by wt. 5% palladium-on-carbon catalyst, during which treatment 30 liters hydrogen (N.T.P.) per kg benzaldehyde per hour was taken up. Subsequently, the mixture was distilled under the same conditions as in Example I. The color value of the main fraction was 10° H. This main fraction was divided into two portions. One portion was heated for 1 hour under a nitrogen atmosphere. The color value rose to 35° H. The other portion was stored for 30 days in a dark bottle under a nitrogen atmosphere. At the end of this period, the color value had risen to 25° H. Comparative Experiment A sample of the same liquid benzaldehyde as used in Example I was distilled without previcus treatment, under the same circumstances as in Example I. The color value of the main fraction was 25° H. This main fraction was divided into two portions. One portion was heated under a nitrogen atmosphere. After 0.2 hour, the color value of this portion had already arisen to well over 100° H. The other portion was stored for 30 days in a dark bottle under a nitrogen atmosphere. At the end of this period, the color value had risen to 50° H.
A process for purification of impure benzaldehyde by which purified benzaldehyde is prepared which has improved color stability and improved olfactory characteristics. The process is comprised of the steps of treatment with hydrogen in the presence of a hydrogenation catalyst followed by distillation. The present invention is a new and novel process for the purification of benzaldehyde and, is in particular, a unique and novel process for the purification of benzaldehyde prepared by the oxidation of toluene with a gas containing molecular oxygen.
2
BACKGROUND OF THE INVENTION FIELD OF THE INVENTION [0001] The present invention relates to a machine for processing sheets, having a delivery for delivering the sheets that includes a delivery drum that is acted on pneumatically. [0002] In German Patent DE 1 561 043 corresponding to U.S. Pat. No. 3,542,358 to Schuhmann, such a machine, whose delivery drum is acted on with blown air, is described. By the application of positive pressure to the delivery drum, a thin air cushion is formed between the sheet and the drum periphery, which prevents the printing ink from the sheet being smeared onto the drum. However, the application of positive pressure does not manage to prevent the printing ink smearing from the sheet transported by the delivery drum to the machine parts adjacent to the delivery drum. SUMMARY OF THE INVENTION [0003] It is accordingly an object of the invention to provide a machine for processing sheets that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that has a delivery drum the transports the sheets safely past the adjacent machine parts without smearing. [0004] With the foregoing and other objects in view, there is provided, in accordance with the invention, a machine for processing sheets, having a delivery, or deliverer, for delivering the sheets includes a delivery drum that is acted on pneumatically, is characterized by acting on the delivery drum with a vacuum. [0005] As a result of acting on the delivery drum with a vacuum, in the machine according to the invention, a route for solving the problem—which is completely opposite to the prior art (e.g., German Patent DE 1 561 043)—is followed. It has been found that, for the protection against smearing onto the adjacent machine parts, it is much more effective to keep the sheet in contact with the delivery drum for some time by a vacuum of the latter, instead of keeping the sheet at a distance from the delivery drum by a blown air cushion. [0006] Advantageous developments will be explained briefly in detail in the following text. [0007] In an advantageous development with regard to protecting the sheets against smearing of their printed image as a result of the contact between the sheet and delivery drum necessitated by the application of vacuum, in accordance with another feature of the invention, the delivery drum includes disks for carrying the sheets. Because of the narrowness of the disks, these carrying disks support the sheet only locally, as seen over its sheet width, and not over the entire sheet width. As viewed in the direction of the sheet width, the disks can be disposed after one another such that contact points determined by the disks are located within corridors that are free of a printed image and that run in the longitudinal direction of the respective sheet. What is important to the disks is primarily their narrowness and less whether the respective disk is circular, corresponding to a full circle or, instead, only has the shape of a circular segment, or whether the respective disk is produced from one piece or is assembled from a plurality of segments. As a result of the interaction between the application of vacuum and the disks of the delivery drum, the sheet is held exactly and in a stable position on its necessary transport path, and the printing ink from the sheet can smear neither onto the delivery drum nor onto the machine parts adjacent to the delivery drum. The delivery drum is, therefore, particularly well suited to transporting sheets printed on both sides. [0008] In accordance with a further feature of the invention, each of the disks includes vacuum channels for holding the sheets. Although it is also conceivable to act on a drum part adjacent to the respective disk with the vacuum holding the sheet on the delivery drum, the application of vacuum to the disks themselves, carried out by the vacuum channels, is more advantageous from a functional and constructional point of view. The vacuum channels can have openings in the peripheral surface of the respective disk, and these openings can form a row running in the peripheral direction of the disk. [0009] In a departure from this development, however, it is also conceivable to provide only a single vacuum channel for each disk and a vacuum groove that extends in the peripheral direction of the disk, in its peripheral surface, which is open toward the sheet and in the base of which the vacuum channel opens. [0010] In a development that is advantageous with regard to avoiding drawing extraneous air into the delivery drum, in accordance with an added feature of the invention, the openings of the vacuum channels and a vacuum connection together form a rotary valve for the cyclic application of vacuum to the vacuum channels. The rotary valve ensures that each of the vacuum channels is connected at least once to the vacuum in the course of a complete revolution of the disk and is, then, isolated from the vacuum again. Although it is, likewise, conceivable for a common rotary valve to be associated with the disks (whose number is at least two and, preferably, exactly two), the valve controlling the vacuum in the vacuum channels of all the disks cyclically, it can be advantageous from various points of view to assign a different, dedicated rotary valve to each of the disks so that the rotary valves work with one another in parallel operation. [0011] In accordance with an additional feature of the invention, a vacuum-active angular range of the delivery drum is determined by the rotary valve or by each rotary valve, and is located in an exit pocket of a drum-cylinder nip. The rotary valve, therefore, ensures that the suction action from the delivery drum or its disks is exerted in a targeted manner in the exit pocket on the sheet section that has already emerged from the drum-cylinder nip and not on the sheet section that has not yet entered the drum-cylinder nip. In the region of an inlet pocket of the drum-cylinder nip, opposite the exit pocket, the vacuum channels are kept vacuum-inactive by the rotary valve so that the vacuum channels attract the sheet by suction at the earliest in the drum-cylinder nip in the course of its rotation. [0012] In accordance with yet a further feature of the invention, a sheet guide device that is adjacent to the delivery drum extends into the vacuum-active angular range. Such a sheet guide device is a machine element that is immediately adjacent to the delivery drum and that is intended to be protected against smearing by the application of vacuum to the delivery drum. The rotary valve or each rotary valve activates the vacuum of the delivery drum in the cycle of the sheets conveyed through between the delivery drum and the sheet guide device. The sheet guide device is, preferably, a pneumatically acting sheet guide device that is equipped with air nozzles, preferably, with blown air nozzles assisting the vacuum of the delivery drum from the opposite side. For example, the sheet guide device can be formed as a blown air box or as a blower pipe configuration. [0013] In a development that is advantageous with regard to pneumatic stabilization of the sheet position of one and the same sheet carried out simultaneously before and after the drum-cylinder nip, in accordance with yet another feature of the invention, the drum-cylinder nip is formed by the delivery drum together with an impression cylinder, and a blowing device for blowing the sheets against the impression cylinder is allocated to the impression cylinder. The blown air from the blowing device is aimed at the sheet and presses the sheet firmly against the peripheral surface of the impression cylinder. The vacuum-active angular range of the delivery drum and the blowing device are disposed to be offset from each other along the sheet transport path such that the blowing device holds the rear half of the sheet still on the impression cylinder while the front half of the sheet is already being held by the activated vacuum channels on the delivery drum. [0014] In accordance with yet an added feature of the invention, the blowing device is allocated to the impression cylinder between a press nip formed by the impression cylinder and the drum-cylinder nip. As viewed in the direction of movement of the sheets, the blowing device is, therefore, disposed after the press nip and before the drum-cylinder nip. The impression cylinder can form the press nip together with a blanket cylinder provided for offset printing or instead for full-surface varnishing or with a printing form cylinder bearing a flexographic printing form for spot varnishing. [0015] In accordance with yet an additional feature of the invention, at least one of the disks is mounted such that it can be adjusted relative to another of the disks in the direction of the width of the sheets, that is to say, transversely with respect to the transport direction of the sheets. The disk is, preferably, mounted such that it can be set as desired to various distances relative to the other disk. This setting can, preferably, be carried out continuously so that, within the adjustment range of the disk, any desired distance between the adjustable disk and the other disk can be set. The respectively selected distance, at which the disk is secured after its setting, can depend on the format of the sheets (sheet width) or on the position of the already mentioned corridors of the sheet that are free of a printed image. [0016] In accordance with again another feature of the invention, the delivery drum is disposed or mounted within a circulation path of a chain conveyor. This means that the delivery drum is disposed such that chains of the chain conveyor run around the delivery drum. [0017] In accordance with again a further feature of the invention, the machine according to the invention is, preferably, configured as a perfecting press. In such a perfecting press, each sheet is printed on both its sides in a single printing cycle. In connection with such sheets printed on both sides, the envisaged anti-smearing measures (vacuum application, disks) come fully into effect. As a result of the vacuum application, smearing of the printed image on the sheet side facing away from the delivery drum is avoided, by its contact with the sheet guide device being avoided and, by the disks, at the same time smearing of the other printed image on the sheet side facing the delivery drum is avoided by the facing sheet side being supported by the disks only in unprinted regions, that is to say, outside the printed image. [0018] With the objects of the invention in view, there is also provided a machine for processing sheets, including a delivery for delivering the sheets, the delivery having a delivery drum with a surface and a vacuum source fluidically connected to the delivery drum and applying a negative pressure vacuum to the delivery drum to draw air from the surface of the delivery drum. [0019] With the objects of the invention in view, there is also provided a machine for processing sheets, including a delivery for delivering the sheets, the delivery having a delivery drum acted on pneumatically by having a vacuum applied thereto, disks for carrying the sheets, each of the disks defining vacuum channels for holding the sheets, and the vacuum channels having openings and a vacuum connection, the openings and the vacuum connection together forming a rotary valve cyclically applying the vacuum to the vacuum channels. [0020] Other features that are considered as characteristic for the invention are set forth in the appended claims. [0021] Although the invention is illustrated and described herein as embodied in a machine for processing sheets, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. [0022] The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0023] FIG. 1 is a cross-sectional view of an overall diagrammatic illustration of a press having a sheet delivery according to the invention; [0024] FIG. 2 is a fragmentary, cross-sectional view of a delivery drum of the sheet delivery of FIG. 1 ; and [0025] FIG. 3 is a fragmentary, perspective view of the delivery drum of FIG. 2 . DESCRIPTION OF THE PREFERRED EMBODIMENTS [0026] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a machine 2 processing sheets 1 . The machine 2 is a sheet-fed press, specifically a recto and verso press, and includes a printing unit 3 . 1 for printing the front side of the sheet and a printing unit 3 . 2 for printing the rear side of the sheet. The printing unit 3 . 2 includes an impression cylinder 4 and a blanket cylinder 27 , these two cylinders 4 and 27 together forming a press nip 24 . In addition, the machine 2 includes a delivery 5 having a chain conveyor 6 and what is referred to as a delivery drum 7 . The chain conveyor 6 runs around the delivery drum 7 and deposits the sheets 1 on a stack 8 . The chain conveyor has grippers 9 , which move along a circulation path 26 , and chains 10 that carry the grippers 9 and determine the circulation path 26 . The impression cylinder 4 transfers the sheets 1 one after another to the grippers 9 at a transfer point. The transfer point is a drum-cylinder nip 23 formed by the delivery drum 7 together with the impression cylinder 4 and is located in the first quadrant of the delivery drum 7 if a sheet transport direction from right to left is used as a basis, as in FIG. 1 . [0027] The delivery drum 7 is what is referred to as a skeleton drum and has disks 11 that carry the sheets 1 and are seated at a distance from one another on a rotating axle 25 . Each of the two disks 11 is mounted such that it can be displaced individually and relative to the other of the two disks 11 along the axle 25 . As a result of the displacement of the two disks 11 , these can be adjusted closer together or further apart as desired, and each of the two disks 11 can be positioned in a manner coordinated with the sheet format of the respective print job such that the disks 11 contact the sheets 1 only at their side edges free of a printed image. Used as the axle 25 is what is referred to as the sprocket shaft, on which there are seated sprockets 12 that engage in the chain teeth and belong to the chain conveyor 6 . The disks 11 have diametrical clearances 13 , into which the grippers 9 , formed as gripper bars, dip during their circulation. The peripheral speeds of the chain conveyor 6 and of the delivery drum 7 or the disks 11 are synchronized. In addition, each disk 11 is associated with a securing device 14 , by which the corresponding disk 11 can be fixed on the axle 12 in its respective axial position suitable for the format, for example, can be clamped firmly. The external diameter of the disks 11 substantially corresponds to that of the sprockets 12 and of the impression cylinder 4 . [0028] The delivery drum 7 , which is acted on pneumatically internally, is what is referred to as a vacuum drum and has vacuum channels 15 that are introduced into the disks 11 . The vacuum channels 15 extend longitudinally substantially radially and open in the peripheral surface of the respective disk 11 . Openings 16 of the vacuum channels 15 are disposed in rows, which run in the peripheral direction of the delivery drum 7 and extend substantially over the entire sheet length of the maximum sheet format. Each of the vacuum channels 15 is formed from a radial bore and a transverse bore that extends parallel to the axle 25 and intersects the radial bore. The transverse bores forming the inner ends of the vacuum channels 15 each have an opening 17 . [0029] These openings 17 of the vacuum channels 15 cooperate periodically in the course of the rotation of the respective disk 11 with a stationary vacuum connection 18 , which does not co-rotate with the disk 11 . The vacuum connection 18 is a groove in the shape of a circular arc and is permanently under a negative pressure that is produced by a vacuum source 30 (only illustrated diagrammatically in FIG. 2 ), which is connected to the vacuum connection 18 . The vacuum connection 18 is open toward the openings 17 that, in the course of the rotation of the disks 10 about the geometric axis of rotation of the axle 12 , overlap one after another with the vacuum connection 18 to which vacuum is applied conducting vacuum from the vacuum channels 15 into the vacuum connection 18 . Each of the curved rows formed by the openings 17 , as viewed in the peripheral direction, is longer than the curved length of the vacuum connection 18 so that always only a subset of the vacuum channels 15 of the respective row and never all the vacuum channels 15 of this row communicates simultaneously with the vacuum connection 18 . The vacuum channels 15 , together with the vacuum connection 18 , therefore, form a rotary valve 19 , which is placed such that the delivery drum 7 is pneumatically active with respect to the outside only within an angular range a that begins substantially only at the transfer point 10 and ends still in the fourth quadrant of the delivery drum 7 . The angular range a is located in the immediate vicinity of an exit pocket 22 from the drum-cylinder nip 23 . Because of the alignment of the rotary valve 19 , the openings 16 are active in applying vacuum to the sheets 1 only within the angular range a. Within the angular range a, it is particularly important that the sheet 1 transported to the chain conveyor 6 is attracted against the delivery drum 7 by suction by the openings 16 to which vacuum is applied and is kept in contact with the rotating disks 10 and at a distance from a sheet guide device 20 , which extends with its curved end section as far as the angular range a underneath the delivery drum 7 . [0030] The sheet guide device 20 , running in a curve partly around the delivery drum 7 , includes a guide plate provided with blower nozzles. A blowing device 21 aimed with its blown air jets at the impression cylinder 4 , substantially in the second quadrant of the impression cylinder 4 , is used to hold the sheet 1 on the impression cylinder 4 . [0031] FIG. 2 illustrates a transport phase of the sheet 1 that is particularly critical in regard to the smearing of the ink printed in the printing unit 3 . 1 from the sheet 1 to the sheet guide device 20 . In this transport phase, the leading sheet end is gripped by a gripper 9 passing the delivery drum 7 and the trailing sheet end has already emerged from the press nip 24 (cf. FIG. 1 ) of the printing unit 3 . 2 . [0032] Without any suitable countermeasure, there would be a risk of the sheet 1 separating from the delivery drum 7 in the angular range α and forming a loop of printing material that, as a result of striking the sheet guide device 20 , could cause smearing. [0033] A countermeasure that prevents this and has been tested successfully by the applicant functions as set forth in the following text. [0034] The vacuum channels 15 , which act after the transfer point (drum-cylinder nip 23 ), and the blowing device 21 disposed before this transfer point act together such that the sheet 1 exactly maintains its substantially S-shaped longitudinal curvature following the peripheral lines of the impression cylinder 4 and of the delivery drum 7 during the critical transport phase and, thus, the disastrous formation of waves in the printing material of the sheet 1 is suppressed. In tests, it has been shown that the action of the blowing device 21 on its own is not completely adequate to force the sheet 1 into its requisite movement path and to keep it at a distance from the sheet guide device 20 within the angular range a. [0035] However, it is not ruled out that, in specific applications, by its vacuum, the delivery drum 7 is sufficiently effective on its own, that is to say, without any support by the blowing device 21 . [0036] Nonetheless, the combination of the pneumatic devices disposed on the two opposite sides of the transfer point (upstream blowing device 21 , downstream angular range a of the vacuum delivery drum 7 ) has proven to be particularly effective. [0037] This application claims the priority, under 35 U.S.C. § 119, of German patent application No. 103 32 217.5, filed Jul. 16, 2003; the entire disclosure of the prior application is herewith incorporated by reference.
The invention relates to a machine for processing sheets, having a deliverer for delivering the sheets which comprises a delivery drum that is acted on pneumatically. The delivery drum has vacuum applied to it. The delivery drum also has disks for carrying the sheets, each of the disks defining vacuum channels for holding the sheets. The vacuum channels have openings and a vacuum connection. The openings and the vacuum connection together form a rotary valve cyclically applying vacuum to the vacuum channels.
1
BACKGROUND OF THE INVENTION [0001] The subject-matter of the invention is a personal document in book form, for example, a passport having a personalized page that together with the other pages of the personal document is bound by means of a seam and attached in a book cover. [0002] The personalized page of a personal document normally comprises a plurality of strata. In particular, when integrating an RFID element for complying with ISO 9303 standards for machine-readable travel documents and for inscribing personal data and the passport photo, sandwich-type layer structures that have long service lives, which are temperature stable, and are protected against falsification are required. Such thermoplastic films and film combinations in general do not provide good articulation properties in the area of the seam. When using polycarbonate (PC) films or polyethylene therepththalate (PET) films, the reverse bending strength is generally limited. In particular, integrating an RFID element into the personalized page requires very thick sandwich-like structures. When using transparent laser-capable polycarbonate (PC) films or transparent laser-capable PET/PE-HD films, the graphic and electronic personalization can be performed in a finished passport document. Existing passport solutions have the problem that they open poorly and do not stay closed well because the stiffness of the personalized page causes the passport not to remain closed or open without the exertion of force. [0003] DE 198 14 420 A1 cites an identification document, such as a passport or the like, that comprises a plurality of sheets that are bound on a seam to make a book. At least one of the sheets forms a data sheet that is provided with information and comprises at least two layers, whereby at least one of the layers is transparent. The format of the layers is selected such that they project beyond the area of the seam, and thus in the area of the seam, connect the data sheet to the other sheets of the identification document. In the area of the information the layers are joined to an inseparable laminate, In the area of the seam, however, they do not adhere to one another. [0004] Thus, the number of bending cycles is intended to be increased and the stiffness of the laminate page is intended to be sharply reduced by the more flexible individual films in the area of the seam. Moreover, in the area of the data sheet, the passport pops open less than with passports that include a data sheet that is laminated across its entire surface. Plastic films made of PC, PETG, or HDT-PETG are preferably used for the films. [0005] EP 1 008 459 B1 refers to a method for producing a booklet, such as, for example, an ID. A band is attached in the same manner as the other sheets of the booklet, and the band is attached to a plate in a special manner, whereby the plate is produced at least partially from a plastic material and has a front side and a reverse side, each side including one page. The aforesaid band is selected, for example, from a synthetic material that is suitable for being sewn in and for frequent bending and is preferably made of polypropylene. [0006] EP 0 936 976 B1 discloses a passport with an information page that contains information about, and an image of, the passport holder, whereby the information page comprises a thermosetting plastic material such as, for example, polycarbonate, and is personalized with laser inscriptions, and whereby this page has a plurality of layers that are laminated to one another using heat and pressure. In the bending area, the output page has a separating layer between the outside layers so that these layers are not laminated, and in this manner, a bendable, long-lived bending location is provided on the information page in the passport. [0007] EP 1 245 407 A2 describes a multi-layer personalized page in a passport that has a plastic layer into which data can be inscribed with the laser. This laser-capable layer made of polycarbonate is laminated by means of PE foam to a flexible backing made of HDPE and is sewn in the area of an excess length of the backing. [0008] The goal of the present invention is to provide an improved personal document in book form that has a longer service life and is less susceptible to falsification. SUMMARY OF THE INVENTION [0009] The goal is attained in accordance with the invention with a personal document in book form including a book cover, a multi-layer personalized page that contains personal data, and interior pages, whereby the personalized page and the interior pages are attached in the book cover by means of a seam. The multi-layer personalized page has a core stratum comprising a textile layer, and is joined on both sides to at least one thermoplastic layer, which cover the core stratum up to a section of excess length. An RFID element with an IC element for contactless transmission of biometric data from the personalized document is integrated in the core stratum. The personalized page is sewn by means of the seam to the other pages and the book cover in the area of the excess length. [0010] The textile layer of the personal document is preferably a fabric, in particular a polyester fabric and/or a polyester satin fabric. This results in a particularly bendable, long-lived articulation in the area of the seam in the personal document. [0011] Another advantageous embodiment results when the textile layer is a cotton fabric and/or a cotton blend fabric or a microfiber fabric made of thermoplastic fibers. However, it is also possible for the textile layer to be a non-woven fabric. [0012] Particular advantages result in that the textile layer can contain machine-readable security elements, which enhances protection against falsification. Such security elements include added security pigments and/or security prints that are used during authentication of the personal document. [0013] The textile layer in accordance with the invention is provided, on at least one page, with a bonding agent layer that can be applied, for example, in the form of a film, in particular a perforated film, in the form of a random fabric, a coating, or print. [0014] The bonding agent layer preferably comprises a thermoplastic adhesive, in particular a hotmelt, that joins the textile layer to the plastic layer covering the core stratum in a manner that cannot be released without visibly damaging the layers. It is particularly advantageous when a reactive resin or a partially reactive resin mixture is used with which the textile layer and the plastic layer covering the core stratum are joined permanently. Preferably, the plastic layers on the front side and on the back side of the personalized page are joined to one another by lamination. [0015] Preferably, the core stratum has recesses through which the plastic layers of the front side and the back side can join one another in a fused compound. Thus it is practically impossible for a forger to subsequently separate the layers. [0016] In accordance with the invention, the plastic layers covering the core stratum include a first opaque thermoplastic film, for example, a white thermoplastic film, and at least one transparent laser-capable film into which the personalized data, in particular the passport photo, are inscribed with laser irradiation. These layers preferably comprise polycarbonate (PC) and/or polyethylene therepththalate (PET) and/or high-density polyethylene (HDPE) or a blend of these materials. The transparent laser-capable film is covered with a protective layer that is laminated thereto in the same manner and cannot be removed without being destroyed. [0017] The personal document in accordance with the invention has a coil integrated into the personalized page, in particular into its core stratum, for contactless reading of biometric data for the holder of the personal document. [0018] Advantageously, diffractive elements can also be laminated in between the layers of the multi-layer personalized page. Moreover, a photopolymer layer can be arranged there, into which layer a “shadow image” of the photo of the holder of the personal document is inscribed. In addition, as an additional security measure during the laser processing of the personalized page, lasered perforation numbering can be added and thus the protection against falsification is further enhanced. [0019] Additional features and advantages of the invention can be found in the following description of the figures. BRIEF DESCRIPTION OF THE DRAWINGS [0020] FIG. 1 is a schematic representation of an inventive personal document, partially opened; [0021] FIG. 2 is the top view of the personalized page; and [0022] FIG. 3 is a section through the personalized page with an RFID element in the textile layer. DETAILED DESCRIPTION OF THE INVENTION [0023] FIG. 1 is a schematic representation of an inventive personal document 1 , partially opened. [0024] The passport binder 2 , 2 ′ is bound by means of the seam 15 , with the personalized page 3 , 4 , 5 , 19 and the interior strata 12 , 12 ′, 13 , 13 ′, 14 , 14 ′ into a book, so that a sort of articulation 15 is formed. The number of interior strata can be selected according to the design desired. In this case, only six interior strata are shown for the sake of simplicity. [0025] The personalized page comprises a laminate with a core stratum 3 between plastic layers on the front side 4 and the back side 5 . The excess length 19 of the personalized page 3 , 4 , 5 in the area of the seam 19 comprises only the core stratum 3 , which is embodied bendable and made of a textile material such that a personal document produced in this manner can be opened and closed easily without there being a high restoring force and in that a high bending number is possible. [0026] On the front, the passport cover 2 , 2 ′ has a projection 6 and can be used with a bound design or in a design that is punched on three sides. [0027] FIG. 2 is a top view of the personalized page 3 , 4 , 5 . In accordance with the invention, the core stratum 3 extends across the entire personalized page, including the excess length 19 . However, the plastic layers of the front side 4 of the personalized page and the back side 5 of the personalized page do not extend across the full width of the core stratum 3 , but rather end at the edge 20 and are exteriorly edged with a common contour 29 . Thus, only the flexible core 3 is to be sewn at the seam or bending site 15 , while the rest of the personalized page has substantially higher stiffness due to the laminated polycarbonate layers. The exterior contour 29 is preferably obtained by punching the bound passport 1 . [0028] An RFID element 16 with an IC element 17 and a coil 18 is integrated into the personalized page 3 , 4 , 5 , the position shown being arbitrary. The RFID element 16 can also be designed either smaller or even larger with respect to the desired specifications. [0029] The IC element 17 is preferably positioned in the vicinity of the seam 15 , because this location can be expected to be subjected to lower mechanical loads. [0030] The personalized data such as the ICAO line 7 , personalized data 8 , and photo 9 are produced in the finished passport 1 by means of laser irradiation, whereby the IC element 17 is also electronically programmed with the corresponding personal data or biometric data in the same working step. [0031] Frequently a diffractive security element 10 is required for increasing protection against falsification. In the present example it is integrated into the strata 24 , 25 . Since this diffractive element 10 is largely transparent, it can be arranged such that it covers the photo 9 in places. [0032] Since the personalized page 3 , 4 , 5 is constructed by means of laser irradiation, the passport number can also be burned into the area of the numbering 11 in the form of a microperforation and/or the photo can be added as a so-called “shadow image” by means of microperforations in addition to or adjacent to the actual photo 9 . [0033] FIG. 3 depicts a section through the personalized page 3 , 4 , 5 with an RFID element 16 in the core stratum 3 . The layers 24 and 26 are embodied as opaque white polycarbonate layers. Both the front side and the back side of these is inseparably joined to a laser-capable polycarbonate layer 25 , 27 . [0034] In this sectional depiction, the core stratum 3 is formed from three strata, whereby in special cases additional strata or layers might be reasonable and even necessary. The textile layer 21 comprises a polyester fabric and/or a polyester satin fabric and/or a cotton fabric and/or a cotton blend fabric and/or a microfiber fabric and/or a non-woven fabric made of thermoplastic fibers. The thickness of the fabric 21 is 50 to 300 μm, preferably 100 to 200 μm. The fabric has security threads woven therein, or is woven from security yams, or can be printed. Preferably machine-readable marking substances are used. In particular, marking substances that can be activated in the near infrared range can be added that can be read through layers arranged thereover, since, for example, conventional printing inks and opaque thermoplastic films are penetrated by NIR radiation in the metrologically interesting range of 800 to 1100 nm. [0035] Excitation is performed using LED or laser radiation sources with appropriate optics, and the data are preferably also read out in the NIR range, whereby the conventional silicon photo diodes can be used since they have high sensitivity up to about 1000 nm and slightly more. The responding signal can be evaluated or verified in terms of frequency and/or time, i.e., in a time-resolved manner. In particular, so-called up-conversion pigments are suitable, such as a fine-grain inorganic gadolinium oxysulfide and the like. Preferably response signals in the NIR range are evaluated when such machine-readable markings are integrated in the interior of the laminate structure 21 , 22 , 23 . [0036] The fabric 21 is provided with one or two bonding agent layers 22 , 23 . These layers can be thermoplastic in nature and in this case must have a corresponding heat resistance or can be designed partially reactive or reactive. In each case a bond is attained that makes it impossible to separate the layers 21 , 22 , 23 , 24 , 25 , 26 , and 27 without visibly damaging or destroying them. [0037] In terms of production engineering, the bonding agent layers 22 , 23 can cover the entire surface of the fabric 21 , that is, the excess length 19 , as well. Depending on the type and thickness of the fabric, however, the excess length 19 can be kept free of one or both bonding agent layers 22 , 23 . [0038] In one variant, the use of the fabric 21 in the production of the articulation 15 in the area of the seam of the personalized page 3 , 4 , 5 can occur in that the fabric 21 in roll form is provided with one or both bonding agent layers 22 , 23 and are then laminated together, in a single image, in strip form, or in multiple images, with the other layers 24 , 25 , 26 , 27 to make a personalized page 3 , 4 , 5 . The lamination is normally performed in a hot and cold transfer press. Lamination temperatures ranging from about 150° C. to more than 200° C. are used, and in particular, temperatures ranging from 190° C. to about 205° C. are used for high security laminate bonds based on polycarbonate. The surface pressures in the hot press are generally 200 to 400 N/cm 2 , and the surface pressures in the cold press are generally 400 to 600 N/cm 2 . Using vacuum support for the lamination process can prevent interfering air inclusions. [0039] Depending on the type of IC element 17 and the possible type of contacting, the RFID coil 18 can be produced using etching in copper or aluminum, or by means of silver through plating, or by means of copper wire winding or laying technique. [0040] As stated in the foregoing, the personalized page 3 , 4 , 5 is produced in single images, in strip form, or in multiple images. The contour 29 is produced using a punch tool or cutting tool. It can be advantageous that the films 24 , 25 , 26 , 27 and any additional films are embodied such that they designed are in a size large enough to include the excess length 19 , but in the area of the excess length 19 to the bonding agent side 22 , 23 are provided with a separating coating, for example, by means of screen printing. The contour punches can then punch the entire contour 29 and at the same time produce the personalized page edge 20 , such that only the films 24 , 25 , 26 , 27 are punched on the edge, and the core strata 21 , 22 , 23 are not punched. [0041] In all of the punch technologies, the punch edge 29 is quite essential since a fabric 21 is integrated as core layer and this fabric 21 must be edged with no fringe. [0042] In this depiction, the transparent films 25 , 27 are conducted over the edge of the opaque plastic layers 24 , 26 , but terminate prior to the excess length 19 in which the seam 15 is provided. In addition, in this embodiment it is even possible to use a relatively thick RFID element 16 , which however makes possible a personalized page 3 , 4 , 5 that is thinner overall than would otherwise be required for relatively thick RFID elements 16 . [0043] In addition, in this depiction, a recess 28 in the core stratum 3 is shown. A fused bond between the layers surrounding the core stratum 3 is possible with one or a plurality of such recesses 28 in the core strata 21 , 22 , 23 . The holes 28 can be lasered or punched. They have a pre-determined circular, oval, or rectangular shape and can also themselves be used as an additional security feature during authentication. LEGEND [0000] 1 Personal document 2 Book cover 2 ′ Book cover printed side 3 Core stratum 4 Plastic layer of front side of personalized page 5 Plastic layer of back side of personalized page 6 Book cover inside page (projection front) 7 ICAO line 8 Personalized data 9 Passport photo 10 Diffractive structure 11 Number punched 12 Inside page; 12 ′ inside page back side 13 Inside page; 13 ′ inside page back side 14 Inside page; 14 ′ inside page back side 15 Seam (personal document articulation) 16 RFID element 17 IC element (chip module, interposer) 18 Coil 19 Excess length of personalized page 20 Edge of personalized page 21 Textile layer 22 Bonding agent for personalized page front side 23 Bonding agent for personalized page back side 24 Opaque personalized page front side 25 Transparent laser-capable personalized page front side 26 Opaque personalized page back side 27 Transparent laser-capable personalized page back side 28 Recess in core stratum 29 Contour/punched edge
The invention relates to a personal document in the form of a book, comprising a book cover, a multi-layered personalised side which contains personalised data, in addition to inner pages. The personalised side and the inner pages are secured by means of a seam to the book cover. The multi-layered personalizing side is provided with a central area which is made of a textile layer which is joined on both sides to a thermoplastic layer which covers the central area until the projecting end. A RFID element comprising an IC element is integrated into the central area for the contactless transfer of biometric data of the personal document owner. The personalised side is sewn by means of a seam in the region of the projecting end.
1
FIELD OF THE INVENTION The application relates to a method for producing a three-dimensional object by successive solidification of individual layers of a curable liquid or powder material under the influence of electromagnetic irradiation, whereby a supporting structure for supporting the object is co-solidified with the object. BACKGROUND OF THE INVENTION A method for producing a three-dimensional object is known as "stereolithography". In this method a layer of a liquid or a powderous material is applied to a support or a previously solidified layer and thereafter solidified by irradiating a focused light beam, for example a laser beam, at the points corresponding to the object. The object is produced in a layerwise fashion by successively solidifying a plurality of layers one after the other. The EP-A-0 338 751 discloses such a method whereby supporting structures for supporting portions of the object or the entire object, respectively, are solidified together with the object itself. When constructing supporting structures, however, the following problems are encoutered. At filigree structures as well as intersections of planes several individual supports are generated because of the separate surface compounds in the CAD-model. The individual supports can be closely adjacent to each other and/or intersect or penetrate each other. For exposing the supporting structure the contour lines of the individual supports are scanned at an extremely small spacing which causes them to melt together. It is not possible or very difficult to remove the thus produced supporting structure without destroying the component. In order to prevent the closely adjacent contour lines of individual supports from melting together, it is possible to scan the supports without contour. In this case, however, the exposure of the supports must be very hard i.e. a high degree of solidification must be produced to prevent the supports from fraying at the edges. Again, it is very labour-intensive to remove the thus produced supporting structure from the component, or it may even be impossible to remove it without destruction thereof. The DE 43 09 524 discloses a method for producing a three-dimensional object whereby the entire object or each layer of the object to be formed, respectively, is decomposed into an inner core region and an outer envelope region and the irradiation is controlled in the core region and in the envelope region so as to produce different characteristics in both regions. The decomposition of the object to be formed into an envelope region and a core region is made in a computer. Object data corresponding to the decomposition of the object to be formed into core and envelope region are provided to a further computer which controls an irradiation device for solidifying the layers of the object to be formed. The decomposition allows to construct an object using constructional forms which are different from each other and advantageous corresponding to the respective requirements. The WO 94/07 681 discloses a method for producing a three-dimensional object by successive solidification of overlying layers of the object, whereby at first partial regions of a layer are solidified and joined with respective partial regions of the previously solidified layer therebelow to form multilayered cells and thereafter adjacent partial regions of one layer are joined by solidifying narrow web regions. It is thereby intended to reduce the deformation of the object. SUMMARY OF THE INVENTION It is the object of the invention to provide a method for producing a three-dimensional object wherein a supporting structure produced simultaneously with the object has a homogeneous texture, the supporting structure can be produced in a short time and easily removed from the object after finishing the same. This object is achieved by a method for producing a three-dimensional object that includes successive solidification of individual layers of a curable liquid or powder material under the influence of electromagnetic irradiation. A supporting structure for supporting the object is co-solidified together with the object. Furthermore, the supporting structure is decomposed in a three-dimensional manner into an inner core region and an outer envelope region, and the irradiation is varied to produce different characteristics in both regions. Further developments are defined in the subclaims. By decomposing the supporting structure into the core region and the envelope or skin region in a three-dimensional fashion, the produced supporting structure is very homogeneous because no double irradiation or double exposure occurs within the supporting structure. By controlling the irradiation in the envelope region so as to differ from that of the core region the envelope region can be build to produce an easily detachable connection with the object and the core region can be build to produce a sufficiently stable supporting structure in a short construction time and to take up strain forces when forming the object with a low deformation of the supporting structure . BRIEF DESCRIPTION OF THE DRAWINGS A description of embodiments with reference to the figures follows. In the figures: FIG. 1 is a diagrammatic representation of a device for carrying out the inventive method; FIG. 2 is a diagrammatic cross-section of a portion of the object under formation together with a supporting structure according to one embodiment of the invention; FIG. 3 is a sectional view along line A--A of FIG. 2; FIG. 4 is a diagrammatic cross-section of an object under formation with a supporting structure according to a further embodiment of the invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS As best shown in FIG. 1 an apparatus for carrying out the inventive method comprises a tank or container 1 having an open top and being filled up to a level or a surface 2, respectively, with a material which is curable by action of electromagnetic radiation. Within the tank 1 there is a support 4 having a substantially plane and horizontal support plate 5 which is arranged parallel to the surface 2 and which can be displaced and positioned upwards and downwards in a direction perpendicular to the surface 3 or to the support plate 5, respectively, by means of a not shown elevation adjustment device. On the support plate 5 there is an object 6 to be formed together with a supporting structure 20, whereby the object 6 and the supporting structure 20 are each formed of a plurality of layers 6a, 6b, 6c, 6d and 6e and 20a, 20b, 20c, respectively, each extending parallel with the surface 2 and the support plate 5. A not shown device for smoothing the surface 2 of the curable material 3 is arranged above the tank 1. An irradiation device 7 producing a focused light beam 8, for example a laser, is disposed above the tank 1. The focused light beam 8 is deflected as a deflected beam 10 onto the surface 2 of the curable material 3 within the tank 1 by means of a deflection device 9, for example a rotating mirror. A control unit 11 controls the deflection device 9 so that the deflected beam 10 strikes any desired point of the surface 2 of the curable material 3 in the tank 1. The control unit 11 is connected with a computer 50 which provides to the control unit 11 the corresponding data for solidifying the layers of the object 6 and of the supporting structure 20. In the method for producing the three-dimensional object a first step is to position the support plate 5 within the tank 1 so that a distance equal to the predetermined layer thickness exists between the upper side of the support plate 5 and the surface 2 of the curable material 3 within the tank 1. The layer of the curable material above the support plate 5 is irradiated at predetermined places corresponding to the object 6 and to the associated supporting structure 20 by means of the light beam 8, 10 which is produced by the irradiation device 7 and controlled by the deflection device 9 and the control unit 11, whereby the material 3 solidifies and forms a solid layer 6a and 20a, respectively, corresponding to the shape of an object and to the supporting structure. Further layers 6b, 6c, 6d and 6e and 20b and 20c, respectively, are successively formed by lowering the support plate 5 by an amount corresponding to the respective layer thickness and again irradiating the places corresponding to the object 6 and to the supporting structure 20, respectively. The object data and supporting structure data are calculated in the computer 50 for controlling the solidification of each layer by decomposing a three-dimensional model of the object 6 and of the supporting structure 20 into individual layers. The entire three-dimensional supporting structure 20 is decomposed in the computer 50 into an envelope region and a core region. The envelope region and the core region form separate independent parts or individual objects of the supporting structure. It is also possible to decompose the three-dimensional model of the supporting structure in a separate computer and to transfer the thus produced data to the computer 50. In the solidification process of each layer the irradiation will be different for the core region or the envelope region of the supporting structure. Owing to the decomposition a double exposure of intersecting parts of the supporting structure no longer occurs. FIG. 2 shows a cross-section through a supporting structure 21 in connection with the object 6 at a connecting region between the supporting structure 21 and the object 6. The supporting structure 21 is decomposed into a core region 22 and an envelope region 23 having different structures and thus a different characteristics. FIG. 3 representing a section along line A--A in FIG. 2 shows the joining of the supporting structure 21 through the envelope region 23 thereof to the object 6 of one layer. Preferably, the irradiation is controlled in the core region 22 to minimize the deformation of the supporting structure 21 during the production of the object 6. To this end the core region 22 must be exposed in a hard and therefore unelastic manner, i.e. a strong solidification must be produced. For reduction of the required construction time and for saving material the core region 22 of the supporting structure 21 is solidified in individual spaced partial regions which are either not connected at all or connected through joining webs. If the envelope region 23 is solidified in a sufficiently stable manner, it is also possible to completely eliminate the solidification of a core region 22. After finishing the object uncured material can be drained through appertures provided in the envelope regions and/or in the core region. In the envelope region 23 the solidification of the supporting structure 21 is preferably controlled to produce a sufficiently stable but easily detachable bond of the supporting structure to the object. To this end the irradiation in the envelope region is soft, i.e. the degree of solidification is less than that of the core region, whereby the envelope region of the supporting structure does not adhere to the object in an undetachable manner in the bonding region. It is also possible to solidify individual spaced partial regions of the envelope region 23 of the supporting structure, whereby the partial regions are either not connected at all or connected through joining webs. Preferably, the spacing of the partial regions in the envelope region is smaller than the spacing of the partial regions in the core region so that the object is sufficiently supported. In those portions of the envelope region 23 of the supporting structure 21 which are adjacent to the object only individual joined blocks or small clumps of the envelope region may be solidified to produce a perforated bonding to the object which facilitates the detachment of the supporting structure after finishing the object. The wall thickness of the envelope region can be adjusted within the entire supporting structure and/or for each layer. This allows to adjust the distance between the supporting structure and the walls of the object under formation. A suitable selection of the irradiation or exposure technique allows to achieve savings in construction time of up to 80% compared with the conventional method. As best shown in FIG. 4 a further embodiment of the inventive method contemplates the decomposition of a supporting structure 30 into a core region 26 and envelope regions 31, 32, 33 forming several shells, whereby the regions 31, 32, 33, 26 are each an independent part or individual object of the supporting structure. The shell thicknesses may be different. For example, an envelope region can completely or partially encompass the core region. In FIG. 4 the envelope 31 has no Z-thickness but a XY-wall thickness. The envelope region 32 has merely Z-thickness whereas the envelope region 33 has a uniform wall thickness in XY- and Z-direction. When using this supporting structure the core 26 can be formed with distant partial regions. In such a shell-type decomposition it is possible to optimize the force flux through the supporting structure within minimum construction time.
In a method for producing a three-dimensional object (6) wherein the object is produced by successive solidification of individual layers (6a, 6b, 6c, 6d, 64) of a liquid or powderous material (3) by action of electromagnetic radiation (8, 10) and a supporting structure (20, 21) for supporting the object (6) is co-solidified together with the object (6), the supporting structure (20, 21) is decomposed in a three-dimensional fashion into an inner core region (22) an an outer envelope region (23) and the irradiation is varied for producing different characteristics of both regions.
1
FIELD OF THE INVENTION This invention relates generally to devices for contacting particulate materials with fluids. More specifically, the invention relates to the design of the internals of reactors for fluid-particle contact. GENERAL BACKGROUND AND RELATED ART Numerous processes use radial flow reactors to effect the contacting of particulate matter with a gaseous stream. These processes include hydrocarbon conversion, adsorption, and exhaust gas treatment. These reactors contain a vertically extending annular bed of particles through which the gases flow radially in an inward or outward direction. The annular bed is formed by an outer screen element located along the outer diameter of the particle bed and an inner screen element located along the inner diameter of the particle bed. The outer screen element alternatively may comprise a series of closed conduits having an oblong cross-section that circles the outside of the particle bed and borders the inside of the particle containing vessel, such that the backs of the conduits will fit closely against the wall of the vessel and thereby minimize the volume between the back of the conduit and the vessel. An alternative design uses a section of profile wire or screen to form conduits positioned against the inner wall of a vessel. Such conduits have an inner wall joined to a pair of side wall portions, generally in a trapezoidal configuration. However, the known art has failed to address issues of flow distribution and axial and radial stresses in a cost-effective way SUMMARY OF THE INVENTION A broad embodiment of the present invention provides an improved device for distributing fluid in a radial-flow direction through particles within a vertically extended vessel having a curved vessel wall, a fluid inlet and a fluid outlet, comprising a plurality of vertically extended cylinders arranged circumferentially about the interior of the vessel wall, each cylinder having a hollow interior and a multiplicity of cylinder perforations, and at least one end of each cylinder communicating with one of the fluid inlet and the fluid outlet; a particle-retaining outer conduit substantially parallel to the vessel wall and adjacent to the cylinders in the direction of the center of the reactor and having a multiplicity of conduit perforations; and a perforated central conduit located in the center of said vessel and communicating with the other of said fluid inlet and said fluid outlet that is not communicating with the cylinders. In a more specific embodiment, the invention comprises an improved device for distributing fluid in a radial-flow direction through particles within a vertically extended vessel having a curved vessel wall, a fluid inlet and a fluid outlet, comprising a plurality of vertically extended cylinders arranged circumferentially about the interior of the vessel wall, each cylinder having a hollow interior and a multiplicity of cylinder perforations; and at least one end of each cylinder communicating with one of the fluid inlet and the fluid outlet; a plurality of panels, each defined by an arcuate section of a particle-retaining outer conduit having a multiplicity of conduit perforations and connected to a plurality portion of cylinders, which portion is fewer than the number of cylinders in the device, in the direction of the center of the reactor and substantially parallel to the vessel wall; and a perforated central conduit located in the center of said vessel and communicating with the other of said fluid inlet and said fluid outlet that is not communicating with the cylinders. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view of a single vertically extended cylinder. FIG. 2 is a view of a panel of cylinders. FIG. 3 is a cross-sectional view of a vessel, showing the placement of two panels of cylinders. FIG. 4 is a view of a connector linking two panels of cylinders. FIG. 5 shows alternative configurations for the end section of a panel FIG. 6 is a schematic view of a stacked-reactor system. FIG. 7 is a partial sectional view of the reactor of FIG. 6 . DETAILED DESCRIPTION OF THE INVENTION This invention is especially suitable to facilitate radial flow or cross flow through a bed of particles within a vessel, and can be applied to any fluid-particle contacting apparatus or process. The invention is particularly beneficial in processes where transient temperature gradients or temperature fluctuations are imposed on vessel internals, causing stresses on these internals and any catalyst particles used to effect a particular reaction. These stresses can impart both axial and radial forces on internal structures and catalyst and result from differences in thermal expansion and even steady-state operating temperatures among the materials within the reactor vessel. The plurality of cylinders of the invention may be arranged in any configuration which is useful to distribute or collect fluids in order to effect the desired fluid-particle contact. Typically, the plurality of cylinders is arranged circumferentially inside the wall of a vessel to distribute fluids through a perforated outer conduit, across a catalyst retention space in a radial direction, and into a perforated central conduit located in the center of the vessel. In this arrangement, the cylinders communicate with the reactor inlet and the central conduit communicates with the reactor outlet. The number of cylinders in the plurality is defined by the circumference of the inner wall of the vessel, cross-sectional area for fluid flow, and size of the cylinders. FIG. 1 shows a single vertically extended cylinder 10 . The cylinder of the present invention can have any curved bounding surface which is useful to effect the desired distribution or collection of fluids. For example, the cylinder may have an oblong cross-section. However, it is preferred that the cylinder has a substantially circular cross-section. The cylinder can be fabricated from any suitable material which can be perforated in a manner to effect the transfer of fluids. Preferably the cylinder comprises a perforated extended section of standard pipe. Alternatively, the cylinder can be fabricated from a single sheet of steel which is rolled into the desired shape and welded along a vertical joint. Either the pipe or the sheet comprises a multiplicity of perforations as is known in the art to enable egress or ingress of fluids; when perforated, this material is referred to as a “perforated-plate” or “punched-plate” cylinder. The perforations 12 can be of any size or orientation for effective distribution or collection of fluids while maintaining the structural integrity of the cylinder and also being small enough to contain the catalyst particles in the event that the primary catalyst containment of outer conduit 22 is breached, and preferably are oblong or slotted in shape. FIG. 2 illustrates a panel 20 of cylinders, each of which is represented as 10 in FIG. 1 . The panel comprises a plurality 24 of cylinders enclosed in an arcuate section of outer conduit 22 which has been cut away partially in the drawing to show the location and orientation of the cylinders. The size of the arc of the panel is determined by the diameter of contained cylinders required for flow distribution as well as fabrication and maintenance considerations; although fabrication of the panel in situ (within the vessel) is within the scope of the invention, it is preferred that the panel would be fabricated outside the vessel and brought in via a vessel opening. The plurality of cylinders may be partially enclosed by the outer conduit 22 or may be totally enclosed in a panel comprising an enclosure conduit 26 , and optionally are attached to the conduit by, for example, welding. The outer conduit and optional enclosure conduit 26 in a panel are arcuate sections of conduits within the vessel which parallel the inner vessel wall at a distance sufficient to accommodate the cylinders and conduits. The outer conduit 22 comprises a multiplicity of perforations as is known in the art to enable passage of fluids and retain particles within a particle-retaining space, preferably as perforated-plate or punched-plate steel as described above; alternatively, profile wire as described in U.S. Pat. No. 5,366,704 may be used. The enclosure conduit 26 preferably is solid, but may be partially or totally perforated sheet to prevent dead spaces of fluid between the panel and the vessel. Preferably the perforations in the cylinder and in the conduit are oriented in opposite directions to avoid complete blockage of one layer (cylinder and/or conduit) of perforations by solid portions of the other layer. When the orientation is opposite for each layer it is not possible for one layer to completely block off the other, and the total open area can be calculated reliably without using some elaborate alignment scheme FIG. 3 is a cross-sectional view of a vessel 30 , showing the placement of two panels 32 of cylinders as described in FIG. 2 around the inner wall of the vessel. The panels are shown without the optional enclosure conduit shown as 26 in FIG. 2 . The optional connector 34 linking the panels is further described in FIG. 4 . Of course, such panels would extend all around the inner periphery of the vessel and the optional connector would extend substantially along the entire length of each panel. FIG. 4 is an expanded view of a connector linking two panels of cylinders. Vessel wall 30 and panel 32 relate to corresponding views in FIG. 3 ; in this illustration, the panel comprises the optional back shown as 26 in FIG. 2 . Connector 34 is a T-bar extending the length of the panels, and preferably is fabricated from the same steel as the panels. Coverplate 36 presses against the T-bar via notches 38 and may be welded in place; the coverplate prevents particles from entering the space between the panels. This system of connectors permits the panels to expand and contract with changes in temperature inside the vessel while maintaining the integrity of the device. FIG. 5 shows alternative configurations for the end section of a panel of cylinders. For orientation of the end section with respect to the previous figures, the inner section adjacent to the catalyst bed of each alternative is designated as 22 to correspond to the same designation in FIG. 2 . The section paralleling the vessel wall is designated as 26 to correspond to the designation in FIG. 2 . Only options ( 1 ) and ( 2 ) represent an actual panel outer enclosure as shown in FIG. 2 , but the designation nevertheless orients the panel with respect to its placement in a reactor. Options ( 1 ) and ( 2 ) require the largest spacing between panels because the enclosed ends require space in order to be able to insert and remove an individual panel. Options ( 3 ) and ( 4 ) provide more maneuverability through partially rounded ends. Option ( 5 ), in which the outer cylinder forms a portion of the panel wall, affords the most maneuverability and thus the closest potential spacing. The device and the resulting advantages in the collection or distribution of fluids can be readily appreciated from in the context of an apparatus and process for reforming hydrocarbons. The description of this invention in the limited context of a specific apparatus and process, is not meant to restrict the broad application of this invention to any specific apparatus or process for fluid solid contacting. The catalytic reforming process is well known in the art. A hydrocarbon feedstock and a hydrogen-rich gas are preheated and charged to a reforming zone containing typically two to five reactors in series. The hydrocarbon feed stream that is charged to a reforming system comprises naphthenes and paraffins boiling within the gasoline range. The preferred class of feed streams includes straight-run naphthas, thermally or catalytically cracked naphthas, partially reformed naphthas, raffinates from aromatics extraction and the like. Usually such feedstocks have been hydrotreated to remove contaminants, especially sulfur and nitrogen. A gasoline-range charge stock may be a full-range naphtha having an initial boiling point from about 40° to about 70° C. and an end boiling point within the range from about 160° to about 220° C., or may be a selected fraction thereof. Operating conditions used for reforming processes usually include an absolute pressure selected within the range from about 100 to about 7000 kPa, with the preferred absolute pressure being from about 350 to about 4250 kPa. Particularly good results are obtained at low pressure, namely an absolute pressure from about 350 to about 2500 kPa. Reforming conditions include a temperature in the range from about 315° to about 600° C. and preferably from about 425° to about 565° C. As is well known to those skilled in the reforming art, the initial selection of the temperature within this broad range is made primarily as a function of the desired octane of the product reformate, considering the characteristics of the charge stock and of the catalyst. The reforming conditions in the present invention also typically include sufficient hydrogen to provide an amount from about 1 to about 20 moles of hydrogen per mole of hydrocarbon feed entering the reforming zone, with excellent results being obtained when about 2 to about 10 moles of hydrogen are used per mole of hydrocarbon feed likewise, the liquid hourly space velocity (LHSV) used in reforming is selected from the range from about 0.1 to about 10 hr −1 , with a value in the range from about 1 to about 5 hr −1 being preferred. A multi-functional catalyst composite, which contains a metallic hydrogenation-dehydrogenation component on a porous inorganic oxide support providing acid sites for cracking and isomerization, is usually employed in catalytic reforming. Most reforming catalyst is in the form of spheres or cylinders having an average particle diameter or average cross-sectional diameter from about 1/16″ to about 3/16″. Catalyst composites comprising platinum on highly purified alumina or on zeolitic supports are particularly well known in the art. Metallic modifiers that improve product yields or catalyst life, such as rhenium, iridium, tin, and germanium, also may be incorporated into the catalyst. The principal reactions that take place are the dehydrogenation of naphthenes to aromatics, dehydrocyclization of paraffins, isomerization of paraffins and naphthenes, hydrocracking of paraffins to light hydrocarbons, and formation of coke which is deposited on the catalyst. Coke formation causing the catalyst to lose activity gradually over time requires regeneration and/or replacement of the catalyst, and transfer of catalyst from and to the reactor on a continuous basis is highly desirable. A reforming reaction section operating with the continuous addition and withdrawal of catalyst particles through a series of radial flow reactors, as illustrated in FIG. 6 , thus provides a good example of a fluid/solid contacting apparatus that can benefit from the present invention. The reaction section contains a series of four reactors arranged vertically in a stacked-reactor vessel 40 . The individual reactors or reaction zones are identified by numerals I-IV. Catalyst particles enter the top of the stacked-reactor arrangement through catalyst transfer line 42 and pass through the series of four reactors under gravity flow. After passage through each reactor section, the catalyst particles are withdrawn from the bottom of reactor IV by one or more catalyst withdrawal lines 44 . Catalyst withdrawn through lines 44 is regenerated by the oxidation and removal of coke deposits in a regeneration zone not shown in this illustration. After regeneration, catalyst particles are again returned to the process by line 42 . The combined hydrocarbon and hydrogen feeds enter the process through a line 50 and pass through a heater 52 to raise its temperature before entering reaction zone I. Partially converted feed is collected from the top of reaction zone I in line 54 and passes through an interstage heater 56 into reaction zone II. Intermediate reactor lines 58 and 60 carry the partially converted feed through reaction zones III and IV, with interstage heaters 62 and 64 respectively bringing the partially converted feed to reaction temperature. A reformate product is recovered from reaction zone IV by a product line 66 . As the catalyst passes through the adjacent stacked reactors of FIG. 6 , it is retained in a bed in each reactor. The arrangement of the internals for forming is the catalyst bed and effecting fluid-particle contacting in FIG. 7 shows a sectional view of reaction zone III, but is representative of intermediate reaction zone II as well. Catalyst particles (not shown) are transferred from a particle-retaining space 72 in zone II by a series of transfer conduits 74 into reaction zone III. A bed of catalyst particles is formed below the transfer conduits in a particle-retaining space defined by vessel partition or head 76 , outer conduit 88 and inner conduit 92 . The catalyst particles eventually are withdrawn from zone III through another series of transfer conduits 78 into reaction zone IV for ultimate removal from the stacked reactor. The partially converted feed enters reaction zone III through a nozzle 80 and flows into a distribution chamber 82 . A cover plate 84 extends across the bottom of chamber 82 to separate it from the particle-retaining space. Chamber 82 communicates the feed through a series of risers 85 that extend through the cover plate into the interior of a plurality of vertically-extended cylinders 86 ; there preferably is provision for a sliding fit between the cover plate 84 and risers 85 . Cylinders 86 and outer conduit 88 are as described in FIG. 2 for cylinders 24 and outer conduit 22 . Coverplate 90 for the panels defined by cylinders 86 and outer conduit 88 is as described in FIG. 4 for coverplate 36 . The foregoing description is presented only to illustrate certain specific embodiments of the invention, and should not be construed to limit the scope of the invention as set forth in the claims. There are many possible other variations, as those of ordinary skill in the art will recognize, which are within the spirit of the invention.
The distribution of fluids within a radial-flow reactor is improved using vertically extended cylinders distributed around the circumference of the vessel. Cylinders with a circular cross-section provide substantial vertical strength, and the configuration minimizes low-flow areas which could cause undesirable reactions. The cylinders are isolated from particles in the reactor by a particle-retaining outer conduit. The cylinders may be fabricated in panels for ease of installation and servicing.
1
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a continuation-in-part of U.S. patent application Ser. No. 13/755,780, filed on Jan. 31, 2013, entitled Passenger and Vehicle Elevator System and claims the benefit of U.S. Provisional Patent Application Ser. No. 61/595,225, filed Feb. 6, 2012, entitled Passenger and Vehicle Elevator System. The prior applications are incorporated herein by reference in their entirety. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to elevators, and particularly to a passenger and vehicle elevator system for carrying a vehicle and at least one passenger within a multi-story building. [0004] 2. Description of the Related Art [0005] The increasing cost of urban land, together with the need to provide affordable high density housing, as well as low-cost commercial or professional office space, presents several problems in the development of building complexes, particularly including motor vehicle parking facilities. Specifically, the need to develop affordable high-density housing, such as apartment or condominium complexes, has presented a problem in providing adequate space for parking personal motor vehicles in close proximity to the apartment or condominium building or buildings without encountering the prohibitive cost of erecting buildings with garage facilities directly above, or more commonly, directly below the building floors or levels that are dedicated to multiple dwelling units. [0006] National and local regulatory requirements with respect to fire ratings of structures with garages directly underneath residential dwelling units is cost prohibitive with respect to providing affordable housing in many urban areas. Further, the irregular shape of land parcels usually available for high-density housing in highly developed urban areas also presents a problem with respect to the placement of adequate parking spaces for personal automobile vehicles, which are closely adjacent the vehicle owner's dwelling unit. [0007] One solution to the above-mentioned problems is the development of multi-story garages for motor vehicles directly adjacent to, or within, the buildings that include the dwelling units to be occupied by the persons normally parking their vehicles in the garage. Multi-story garages are desired in areas where land costs require a maximum utilization of land area for rentable or saleable building space. However, multi-story garages can be inconvenient to use for many building occupants if parking is required on an upper level of the garage and a pathway between an upper level dwelling unit and the garage requires travel between ground level and the upper garage level, as well as travel between ground level and an upper level dwelling or other occupiable unit in the building or buildings adjacent to the garage. [0008] Multi-story garages have been constructed in which connecting bridges or walkways between parking decks and upper floors of buildings adjacent thereto have required stairways interconnecting the walkways or bridges with the parking decks, since the decks and the respective building floors have not been placed at the same elevations. Such arrangements have been unsatisfactory for elderly and disabled persons, as well as when moving large articles and furnishings between the garage and living units on the closest adjacent floors. [0009] Other considerations that must be taken into account in the development of high-density housing with multistory garages adjacent thereto concerns placement of the garage with respect to the dwelling units while maintaining adequate open space therebetween to conform to regulatory requirements and aesthetic desires of the building occupants. [0010] It would obviously be desirable to be able to provide the same access between a building dwelling unit on an upper floor or level and an upper story garage parking space as is provided for persons occupying a ground floor dwelling unit and corresponding ground level parking. Consideration should be given not only to the convenience of walking a substantially level pathway between a dwelling unit and the parking place for the building occupants' personal vehicles, but also with regard to such activities as trash disposal, mail delivery and pickup and the ease of moving personal effects and furniture in and out of a dwelling unit. Further, it would also be desirable to be able to maximize space for both parking and the residential or office spaces in such an arrangement. [0011] Thus, a passenger and vehicle elevator system solving the aforementioned problems is desired. SUMMARY OF THE INVENTION [0012] The passenger and vehicle elevator system carries a vehicle containing at least one passenger to a desired parking spot within a multi-story building. The passenger and vehicle elevator system includes a plurality of elevator cars arrayed substantially equidistantly from a central shaft of the building. Each elevator car includes a housing and at least one door. The elevator car housing has a floor, a ceiling and at least one sidewall. The elevator car is dimensioned and configured for carrying a vehicle and at least one passenger. Preferably, parking location-related information is read from the vehicle by an external sensor, such as an RFID sensor, bar code reader, or the like. [0013] A linearly translating platform is mounted to the floor of each of the elevator car housings. The linearly translating platform is adapted for automatically carrying the vehicle and the at least one passenger through the at least one door. Further, the vehicle may be rotated within the housing by driven rotation of the platform or rotation of the floor, allowing for selective angular positioning of the vehicle with respect to the housing. The elevator car ascends and descends within a corresponding elevator shaft in a manner similar to that of a conventional elevator. [0014] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings. BRIEF DESCRIPTION OF DRAWINGS [0015] FIG. 1 is a diagrammatic plan view of a single exemplary floor of a multi-story building utilizing a passenger and vehicle elevator system according to the present invention. [0016] FIG. 2A is a diagrammatic side view in section of an individual elevator car of the passenger and vehicle elevator system according to the present invention. [0017] FIG. 2B is a diagrammatic top view of the individual elevator car of FIG. 2A . [0018] FIG. 3A is a diagrammatic environmental top view, partially in section, illustrating a vehicle approaching an individual elevator of the passenger and vehicle elevator system according to the present invention. [0019] FIG. 3B is a diagrammatic environmental top view, partially in section, illustrating extension of a platform of the elevator of FIG. 3A to carry the vehicle into the elevator. [0020] FIG. 3C is a diagrammatic environmental top view, partially in section, illustrating the vehicle carried within the elevator of FIG. 3A . [0021] FIG. 4 is a diagrammatic partial perspective view of a floor of a garage space of the passenger and vehicle elevator system. [0022] FIG. 5 is another diagrammatic plan view of a single exemplary floor of a multi-story building showing garage and living spaces of a passenger and vehicle elevator system according to the present invention. [0023] Similar reference characters denote corresponding features consistently throughout the attached drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0024] FIG. 1 illustrates an exemplary floor plan of a single floor of a multi-story building B utilizing the passenger and vehicle elevator system 10 . In the exemplary floor plan of FIG. 1 , three separate elevators 12 , 14 , 16 are shown positioned about a central axis A of the building B. It will be understood that each elevator 12 , 14 , 16 includes an elevator car that may be selectively raised or lowered within a cylindrical elevator shaft by conventional elevator machinery, which is not shown in the drawings for clarity. It should be understood that the cylindrical elevator shaft is shown for exemplary purposes only, and that the contouring and relative dimensions of both the elevator shaft and corresponding elevator car may be varied as desired. Each elevator car includes at least one inner set of doors (or a single door) that selectively open and close, and each floor of the multi-story building includes at least one set of outer doors (or a single door), and preferably two angularly offset sets of outer doors, corresponding to each elevator 12 , 14 , and 16 . It should be understood that any desired number of elevators may be utilized, and that their positioning with respect to a building floor may be varied. In the exemplary configuration of FIG. 1 , in which the three elevators 12 , 14 , 16 are positioned such that their centers are equidistant from axis A, the elevators 12 , 14 , 16 are arrayed as an equilateral triangle, with each of elevators 12 , 14 , 16 serving one of regions 18 , 20 , 22 . For the circular arrangement of the floor plan shown in the example of FIG. 1 , each of regions 18 , 20 , 22 spans approximately 120° of arc, and each region 28 , 20 , 22 is separated from the adjacent region(s) by exemplary stairwells S or the like. [0025] In the exemplary configuration of FIG. 1 , each of regions 18 , 20 , 22 is bisected (as indicated by the dashed, radial lines in FIG. 1 ), such that region 18 is divided into sub-regions 24 , 26 ; region 20 is divided into sub-regions 28 , 30 ; and region 22 is divided into sub-regions 24 - 34 . Each of the sub-regions 24 - 34 represents an individual office or dwelling space. As used herein, a dwelling space or dwelling is defined as a temporary or permanent place or shelter where a person/people live such as but not limited to a home, apartment, condominium, unit, residence, living quarters, or hotel space. As shown, each individual office or dwelling space 24 - 34 has a respective garage space 24 g - 34 g. Each garage space has parking spaces PS disposed therein. Each garage space 24 g - 34 g has a respective entrance/egress 24 e - 34 e in a corresponding wall 24 w - 34 w for direct access between the office/dwelling space and the corresponding garage space. This allows a vehicle to be parked in the garage space with the user therein and allows the user to directly access their office/dwelling space via the entrance/egress. Thus, in this exemplary layout, each of the three regions 18 , 20 , 22 contains two individual offices or dwelling spaces having two parking spaces PS. Sub-region 24 includes a pair of parking spaces 36 ; sub-region 26 includes a pair of parking spaces 38 ; sub-region 28 includes a pair of parking spaces 40 ; sub-region 30 includes a pair of parking spaces 42 ; sub-region 32 includes a pair of parking spaces 44 ; and sub-region 34 includes a pair of parking spaces 46 . The living quarters or office space for each sub-region may be disposed radially outward from the corresponding parking spaces for the sub-region. [0026] Each of elevators 12 , 14 and 16 operates in an identical manner. In FIGS. 2A and 2B , a single elevator car 12 is illustrated. In order for the elevator car 12 to provide access to any of the two parking space pairs 36 , 38 in sector 18 (in the configuration of FIG. 1 ), either the inner doors 54 of the elevator car of elevator 12 may comprise one set spanning 180° of the elevator car and the elevator 12 may be equipped with a turntable to select either sub-region 24 to access parking spaces 36 or sub-region 26 to access parking spaces 38 , or the inner doors 54 of the elevator car may comprise two side-by-side sets which each span 90° and the floor of the elevator car may rotate to select either sub-region 24 or sub-region 26 . Preferably sub-region 24 has one set of outer doors 56 that open when sub-region 24 is selected, and sub-region 26 has another set of outer doors 56 that open when sub-region 26 is selected. In the exemplary circular configuration of the elevators illustrated in FIGS. 1 and 2B , the inner doors 54 and the outer doors 56 must open and close along an arcuate or circumferential path, rather than the conventional rectilinear path of conventional elevator doors. [0027] As shown in FIG. 2A , the vehicle V is positioned on a platform 50 within the elevator 12 , and the platform 50 is mounted on a controllable, rotational mount 52 . This rotational mount drives rotation of the platform 50 . This rotation not only allows selection of any of the four parking spaces within a particular region, but further allows the vehicle V to enter the elevator 12 front end first and then be rotated within the elevator to also exit the elevator 12 front end first. Such rotating platforms and drive systems are well known, and any suitable type of controllable, rotational mount 52 may be utilized. One such rotating platform is manufactured by PALIS Global Parking Technologies GmbH of Gersthofen, Germany. Another such mount is the Turntable 505 , manufactured by Otto Wahr GmbH of Fiolzheim, Germany. Other examples of such rotating platforms for vehicles are shown in U.S. Pat. No. 4,264,257, issued to Saurwein, and U.S. Patent Application Publication No. US 2005/0095092 A1, to Segal et al, each of which is hereby incorporated by reference in its entirety. [0028] In addition to the rotation of the platform 50 by rotational mount 52 , the platform 50 is also preferably horizontally translatable. FIG. 3A illustrates a vehicle V first approaching the doors 54 of the elevator 12 . In FIG. 3B , the doors 54 have circumferentially opened, as described above, and the platform 50 is linearly translated beneath the vehicle V and raised to carry the vehicle V. Once the platform 50 is fully positioned under the vehicle V and raised to support the vehicle, the platform 50 is translated back into the elevator 12 , as shown in FIG. 3C , and the vehicle V may be carried to the desired floor. [0029] It should be understood that any suitable type of driven platform may be utilized. Such translational dollies and mounts are well known. One such driven platform is manufactured by PALIS Global Parking Technologies GmbH of Gersthofen, Germany. Other examples of other such systems are shown in PCT Application Publication No. WO 2004/045932 A1, to Zangerle et al., and U.S. Pat. No. 4,768,914, issued to Sing, each of which is hereby incorporated by reference in its entirety. [0030] It should be understood that the system 10 may be used in combination with any suitable type of multi-story building. In use, vehicle V enters a ground floor, below-ground floor or lobby level and drives to one of elevators 12 , 14 , 16 , positioning the vehicle as shown in FIG. 3A . Preferably, at the entrance, the vehicle passes by a sensor 70 , as shown in FIG. 3A . Sensor 70 may be a bar code reader, an RFID sensor or the like, exchanging signals 72 with a matching label or device mounted on vehicle V for identifying the vehicle, including data identifying the vehicle's assigned floor and parking space. In response to the identification of the particular vehicle V and its assigned floor and parking space, the vehicle V is directed towards the appropriate entry or staging area in front of the corresponding one of elevators 12 , 14 , 16 for the particular parking space. [0031] Once at the appropriate staging area, the driver turns off the ignition of vehicle V and preferably remains within the vehicle V. The doors 54 to the elevator associated with the particular staging area open and the automatically controlled translating platform or dolly 50 moves outward from the elevator. The platform 50 moves underneath the vehicle V, lifts the vehicle V, and withdraws back into the elevator with the vehicle V remaining on the platform 50 . The elevator doors 54 then close and the elevator ascends to the appropriate floor or level. [0032] Once at the appropriate floor or level, the elevator doors 54 open and the laterally moving platform extends outward and deposits the vehicle V in its assigned parking space. The laterally moveable platform then withdraws from under the vehicle V, moves back into the elevator, the elevator doors 54 close, and the elevator is then ready to move the next vehicle. When the driver of vehicle V wishes the leave the building B, the driver signals for the appropriate elevator and the process is reversed. [0033] Because at least some of the garage spaces 24 g - 34 g are disposed above occupied spaces of an adjacent unit, such as bedroom(s), living rooms, office space etc., consideration is made to provide sound isolation from the floor of the garage spaces so as to reduce any noise associated with the platforms 50 transferring vehicles to/from the garage spaces 24 g - 34 g . Such is achieved by a sound isolation flooring which includes stainless steel sheets 104 (3-4 mm in thickness) which correspond to the maximum parking space PS size. The stainless steel sheets 104 are mounted on top of a 1.5 inch thick rubber layer 100 , where the rubber layer 100 can be provided in squares of a manageable size (24 inches×24 inches). The rubber layer 100 is adhered 100 a on to the concrete sub-floor 106 and the stainless steel sheets 104 are affixed to the rubber layer 100 by mechanical fasteners 105 . The concrete sub-floor 106 at the parking spaces PS has to be level in order for the platform 50 to be able to function properly. The area in the garage space 24 g - 34 g surrounding the parking spaces PS may be provided with a thinner rubber layer 101 covered by tiles 103 (ceramic, porcelain, granite etc.), which provides a flooring surface with a smooth/flush transition to the stainless steel sheets 104 . [0034] As noted above, since at least two parking spaces are preferably associated with each office or residential unit, the system 10 not only raises the vehicle V from the entrance level to the appropriate floor of the building B, but is also capable of moving the vehicle V to the correct parking space. This is accomplished by the rotating mount 52 for rotating the platform 50 . As an alternative, the platform 50 may be equipped with its own turntable, rather than being mounted thereon. During the ascent from the entrance level, the platform 50 may be rotated, if necessary, such that the vehicle V is placed into the correct parking space. During the descent back to the street level, the platform 50 is rotated so that when the elevator doors 54 open, the platform 50 moves the vehicle V outwardly into the departure area. Preferably, the departure area is spaced apart from the staging or loading area such that vehicles may egress from the building without interfering with the progression of other vehicles which are entering the building and waiting in the staging area. It should be understood that though two exemplary parking spaces are shown for each office or residential unit, any desired number of parking spaces may be allotted. [0035] Since the vehicle V is being transported vertically with one or more passengers within the elevator, and since the vehicles are being parked within the building at a level coextensive with an office or a residence, it is desirable to avoid having the vehicle engine operating either in the elevator or in the parking area. Thus, once the vehicle V initially enters the loading or staging area, a carbon monoxide detector 74 will register if the vehicle engine is operating and a positive response from the carbon monoxide detector 74 will prevent loading the vehicle onto the elevator. For example, doors 54 may remain closed until a zero or minimal level of carbon monoxide is measured by sensor 74 . Should the vehicle engine be off upon the entry into the elevator, but the engine started thereafter, one or more carbon monoxide sensors 76 within the elevator will stop the elevator's ascent and return the elevator to the entrance level. It should be understood that any suitable type of sensors may be utilized to ensure that the vehicle is not in operation. Additional sensors may be used to measuring vehicle dimensions, motion or the like, such as laser sensors, for example. [0036] In order to avoid injury to the operator of the vehicle and/or any passengers, suitable motion detectors or optical sensors 78 may further be provided within the elevator to detect opening of the vehicle door or trunk, which may be utilized as a basis for stopping the ascent or descent of the elevator. Further, conventional smoke, heat or fire detectors may also be mounted within the elevator. [0037] Although the elevators 12 , 14 , 16 may be varied in number, size and overall configuration, each elevator should be of a size sufficient to accommodate, for example, a vehicle of approximately six meters in length and two meters in width. Similarly, each elevator should be able to accommodate the weight of a motor vehicle and its passengers, preferably being able to carry loads up to approximately 3,500 kg. [0038] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
The passenger and vehicle elevator system includes a plurality of elevator cars arrayed substantially equidistantly and equiangularly from a central shaft of the building (B). Each elevator car ( 12, 14, 16 ) includes a housing and at least one door ( 54 ). The housing has a floor, a ceiling, and at least one sidewall. A linearly translating platform ( 50 ) is mounted on the floor of each of the housings. The linearly translating platform ( 50 ) is adapted for automatically carrying the vehicle (V) and the at least one passenger through the at least one door ( 54 ). Further, the vehicle (V) may be rotated within the housing by driven rotation of the platform ( 50 ) or the floor, allowing for selective angular positioning of the vehicle (V) with respect to the housing. The elevator car ( 12 ) ascends and descends within a corresponding elevator shaft in a manner similar to that of a conventional elevator.
4
BACKGROUND OF INVENTION 1. Technical Field of Invention The present invention generally relates to a modified glycol coolant circuit within a motor vehicle having a coolant/refrigerant heat exchanger for thermal coupling of a cooling plant/heat pump with the coolant circuit, whereby the glycol circuit is adapted to the requirements of a heat pump for the heating of the interior passenger compartment of the motor vehicle with a glycol/water mixture as the heat carrier. 2. Description of the Prior Art Cooling plants and heat pumps are utilized to cool or heat an interior space. The varying weather conditions caused by the sequence of seasons frequently require a heating system in winter and transitional periods and a cooling system in summer. Prior art devices have been developed comprising the combination of a heat pump and a cooling plant to alternately provide heating or cooling to interior rooms of a building or to provide heating or cooling to the interior passenger compartment of an automotive vehicle. Typically, in an automotive vehicle, heat from the engine is used to heat the interior of the vehicle. Modern combustion engines and electric motors tend to produce smaller and smaller amounts of waste heat. Therefore, future vehicle engines will yield sufficient amounts of heat to heat the passenger compartment, but not at the temperature level required. Particularly in winter, the cold-start phase is a problem. In some current diesel engine vehicles, supplementary heating systems with heater plugs, resistance heating systems, or fuel-fired burners have been provided, to supplement the heat provided by the engine. Many automotive vehicles are equipped with a cooling plant to air condition the passenger compartment in hot weather situations. One alternative to using a supplementary heating system of improve the heating of the interior passenger compartment within the vehicle is to alternatively use the cooling plant as a heat pump in cold weather situations. Prior art devices have combined cooling plants and heat pumps for use within automotive vehicles. The heat of the environment is used as a heat source, and alternatively, when needed, the temperature of the engine's waste heat is increased by the heat pump. For the use of a combined cooling plant/heat pump, where a glycol coolant circuit is the heat source of the heat pump, the cooling circuit must be adapted for this use. Referring to FIG. 1, a prior art coolant circuit is divided into a first circuit 1 and a second circuit 2 . A glycol/water mixture flows through the coolant circuit and is moved by a pump 7 . The glycol/water mixture cools the engine 16 , thereby assimilating heat and continuously flowing within the first circuit 1 . A heat exchanger 3 of the heating system is positioned within the first circuit, whereby heat is absorbed from the glycol/water mixture and used to heat the passenger compartment of an automotive vehicle. A thermostat 4 is adapted to open when the temperature of the glycol/water mixture exceeds a pre-determined value. Once the thermostat 4 is opened, the glycol/water mixture is allowed to flow into the second circuit 2 . A radiator is positioned within the second circuit 2 and is adapted to radiate heat from the glycol/water mixture to the environment, thereby removing waste heat of the engine to the environment. In addition, the refrigerant circuit, which preferably uses carbon dioxide as refrigerant, is designed according to the state-of-the-art such that both the cooling plant operational mode and the heat pump operational mode are possible. The refrigerant circuit and the coolant circuit each have a number of components. The components must be meticulously assembled, either manually or by automated methods, because leakage in the system will prevent the system from working properly. Space limitations add difficulties to the assembly of these components. Therefore, it is the objective of this invention to provide a coolant circuit having features to transfer the heat to a refrigerant circuit wherein the coolant circuit optimizes size, maintenance, and assembly considerations, and the coolant circuit acts as the heat source for a heat pump to heat the passenger compartment of a motor vehicle. SUMMARY OF THE INVENTION The disadvantages of the prior art are overcome by providing a coolant circuit for a motor vehicle with a coolant/refrigerant heat exchanger for thermal coupling of a cooling plant/heat pump to the coolant circuit. The coolant circuit is preferably a glycol circuit, whereby the glycol circuit according to the invention is adapted to the requirements of a heat pump for the heating of the passenger compartment of the motor vehicle with a glycol/water mixture as heat carrier, wherein the glycol circuit is thermally coupled over the glycol/refrigerant heat exchanger to the refrigerant circuit of the cooling plant/heat pump such that the glycol/refrigerant heat exchanger together with the external heat exchanger, the radiator, the accumulator/collector, and internal heat exchanger forms a space-saving, easy to assembly and low maintenance heat exchanger module with integrated connection lines for heat transfer from the glycol circuit to the refrigerant circuit. In another aspect of the present invention, a high-pressure selector valve and a low-pressure selector valve of the refrigerant circuit are integrated into the heat exchanger module. The design of the coolant and refrigerant circuits according to the present invention allows the number of connection ports to be reduced, and the supplier can pre-assemble the heat exchanger module using dedicated assembly technology. These features result in cost savings and enhanced quality. Additionally, particularly in winter, the ride comfort improves due to the coupling according to the present invention of the coolant and refrigerant circuits and use of the heat pump, as the desired temperature in the interior of the passenger compartment can be achieved more rapidly. Further details, features and advantages of the invention ensue from the following description of examples of embodiments with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of a prior art coolant circuit; FIG. 2 is a schematic view of a refrigerant circuit and a coolant circuit for a heat pump; FIG. 3 is a schematic view of a glycol circuit with a bypass for the glycol/refrigerant heat exchanger and controlled heating heat exchanger; FIG. 4 is a schematic view of a Glycol circuit with a controlled glycol/refrigerant heat exchanger and a controlled heating heat exchanger; FIG. 5 is a schematic front view of a heat exchanger module of the present invention; and FIG. 6 is a schematic top view of the heat exchanger module shown in FIG. 5 . DETAILED DESCRIPTION OF THE INVENTION The following description of the preferred embodiment of the invention is not intended to limit the scope of the invention to this preferred embodiment, but rather to enable any person skilled in the art to make and use the invention. Referring to FIG. 2, a first preferred embodiment of the cooling circuit according to the present invention is shown. A glycol circuit 1 , 2 is thermally coupled over a glycol/refrigerant heat exchanger 6 to a refrigerant circuit 23 . The refrigerant circuit 23 is adapted to function as either a cooling plant, for cooling and air conditioning of the passenger compartment or as a heat pump, for the heating of the passenger compartment of the vehicle. When the cooling circuit is operating as a cooling plant, the refrigerant is compressed in the compressor 9 . Preferably, the refrigerant is carbon dioxide (R744), tetrafluorethane (R134a), or propane (R290), however it is to be understood, that other refrigerants could be used within the scope of the present invention. The compressed refrigerant passes through a high-pressure selector valve 17 and into an external heat exchanger 22 , where the refrigerant dissipates heat energy to the environment. The cooled, and at least partially condensed, refrigerant then passes through an internal heat exchanger 20 , which also functions as an accumulator/collector, and on to a flash element 19 , where the refrigerant expands to the evaporation pressure level. When the cooling circuit is functioning as a cooling plant, an internal heat exchanger 18 functions as an evaporator, wherein the refrigerant evaporates, thereby taking heat from the passenger compartment. The vaporized refrigerant then passes through a low-pressure selector valve 21 and a low-pressure side of the internal heat exchanger 20 to the compressor 9 , where the circuit for operation as a cooling plant closes. When the circuit is operating as a heat pump, the refrigerant is first compressed in the compressor 9 , then flows through the high-pressure selector valve 17 to the internal heat exchanger 18 . The internal heat exchanger 18 works as a condenser when the circuit is operating as a heat pump, and dissipates the condensation heat to the passenger compartment for heating. The refrigerant then flows in a direction opposite to the direction of flow in coolant plant mode, through the expansion element 19 and the internal heat exchanger 20 and finally reaches the glycol/refrigerant heat exchanger 6 , which thermally couples the refrigerant circuit to the coolant circuit. Within the glycol/refrigerant heat exchanger 6 , the liquid refrigerant takes heat from the coolant circuit while evaporating, and the refrigerant vapor then passes through the low-pressure selector valve 21 and the low-pressure side of the internal heat exchanger 20 to the compressor 9 . When functioning as a cooling plant, the external heat exchanger 22 is bypassed, and when functioning as a heat pump, the glycol/refrigerant heat exchanger 6 is bypassed. All other components of the circuit are required for both operation as a cooling plant and as a heat pump. When using the engine's waste heat as a heat source as shown in FIG. 2, the engine heat is fed to the heat pump through the coolant circuit. To achieve this, the glycol/refrigerant heat exchanger 6 is channelled into the small circuit 1 of the glycol circuit parallel to the heating heat exchanger 3 . In the coolant circuit the glycol/water mixture is moved by a pump 7 . The glycol/water mixture passes through the cooling system of the engine 16 and absorbs waste heat of the engine. Within a thermostat valve 4 the coolant is passed into the small circuit 1 and/or the big circuit 2 . In the small circuit 1 the coolant flows to a multi-way directional valve 8 , where the coolant flow is divided, flowing in parallel through the glycol/refrigerant heat exchanger 6 and the heating heat exchanger 3 . In this way, the multi-way directional valve is adapted to enable both the parallel passage of the heating heat exchanger 3 and the glycol/refrigerant heat exchanger 6 , and the alternate single passage of the heat exchangers 3 , 6 . The refrigerant is then again moved by the pump 7 through the engine 16 to absorb waste heat from the engine, thus closing the circuit. When the heating demand of the passenger compartment decreases, the thermostat valve 4 provides the big circuit 2 with coolant in that measure as less heat is needed and the engine's waste heat is dissipated through the radiator 5 to the environment. Dependent on the operational cycle different switching versions must be made possible by the coolant and refrigerant circuits 2 , 23 . These operation versions include operation as an air conditioner; operating to reheat or heat; warm-up operation, wherein the circuit operates as a heat pump with glycol as the heat source; stationary operation or operating to heat the heat exchanger, wherein after the glycol reaches the necessary temperature the heat pump is switched off; and safety function. If the refrigerant is unintendedly stored in the refrigerant/glycol heat exchanger and does not actively take part in the circuit operation as a cooling plant, the heat exchanger is passed by “warm” glycol and the refrigerant “expelled”. To achieve these variations, a multi-way directional valve 8 is provided within the coolant circuit. The multi-way directional valve is adapted to function either as a thermostat or as an electronic valve. Further, the multi-way directional valve 8 is adapted to function as an electrical controlling unit so that it can also be used for flow control, and hence temperature control, of the heat exchanger 3 of the heating system. This also allows the system to be smaller by eliminating components normally required for the air conditioning unit. Referring to FIG. 3, in a second preferred embodiment, an electrical controlling unit is adapted such that the flow through the heating heat exchanger is controlled with a multiway water valve 10 , whereby a bypass flow is passed over the glycol/refrigerant heat exchanger 6 . Referring to FIG. 4, by using two-way water valves 10 , the coolant flow can be controlled over both heat exchangers 3 , 6 , or over several heating heat exchangers 3 or heat exchanger zones that are given different temperatures. Multiway valves could also be used in place of the two-way water valves 10 . By use of the heat pump according to the present invention the space requirements of the heating heat exchangers can be reduced by up to 30%. Referring to FIGS. 5 and 6, The space-saving design and arrangement of heat exchangers and valves according to the present invention is illustrated. According to the present invention, the glycol/refrigerant heat exchanger 6 for thermal coupling of the cooling plant/heat pump to the glycol circuit is combined with the external heat exchanger 22 , radiator 5 , and accumulator/collector and internal heat exchanger 20 to form a space-saving, easy to assembly, and maintenance-friendly heat exchanger module 28 , which contains connection lines between the components of the module 28 . The structural integration of the glycol/refrigerant heat exchanger 6 , external heat exchanger 22 , and radiator 5 reduces the number of connections and enables a compact design with reduced leakage flow. It is particularly advantageous to integrate the high-pressure selector valve 17 and the low-pressure selector valve 21 of the refrigerant circuit 23 into the heat exchanger module 28 . This allows that the heat exchanger module 28 to be equipped with only four refrigerant outer ports. One port for the connection of the heat exchanger module 28 to the suction side of the compressor 24 , one port for the connection to the pressure side of the compressor 25 , one port for the connection to the flash element 26 , and one port for the connection to the internal heat exchanger 27 . Additionally, the heat exchanger module 28 includes four coolant ports, which are not shown, for the connection to the radiator 5 and glycol/refrigerant heat exchanger 6 . Preferably, a connection line from the glycol/refrigerant heat exchanger 6 and the low-pressure selector valve 21 is installed within the accumulator/collector and internal heat exchanger 20 , such that the connection of the line to the glycol/refrigerant heat exchanger 6 and the low-pressure selector valve 21 is performed during the pre-assembly process, thereby eliminating another connection point. The glycol/refrigerant heat exchanger 6 is dimensioned according to the invention such that during the start phase of the engine 16 in winter operation only a portion of the waste heat is taken from the glycol circuit. This is necessary because at very deep temperatures the engine works with a very low efficiency and produces harmful noxious emissions. Therefore, only heat that originates from the operation of the compressor 9 can be used. This portion should be in the range of approximately 50%, depending upon the dimensioning of the engine. At higher temperatures of the glycol in warmed-up conditions of the engine 16 this limit no longer applies. The foregoing discussion discloses and describes the preferred embodiments of the invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that changes and modifications can be made to the invention without departing from the scope of the invention as defined in the following claims. The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
A heat exchanger module includes a glycol coolant circuit adapted to function as a heat pump for the heating of the interior passenger compartment of the motor vehicle with a glycol/water mixture as the heat carrier, a refrigerant circuit, and a glycol/refrigerant heat exchanger positioned between and interconnecting the cooling circuit and the refrigerant circuit, wherein the glycol/refrigerant heat exchanger has integrated connection lines for heat transfer from the coolant circuit to the refrigerant circuit.
5
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to an augmented reality system with mobile and interactive functions for multiple users that can, for example, be applied to virtual prototype evaluations for vehicles. [0003] 2. Description of the Related Art [0004] Augmented reality is a new virtual reality technology that combines environmental images with computer virtual images. [0005] An augmented reality kit (ARtoolKit) can provide users with one of the most natural of browsing methods; a virtual model will move or rotate with the viewing direction of the user, which provides a more vivid experience than browsing simply with a mouse or keyboard. However, the augmented reality kit requires huge computing capabilities, which are not offered by typical mobile computing devices, such as PDAs; any computer capable of providing this huge computing ability will inevitably have a large volume and little mobility. [0006] Moreover, how to reach a discussion from different locations or even let one user can see other user's vision. [0007] Therefore, it is desirable to provide an augmented reality system with mobile and interactive functions for multiple users to mitigate and/or obviate the aforementioned problems. SUMMARY OF THE INVENTION [0008] A main objective of the present invention is to provide an augmented reality system with mobile and interactive functions for multiple users that can, for example, be applied to virtual prototype evaluations for vehicles. So multiple users can have real-time discussion at different locations, and even see other user's vision. These discussions can be performed by PDA so the users can also input comment for record. [0009] In order to achieve the above-mention objective, the augmented reality system with mobile and interactive functions for multiple users includes two major portions: a computer system for handling augmented reality functions, and a user system for each user. The computer system for handling augmented reality functions has very powerful functionality for processing digital image data and transforming the digital image data into a three-dimensional virtual image for each user system. [0010] The user system includes the head-mounted display, a camera and a microphone on the display, and a portable computer. The user utilizes the head-mounted display to watch the three-dimensional virtual image and the microphone or the portable computer to communicate with other user. The camera can obtain the viewing position of the user. When the user wants to see other user's vision, the augmented reality computer system can compute the other three-dimensional virtual image watched by other user by obtaining other user's position. [0011] 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 [0012] FIG. 1 is a system structure drawing of the present invention which shows the performance environment in a single area. [0013] FIG. 2 is a system structure drawing of the present invention which shows the performance environment in two different areas. [0014] FIG. 3 is a structure drawing of a software program related to the present invention. [0015] FIG. 4 is a flow chart for displaying virtual images according to the present invention. [0016] FIG. 5 is a flow chart of showing a usage status for multiple users. [0017] FIG. 6 is a drawing of an embodiment of a portable computer according to the present invention. [0018] FIG. 7 is a schematic drawing of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0019] Please refer to FIG. 1 . FIG. 1 is a system structure drawing of the present invention which is used for designing the appearance of vehicles. [0020] The present invention provides an augmented reality system with mobile and interactive functions for multiple users 10 , which includes two major portions: an augmented reality computer system 20 , and multiple user systems 50 for each user. In this embodiment, there are two users 80 a , 80 b using the augmented reality computer system at the same time. [0021] In this embodiment, the augmented reality computer system 20 comprises a first augmented reality computer subsystem 20 a and a second augmented reality computer subsystem 20 b , wherein each subsystem 20 a , 20 b are basically electrically connected together. With reference also to FIG. 3 , each subsystem 20 a , 20 b utilizes one computer, and each subsystem 20 a , 20 b comprises an augmented reality system application program 21 . In the present invention, the augmented reality system application program 21 comprises computer image generation program code 22 , data transmission program code 23 , viewing point position analysis program code 24 and three-dimensional computer drawing data 25 . In this embodiment, the three-dimensional computer drawing data 25 is related to the vehicle appearance design drawing data. [0022] The user system 50 comprises user systems 50 a , 50 b for each user 80 a , 80 b . The user system 50 a comprises a head-mounted display 30 a (which usually includes a speaker), a camera 3 la and a microphone 32 a mounted on the head-mounted display 30 a , and a portable computer 40 a . Similarly, the user system 50 b also comprises a head-mounted display 30 b , a camera 31 b , a microphone 32 b and a portable computer 40 b. [0023] In this embodiment, each user 80 a , 80 b wears the head-mounted display 30 a , 30 b , and when the user 80 a , 80 b moves, his or her current position or the angle of his or her head changes, as does a virtual image 60 displayed a real image. There is a position reference object 70 in this embodiment; when the user 80 a , 80 b moves around the position reference object 70 , the virtual image 60 displayed an image would be seen at the position of the position reference object 70 , as shown in FIG. 7 . [0024] The embodiment of FIG. 1 is substantially a performance environment in a single area. Please refer to FIG. 2 . FIG. 2 is a system structure drawing of the present invention which shows a performance environment in two different areas. The subsystems 20 a , 20 b are electrically connected together via the Internet 90 (or via an intranet for shorter distances). Since the users 80 a , 80 b are located at different positions, there are two different reference objects 70 a , 70 b , and the virtual images 60 a , 60 b are separately shown at the position of the reference objects 70 a , 70 b. [0025] Please refer to FIG. 4 . FIG. 4 is a flow chart for displaying virtual image according to the present invention. The following description is performed at the user 80 a end: [0000] Step 401 : [0026] The augmented reality computer subsystem 20 a obtains the three-dimensional computer drawing data 25 . [0000] Step 402 : [0027] The image of the position reference object 70 is obtained; the camera 31 a is placed on the head-mounted display 30 a , so when the user 80 a faces the position reference object 70 , the camera 3 la can obtain an image of the position reference object 70 and send the image to the subsystem 20 a. [0000] Step 403 : [0028] The image of the position reference object 70 is analyzed to obtain a viewing point position parameter. [0029] The viewing point position analyze program code 24 of the subsystem 20 a analyzes the image of position reference object 70 to obtain the position of the viewing point of the user 80 a . The position reference object 70 has a reference mark 71 (such as “MARKER”), and by analyzing the size, shape and direction of the reference mark, the position of the viewing point of the user 80 a can be obtained, which is indicated by a viewing point position parameter (such as a coordinate or a vector, etc.). However, this is a well-known technology, and so requires no further description. [0000] Step 404 : [0030] The three-dimensional virtual image 60 is calculated according to the viewing point position parameter; with the viewing point position parameter, the computer image generation program code 22 can transform the three-dimensional computer drawing data 25 into a three-dimensional virtual image 60 . This process is a well known imaging procedure [0000] Step 405 : [0031] The virtual image 60 is sent to the head-mounted display 30 or the portable computer 40 , so that the user 80 a can see the virtual image 60 . Please refer to FIG. 5 . FIG. 5 is a flow chart of showing a usage status for multiple users. The following description considers when the user 80 a wants to send his or her comments to the user 80 b , or the user 80 b wants to send his or her comments to the user 80 a. [0000] Step A 1 : Recording the Comment. [0032] In the present invention, the user 80 a can record his or her comments about the virtual image 60 in the portable computer 40 a ; for example, comments about the shape or color of the vehicle, or the inputting of instructions via the portable computer 40 a to control the subsystem 20 a to change the shape or color of the vehicle. Please refer to FIG. 6 . The portable computer 40 is a PDA; a screen 41 of the portable computer 40 displays a virtual image window 42 and a comment window 43 . [0000] Step A 2 : Sending the Comment. [0033] The user 80 a sends a virtual image window 42 and a comment window 43 to the subsystem 20 b via the subsystem 20 a by controlling the portable computer 40 a. [0000] Step B 1 : Receiving the Comment. [0034] The subsystem 20 b receives the virtual image window 42 and the comment window 43 sent from the subsystem 20 a and sends the virtual image window 42 and the comment window 43 to the portable computer 40 b . [0000] Step B 2 : Executing an Image Switch Instruction. [0035] If the user 80 b wants to have a direct discussion with the user 80 a , it is preferably to involve a discussion of the virtual image 60 a as seen by the user 80 a . The user 80 b can use the portable computer 40 b to execute the image switch instruction. [0000] Step B 3 : Sending an Image Switch Execution Instruction. [0036] The subsystem 20 b sends an image switch execution instruction to the subsystem 20 a. [0000] Step A 3 : the Subsystem 20 a Receives the Image Switch Execution Instruction. [0000] Step A 4 : the subsystem 20 a continuously sends the first viewing point position parameter, which is the viewing point of the user 80 a. [0000] Step B 4 : the subsystem 20 b receives the first viewing point position parameter. [0000] Step B 5 : The three-dimensional virtual image as seen by the first user is calculated. [0037] Meanwhile, the subsystem 20 b calculates the virtual image 60 a according to the first viewing point position parameter. [0000] Step B 6 : The virtual image 60 a is sent to the head-mounted display 30 b and the portable computer 40 b. [0038] The user 80 b can thus see on the head-mounted display 30 b the image seen by the user 80 a . Since the first viewing point position parameter is a small sized piece of data, so it can be sent quickly. [0039] Of course, while the user 80 a changes his or her viewing position, step A 4 will continuously be performed, as do steps B 4 -B 6 . [0040] Furthermore, the users 80 a , 80 b can communicate via audio, particularly when the users 80 a , 80 b are at different positions (as shown in FIG. 2 ). For example, there are microphones 32 a , 32 b mounted in the head-mounted displays 30 a , 30 b , and the head-mounted displays 30 a , 30 b also have built-in speakers for real-time communications. Therefore, there may be no comments, and consequently no steps A 1 , A 2 , B 1 . Of course, the portable computers 40 a , 40 b may also have built-in microphones and speakers (not shown), in which case no microphones 32 a , 32 b and speakers need to be mounted in the head-mounted display 30 a , 30 b. [0041] Data transmissions between the two subsystems 20 a , 20 b or between the subsystems 20 a , 20 b and the portable computer 40 a , 40 b can be performed by the data transmission program code 23 . [0042] Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. For example. The augmented reality computer system 20 shown in FIG. 1 can be one super computer, and so there would be no need for other subsystems, or the three-dimensional computer drawing data 25 can be stored in another computer for sharing with the two computers.
An augmented reality system with mobile and interactive functions for multiple users includes two major portions: a computer system for handling augmented reality functions, and a user system for each user. The computer system for handling augmented reality functions has very powerful functionality for processing digital image data and transforming the digital image data into a three-dimensional virtual image for each user system. The user system mainly includes a Head-Mounted Display (HMD), a microphone and a PDA. A user can see the virtual image from the HMD and use the microphone or the PDA for communication with other users.
6
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to cured adhesive systems, e.g., epoxy adhesives. The invention also relates to complete knock-down assembly systems and methods of assembly using such epoxy adhesive systems. [0003] 2. Discussion of Background Information [0004] A common practice in the automotive industry is to manufacture parts in one country or region, then export and/or ship to another location (e.g., country or region) for final assembly. This is called CKD (complete knock-down). [0005] In a CKD system, parts may be partially assembled prior to shipping to the location of final assembly. In particular, in a first location (e.g., an auto parts factory), components may be bonded together using an epoxy adhesive, which is then partially cured, e.g., with elevated temperature. The partially assembled components are then shipped to a second location, e.g., the location of final assembly. Typically, additional assembly takes place at the second location, and then the curing process (begun in the first location), is completed. [0006] If a part used in the automotive body is adhesively bonded at the first location, the adhesive needs to fulfill special performance criteria concerning the humidity resistance and tolerance such that the article assembled at the second location meets product and manufacturing specifications. A lab test to fulfill the requirements of the automotive industry consists of lap shear specimen bonded with a crash-durable adhesive, pre-hardened at 170° C. for 12 min, to which a CKD-conservation oil is applied, and aged at a constant climate of 40° C. and 100% relative humidity for 5 weeks (DIN EN ISO 6270-2CH). Then, the specimen is fully cured at 175° C. for 25 min and lap shear strength is tested according to DIN EN 1465. The loss of strength compared to the un-aged but cured specimen and the failure mode is evaluated. [0007] Some adhesives used in CKD bonding in vehicle manufacture are disclosed in EP 1,186,462 A1, US 2004/0079478 A1, and U.S. Pat. No. 6,478,915, the disclosures of which are incorporated by reference in their entireties. These pertain to a two-part BIW-sealer and adhesive, hardened by a UV-induced and a thermal mechanism. These are very expensive systems, and do not result in a crash-durable type (CDA) adhesive. [0008] Adhesives used in CKD assembly may include epoxy adhesives. Epoxy adhesives typically comprise an epoxy resin which is cured with a hardener (or curing agent), and may include other components to modify properties of the material. In order to assure adequate curing, epoxy adhesive resins are typically prepared using an excess of hardener agent relative to epoxy resin, that is, an amount of hardener in excess of the stoichiometric amount thought to be necessary for fully curing the adhesive and getting the optimum crosslinking density. [0009] While the predominant part of scientific studies, carried out with model epoxy resins, are consistent in finding that the optimum crosslinking density resulted in an epoxide (equivalents)/DICY (mols) ratio of 6-7, see e.g. Guenther et al. from Degussa (J. Appl. Polymer Sci, vol. 50, 1453-1459 (1993)) (the disclosure of which is incorporated by reference in its entirety), a few studies involving curing of epoxy resins with dicyandiamide as a curing agent and urones as accelerators, came to different conclusions. [0010] The Handbook of Adhesive & Sealants in its standard formulations uses 5%, 6%, but most frequently 10% by wt. of DICY referred to the total of liquid epoxy resin (while the 6% wt/wt of basic epoxy resin would represent about optimum crosslinking density according to the Degussa references by Guenther et al.). [0011] For the comparative ratio calculations in relevant CDA IP references the following epoxide to DICY ratios resulted: [0012] EP 1,186,462 A1 discloses ratios of equivalents epoxide/mol DICY of 5.73 to 5.98, with an average value of 5.81. [0013] US 2004/0079478 A1 discloses ratios of equivalents epoxide/mol DICY of 5.31 to 5.66, with an average value of 5.48. [0014] U.S. Pat. No. 6,478,915 discloses ratios of equivalents epoxide/mol DICY of 5.36 to 5.61, with an average value of 5.45. [0015] EP308664B1 to Muelhaupt discloses in examples 1-20 ratios of equivalents epoxide/mol DICY of 3.66, and in examples 21-46 discloses ratios of 4.25 to 4.53. [0016] These latter results indicate that in current industrial adhesive formulations, an excess of DICY over the stoichiometric ratio of 6-7/1 is typically applied. SUMMARY OF THE INVENTION [0017] It has been surprisingly found that by increasing the ratio of epoxy functionality to hardener concentration (e.g. dicyandiamide), a fully cohesive failure mode (cohesive failure mode is obtained if a crack propagates in the bulk adhesive; ISO 10365) and low decrease of lap shear strength according to DIN EN 1465 after aging could be achieved. [0018] The invention provides an epoxy hardener ratio with improved humidity resistance. [0019] As noted above, the epoxy to hardener ratio in an adhesive is usually set to an excess of hardener compared to epoxy functional groups. After CKD aging (see above), the failure mode is critical and decrease of lap shear strength is not optimal. We have found that by decreasing the amount of hardener (increasing the ration of epoxy to hardener) the failure mode after aging is heavily improved and decrease of lap shear after aging minimized. [0020] The present invention provides an epoxy adhesive comprising an epoxy resin and a hardener, wherein the amount of hardener is less than or about a stoichiometric amount relative to the epoxy resin. In the epoxy adhesive, the ratio of equivalents of epoxy resin to moles of hardener may be 6-11, preferably 6.5-10, more preferably 7-9. The epoxy adhesive is preferably a partially curable adhesive, preferably a heat curable adhesive. [0021] The invention also provides an article of manufacture comprising a first surface and a second surface, wherein the provided epoxy adhesive is in contact with the first and second surfaces. [0022] The present invention also provides a manufacturing method comprising applying an epoxy adhesive between two components; and pre-curing the epoxy adhesive in a first curing stage to obtain an at least partially cured article; wherein the epoxy adhesive bonds the two components, and wherein the epoxy adhesive comprises an epoxy resin and less than or about a stoichiometric amount of hardener. [0023] The present invention also provides a manufacturing method comprising receiving a partially cured article, the partially cured article comprising at least two components bonded by partially cured epoxy adhesive therebetween; and curing the partially cured article in a second curing stage; wherein the epoxy adhesive comprises an epoxy resin and less than or about a stoichiometric amount of hardener. [0024] The present invention also provides a manufacturing method comprising applying an epoxy adhesive between two components; bonding the two components by partially curing the epoxy adhesive in a first curing stage to obtain a partially cured article; aging the partially cured article; and curing the partially cured aged article in a second curing stage, wherein the epoxy adhesive comprises an epoxy resin and less than or about a stoichiometric amount of hardener. [0025] The present invention also provides compositions, articles, and methods, in which the epoxy adhesive preferably comprises an epoxy resin having general formula: [0000] [0000] where n is in the range of 0 to about 25. The hardener preferably comprises dicyandiamide. [0026] The present invention also provides compositions, articles, and methods, in which the epoxy adhesive may comprise an accelerator. When used, the accelerator preferably comprises 0.3-5 wt %, preferably 0.5-2 wt %, based on weight of the epoxy adhesive. [0027] The present invention also provides compositions, articles, and methods, in which the epoxy adhesive may also comprise at least one of a toughener, a mineral filler, a thixotropic agent, a viscosity regulator, silica, a diluent, an adhesion promoter, a surfactant, a wetting agent, a flexibilized epoxy agent, a gelling compound, a flame retardant, a pigment, and combinations of two or more thereof. [0028] The present invention also provides compositions, articles, and methods wherein the epoxy adhesive resin is partially cured. [0029] The present invention also provides compositions, articles, and methods, wherein the composition or article is aged 2 days to 1 year, preferably 1 week to 9 months, more preferably 1 month to 4 months. The present invention also provides methods that include aging pre-cured compositions and/or articles for 2 days to 1 year, preferably 1 week to 9 months, more preferably 1 month to 4 months. [0030] The present invention also provides compositions, articles and methods wherein the epoxy adhesive is a partially curable adhesive, preferably a heat curable adhesive. BRIEF DESCRIPTION OF THE DRAWINGS [0031] FIG. 1 is a photograph of blocks to which epoxy adhesive according to Comparative Example A was applied and aged 5 weeks under simulated CKD conditions. [0032] FIG. 2 is a photograph of blocks to which epoxy adhesive according to Comparative Example B was applied and aged 5 weeks under simulated CKD conditions. [0033] FIG. 3 is a photograph of blocks to which epoxy adhesive according to Example C was applied and aged 5 weeks under simulated CKD conditions. [0034] FIG. 4 is a photograph of blocks to which epoxy adhesive according to Example D was applied and aged 5 weeks under simulated CKD conditions. [0035] FIG. 5 is a photograph of blocks to which epoxy adhesive according to Example E was applied and aged 5 weeks under simulated CKD conditions. DETAILED DESCRIPTION OF THE INVENTION [0036] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. [0037] Unless otherwise stated, a reference to a compound or component includes the compound or component by itself, as well as in combination with other compounds or components, such as mixtures of compounds. [0038] As used herein, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. [0039] Except where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not to be considered as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding conventions. [0040] Additionally, the recitation of numerical ranges within this specification is considered to be a disclosure of all numerical values and ranges within that range. For example, if a range is from about 1 to about 50, it is deemed to include, for example, 1, 7, 34, 46.1, 23.7, or any other value or range within the range. Similarly, when a parameter, variable, or other quantity, is described with a set of upper values, and a set of lower values, then this is to be understood as an express disclosure of all ranges formed from each pair of upper and lower values. [0041] The present invention provides an epoxy adhesive, and provides for methods of using the epoxy adhesive, e.g., in a CKD assembly system. The epoxy adhesive may comprise one or more epoxy resins, and one or more hardeners, wherein the hardener is present in about, or less than, a stoichiometric amount relative to the epoxy resin. The epoxy adhesive may also comprise one or more other additional components to modify a property of the composition before, during, or after curing. Such additional components may include, e.g., one or more of accelerators, tougheners, fillers, thixotroping agents, viscocity regulators, adhesion promoters, wetting agents, corrosion inhibitors, shrinkage inhibitors, humidity scavengers, epoxy silane, fumed silica, and pigments. [0042] Epoxy resins useful in this invention include a wide variety of curable epoxy compounds and combinations thereof. Useful epoxy resins include liquids, solids, and mixtures thereof. Typically, the epoxy compounds are epoxy resins which are also referred to as polyepoxides. Polyepoxides useful herein can be monomeric (e.g., the diglycidyl ether of bisphenol A, diglycidyl ether of bisphenol F, digylcidyl ether of tetrabromobisphenol A, novolac-based epoxy resins, and tris-epoxy resins), higher molecular weight resins (e.g., the diglycidyl ether of bisphenol A advanced with bisphenol A) or polymerized unsaturated monoepoxides (e.g., glycidyl acrylates, glycidyl methacrylate, allyl glycidyl ether, etc.) to homopolymers or copolymers. Most desirably, epoxy compounds contain, on the average, at least one pendant or terminal 1,2-epoxy group (i.e., vicinal epoxy group) per molecule. Solid epoxy resins that may be used in the present invention can preferably comprise or preferably be mainly based upon Bisphenol A. For example, a preferred epoxy resin is diglycidyl ether of bisphenol A Dow Chemical DER 664 UE solid epoxy. [0043] One preferable epoxy resin has general formula: [0000] [0000] where n is generally in the range of 0 to about 25. Basic liquid resins, e.g. D.E.R. 331, have epoxy equivalent weights in the range of about 180-195 g/mol. [0044] Combinations of epoxy resins may be used to adjust properties of the epoxy adhesive. In compositions and methods of the present invention, the epoxy adhesive may comprise any amount of epoxy resin. Preferably, the liquid and/or solid epoxy resin comprises more than or about 35 wt %, more preferably more than or about 40 wt %, of the epoxy adhesive. Preferably, the liquid and/or solid epoxy resin comprises less than or about 60 wt %, more preferably less than or about 55 wt %, of the epoxy adhesive. [0045] The hardener preferably comprises a latent catalyst. Any hardener that does not cause hardening under ambient conditions (“ambient conditions” meaning, e.g., typical room temperature and normal lighting conditions) may be used. A hardener that causes the epoxy adhesive to be curable by application of heat is preferred. Some preferred hardeners include dicyandiamide, imidazoles, amines, amides, polyhydric phenols, and polyanhydrides. Dicyandiamide (also known as DICY, dicyanodiamide, and 1- or 2-cyanoguanidine) is preferred. DICY (CAS 461-58-5) has empirical formula C 2 N 4 H 4 , molecular weight 84 , and structural formula: [0000] [0046] The hardener, preferably DICY, e.g. available from AirProducts under the trade name Amicure™, may be present in any amount that is stoichiometric or sub-stoichiometric with respect to the epoxy resin. Amounts of hardener are typically measured using percents by weight rather than percents by moles or equivalents when referring to formulas for epoxy adhesives. The same is valid for epoxy resins. In order to calculate the ratio of equivalents of epoxy resin to moles of DICY the following conversion may be calculated: The weight of each epoxide-group-containing component of a composition is to be divided by the respective epoxy equivalent weight of that component and added to give the total epoxy equivalent of a composition. The desired ratio is then obtained by dividing the thus obtained total of epoxy equivalents by the number of moles of hardener, e.g., DICY, in the composition. The latter is obtained by dividing the weight of hardener in the composition by the molecular weight (e.g., 84 g/mol for DICY), as is obvious to those skilled in the art. [0047] With this in mind, the ratio of epoxy equivalent to moles DICY is preferably present in an amount more than or about 6, more preferably more than or about 6.5, most preferably more than or about 7. Preferably, the ratio of epoxy equivalent to molar DICY is present in less than or about 11, more preferably less than or about 10, most preferably less than or about 9 of the epoxy adhesive. [0048] Common flexibilizer like polyamine modified epoxy resins, fatty acid modified epoxy resins, core shell rubber epoxy adducts etc. may be used. [0049] A toughener is optionally used in the compositions and methods of the present invention. Any tougheners may be used, including, e.g., RAM tougheners and rubber epoxy resins, as well as combinations thereof. Some preferred RAM tougheners include those described in EP 0308664 A1 or US 2006/0276601 A1 (both of which are incorporated by reference herein in their entireties). When used, tougheners, e.g., RAM tougheners are present in amounts more than or about 5 wt %, preferably more than or about 10 wt % of the epoxy adhesive. When used, tougheners, e.g., RAM tougheners are present in amounts less than or about 20 wt %, more preferably less than or about 18 wt % of the epoxy adhesive. [0050] Some preferred rubber modified epoxy resins are sold under the trade name Struktol®, e.g., Struktol® 3604. When used, rubber modified epoxy resins may be present in amounts more than or about 5 wt %, more preferably more than or about 8 wt %, more preferably more than or about 10 wt % of the epoxy adhesive. When used, rubber modified epoxy resins may be present in amounts less than or about 25 wt %, more preferably less than or about 20 wt % of the epoxy adhesive. [0051] Other optional fillers include mineral fillers, such as calcium carbonate, calcium oxide, and talc. Calcium carbonate (e.g., sold under trade name Omya®), which can be used to reduce shrinkage and increase corrosion resistance. Calcium oxide (e.g., sold under the trade name Chaux Vive) is a humidity scavenger that may help to preserve a partially-cured epoxy adhesive prior to final curing. Talc is available, e.g., under the trade name Mistrofil®, and aluminum magnesium silicate (wollastonite) is available, e.g., under the trade name Nyad® 200. [0052] When used, fillers may be present in any useful amount. Typically, fillers may be present in amounts more than or about 3 wt %, more preferably more than or about 5 wt % of the epoxy adhesive. Fillers may be present in amounts less than or about 20 wt %, more preferably less than or about 15 wt % of the epoxy adhesive. [0053] Thixotropic agents and other viscosity regulators may also be optionally used. One such preferred example includes fumed silica (e.g., sold under the trade name Aerosil®). A preferred thixotropic agent that also improves wash-off resistance is a mixture of polyester and liquid epoxy resin (LER), such as Dynacol (25% polyester 7330 and 75% LER 330). [0054] When used, fumed silica may be present in amounts more than or about 2 wt %, preferably more than or about 6 wt % of the epoxy adhesive. Fumed silica may be present in amounts less than or about 15 wt %, more preferably less than or about 12 wt % of the epoxy adhesive. [0055] Reactive and non-reactive diluents may also optionally be used. A preferred reactive diluent is a monoglycidyl ester of neodecanoic acid, which also can act as a viscocity-reducing agent. It is commercially available, e.g., under the trade name Erisys GS-110. [0056] A curing accelerator may be optionally used to modify the conditions under which a latent catalyst becomes catalytically active. For example, when a high-temperature latent catalyst such as DICY is used, e.g., in a heat-curable epoxy adhesive, a curing accelerator can be optionally used to reduce the temperature at which DICY becomes catalytically active. A preferred curing accelerator for a heat-curable epoxy adhesive includes a tertiary polyamine embedded in a polymer matrix. A preferred example is 2,4,6-tris(dimethylaminomethyl)phenol integrated into a poly(p-vinylphenol) matrix such as described in EP-A-0 197 892, the disclosure of which is incorporated by reference. [0057] When used, curing accelerator may be present in any amount that suitably adjusts the activation condition of latent catalyst. Preferably, a curing accelerator may be present in amounts more than or about 0.3 wt %, more preferably more than or about 0.5 wt % of the epoxy adhesive. Preferably, curing accelerator may be present in amounts less than or about 5 wt %, more preferably less than or about 2 wt % of the epoxy adhesive. [0058] At least one adhesion promoter may also be optionally used. Preferred adhesion promotes include epoxy silanes, e.g., sold under the trade name Silquest™ A-187. [0059] At least one surfactant or wetting agent may be optionally used. A preferred wetting agent is a non-ionic fluorinated polymer. Such agents are also preferably capable of absorbing residual oils (e.g., manufacturing and processing oils) on metal surfaces, thereby facilitating adhesion to metal surfaces. [0060] At least one aliphatic phenol may also be optionally used, preferably a phenol derivative with an aliphatic group in the meta-position, e.g., cardanol. Such compounds promote adhesion and corrosion resistance. Cardanol is commercially available, e.g., under the trade name Cardolite™ NC 700. [0061] Other additives may also be used. Some non-limiting examples of other additives include flexbilized epoxy resins such as fatty acid or polyamine epoxy adducts, gelling compounds such as polyester or PVB, and flame retardants such as aluminium-tris-hydroxide. Pigments or coloring agents, e.g., Irgalite® green, may also be used. [0062] The present invention provides epoxy adhesives that may be used on a variety of surfaces. Some suitable materials include metals (e.g., aluminum, steel), thermoplastic polymers (e.g., polyethylenes, polypropylenes, polyurethanes, acrylics, and polycarbonates, including copolymers, terpolymers, etc.), thermoset polymers (e.g., vulcanized rubber, urea-formaldehyde foams, melamine resins), wood, and composites. The epoxy adhesives may be used to bond identical materials (e.g., steel and steel), similar materials (e.g., steel and aluminum) or dissimilar materials (e.g., polycarbonate and vulcanized rubber, or aluminum and wood). [0063] Methods according to the present invention include preparation of an epoxy adhesive by combining one or more epoxy resins, and one or more hardeners, wherein the hardener is present in about, or less than, a stoichiometric amount relative to the epoxy resin. Other components may also be combined with the epoxy adhesive. [0064] The present invention also provides a manufacturing method that comprises bonding two components with an epoxy adhesive that comprises an epoxy resin and less than or about a stoichiometric amount of hardener, followed by pre-curing, or partially curing, the epoxy adhesive. [0065] The pre-cured article, or partially cured article, so manufactured may be stored for later additional assembly, and/or shipped to another location for additional assembly. After the pre- or partially-cured article is received (e.g., arrives at a second location for additional assembly), it may undergo further assembly into a more complete, or complete, article of manufacture, and is then subjected to second curing conditions. When the article ispartailly cured, the second curing conditions preferably more fully cure, or completely cure, the epoxy adhesive. The second location may be the same as the first location. [0066] The passage of time between the end of the pre-curing and the beginning of the second curing is referred to as aging. Aging is preferably more than or about 2 days, more preferably more than or about 1 week, more preferably more than or about 1 month. Aging is preferably less than or about 1 year, more preferably less than or about 9 months, more preferably less than or about 4 months. An article that has subjected to aging is referred to as being in a state that is aged. [0067] By “partially cure” is meant that the article is subjected to curing conditions that are insufficient to fully cure the article. A pre-cured article may be completely cured or partially cured. A “partially curable” adhesive is one in which the curing process can be halted after initiation, and prior to full curing, e.g., an epoxy adhesive comprising a latent catalyst, e.g., a heat curable epoxy adhesive. EXAMPLES [0068] The following examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Unless otherwise stated, the units are percent by weight. Preparation of Epoxy Adhesives [0069] Comparative Example A uses a large excess of DICY, and Comparative Example B is a typical CDA formulation using an excess of DICY. Example C uses a very slight excess of DICY, Example D uses a stoichiometric amount of DICY, and Example E uses less DICY than the stoichiometric amount. [0000] TABLE 1 A B C D E Epoxy/DICY ratio 3 4.8 6 7 9 Liquid epoxy resin14) 21.5 21.5 21.5 21.5 21.5 Solid epoxy resin14) 2.7 2.7 2.7 2.7 2.7 Tougheners 1) 14.90 14.90 14.90 14.90 14.90 rubber epoxy2) 12.8 12.8 12.8 12.8 12.8 Omya BSH3) 8 8 8 8 8 Mistrofil4) 0.4 0.4 0.4 0.4 0.4 Fumed Silica5) 6.8 9.03 9.8 10.25 10.87 DICY6) 6.3 4.07 3.3 2.85 2.23 Color Pigment7) 0.3 0.3 0.3 0.3 0.3 2,4,6- 1 1 1 1 1 tris(dimethylaminomethyl)phenol in a poly(p-vinylphenol) matrix PE-Intermediate8) 14.7 14.7 14.7 14.7 14.7 Erisys GS1109) 1.1 1.1 1.1 1.1 1.1 Silquest A-18710) 0.6 0.6 0.6 0.6 0.6 Wetting Agent 0.3 0.3 0.3 0.3 0.3 Cardolite NC70011) 0.6 0.6 0.6 0.6 0.6 Nyad 20012) 2 2 2 2 2 CaO13) 6 6 6 6 6 1) Such as decribed in EP 0308664 A1 (example 13) or US 2006/0276601 A1 (example 2) 2)Such as Struktol 3604 from Schill&Seilacher. 3)Available from Omya. 4)Available from Luzenac. 5)Available from Degussa. 6)Available as Amicure from Air Products. 7)Available from Huntsman. 8)LER 330-Dynacoll 7330 crystalline polyester-diol 8:2 blend. Dynacoll is available from Evonik 9)Available from CVC. 10)Available from Momentive. 11)Available from Cardolite. 12)Available from Nyco. 13)Available from Lloist. 14)Available from Dow Simulated CKD Aging [0070] Adhesive compositions A-E were applied to two sets of hot dipped galvanized steel substrates HC 400T+Z100. They were then subjected to simulated CKD aging in accordance with DIN EN ISO 6270-2CH as follows. [0071] The samples were partially cured for 12 minutes in an oven at 170° C. One set of blocks was aged for 3 weeks, and the other was aged for 5 weeks. Aging was done at 40° C. and 100% relative humidity. The aged samples were then cured for 25 minutes in an oven at 175° C. [0072] The results of lap shear strength testing according to DIN EN 1465 are shown in Table 2, wherein “Ep/DICY ratio” refers to the ratio of equivalents of epoxy resin to moles of DICY as discussed above. Test temperature of 23° C., test speed of 10 mm/min, adhesive layer thickness of 0.2 mm and bonding dimension of 10×45 mm were used. [0000] TABLE 2 Hot dipped galvanized steel HC 400T + Z100; degreased Change Change 3 weeks from 5 weeks from Ep/DICY CKD Initial CKD Initial Ratio Initial [MPa] [%] [MPa] [%] A 3 26. 3.3 −87 3.4 −87 B 4.9 27.5 17.8 −35 13.4 −51 C 6 26.2 19.0 −27 18.7 −28 D 7 23.8 18.1 −24 20.4 −14 E 9 22.9 20.1 −12 20.4 −11 [0073] Photographs of Samples A-E after aging for 5 weeks and curing are shown in FIGS. 1-5 , respectively. The failure modes are, respectively, 100% adhesive failure mode for FIG. 1 ; 50% cohesive failure mode/50% adhesive failure mode for FIG. 2 ; and 100% cohesive failure mode for FIGS. 3 , 4 , and 5 . Cataplasma Aging [0074] Adhesive compositions A-E were applied to hot dipped galvanized steel samples (DX 56 D+Z 100MC). They were then subjected to simulated cataplasma aging as follows (according to DIN EN ISO 9142, which is 70° C. at 98% relative humidity). [0075] The samples were partially cured for 12 minutes in an oven at 170° C. The blocks were then aged for 7 days at 70° C. and 100% relative humidity. The aged samples were then cured for 25 minutes in an oven at 175° C. [0076] The results of lap shear strength testing according to DIN EN 1465 are shown in Table 3, wherein “Ep/DICY ratio” refers to the ratio of equivalents of epoxy resin to moles of DICY as discussed above. Test temperature of 23° C., test speed of 10 mm/min, adhesive layer thickness of 0.2 mm and bonding dimension of 10×45 mm were used. [0000] TABLE 3 Hot dipped galvanized steel DX 56 D + Z 100MC Ep/DICY Initial 7 d Cata Change from Ratio [MPa] [MPa] Initial [%] A 3 17.5 2.2 −87 B 4.9 17.8 8.5 −52 C 6 17.4 8.9 −49 D 7 16.8 13.1 −22 E 9 15.1 12.8 −15 Sample A shows 100% adhesive failure mode, Samples B and C show 40% adhesive failure mode and 60% cohesive failure mode, Sample D shows 5% adhesive failure mode and 95% cohesive failure mode, and Sample E shows 0% adhesive failure mode and 100% cohesive failure mode. [0077] All documents cited herein are incorporated by reference herein in their entireties as if their disclosures are set forth in full. [0078] Although the present invention has been described in considerable detail with regard to certain versions thereof, other versions are possible, and alterations, permutations, and equivalents of the version shown will become apparent to those skilled in the art upon a reading of the specification and study of the drawings. Also, the various features of the versions herein can be combined in various ways to provide additional versions of the present invention. Furthermore, certain terminology has been used for the purposes of descriptive clarity, and not to limit the present invention. Therefore, any appended claims should not be limited to the description of the preferred versions contained herein and should include all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention. [0079] Having now fully described this invention, it will be understood to those of ordinary skill in the art that the methods of the present invention can be carried out with a wide and equivalent range of conditions, formulations, and other parameters without departing from the scope of the invention or any embodiments thereof.
A structural adhesive exhibiting good humidity resistance in the uncured state, good failure mode after curing, good crash stability, and good corrosion resistance, is provided, as well as methods of use thereof. The structural adhesive and methods of use thereof are applicable, e.g., in complete knock down (CKD) assembly systems, e.g., in the assembly of automobile body structures.
8
The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory. RELATED APPLICATION This application is a continuation-in-part of U.S. application Ser. No. 08/264,261, files Jun. 23, 1994, entitled "Star Cell Type Core Configuration For Structural Sandwich Materials", now U.S. Pat. No. 5,437,903 issued Aug. 1, 1995, and assigned to the same assignee. BACKGROUND OF THE INVENTION The present invention relates to the fabrication of sandwich type structural materials, particularly to the fabrication of light weight core material of the sandwich type, and more particularly to a method for fabricating a core material pattern which utilizes star shaped cells. Sandwich constructions involve a light weight core material that supports the faces and transfers load between them. The sandwich constructions generally utilize low density core materials. The elastic mechanical behavior for low density materials allows for deformation due to the flexibility of the core material when utilized in sandwich type constructions. The traditional core material is of a triangular cell pattern, and more recently of a honeycomb (hexagonal) cell pattern. However, the triangular or hexagonal cell patterns of core materials do not easily conform to curved shapes needed to fabricate curved sandwich material panels. Thus, there has been a need for a core material which supports the faces of the sandwich construction materials on transfer loads between the faces, while being sufficiently flexible so as to conform easily to curved shapes. That need has been satisfied by the invention described and claimed in above-identified U.S. Pat. No. 5,437,903, which involves an improved microstructure for light weight core material utilizing a star/hexagonal pattern which allows easy conformation to curved shapes. Various fabrication processes have been developed for the cellular sandwich structural materials, in an effort to produce these materials at a reasonable cost. For example, the prior honeycomb (hexagonal) material is fabricated by first vertically stacking a series of flat sheets with bonds located at the points of interconnection between the hexagonal cells, honeycomb configuration. The present invention, involving a method for fabricating an improved microstructure for light weight core material using the star containing pattern of the above-identified patent, utilizes features of the prior known processes by bonding or welding folded or unfolded sheets of material at selected locations to interconnect the sheets in both a vertical and a horizontal direction, and then mechanically pulling the interconnected sheets normal to the plane of the sheets which expands the sheets and form the star cells. SUMMARY OF THE INVENTION It is an object of the present invention to provide a fabrication method for an improved micro-structure for light weight core material of sandwich constructions. A further object of the invention is to provide a method of fabricating a core material for structural sandwich constructions which utilizes star shaped cells. Another object of the invention is to provide a fabrication method for a new pattern for microstructures which includes star shaped cells. Anther object of the invention is to provide a method for fabricating sandwich type materials which utilizes star shaped cells, which involves bonding flat or folded sheets of material in both vertical and horizontal directions, to form a block of sheets, whereafter the sheets are mechanically pulled normal to the plane of the sheets causing expanding and formation of the cells. Other objects and advantages of the invention will become apparent from the following description and accompanying drawings. The invention enables a simple and cost effective method to produce the star cell containing microstructure for cellular core material used in sandwich type structural materials. The fabrication method of this invention merely involves bonding folded or unfolded sheets of low density material in both vertical and horizontal directions to form a block which when mechanically pulled normal to the plane of the sheets expands to form interconnected star shaped cells. The fabrication method of this invention produces a cellular core material that is much more flexible than prior known core materials and can be conformed easily to curved shapes, thereby providing for the fabrication of curved sandwich panels. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated into and form a part of the disclosure, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. FIG. 1 illustrates a star/hexagonal cell configuration, for use such as in sandwich type structures. FIG. 2 is an enlarged partial cross-sectional view of a block of bonded or welded flat sheets of low density material in accordance with the fabrication method of this invention. FIG. 3 is an enlarged partial cross-sectional view similar to FIG. 2 except the sheets of low density material are folded and bonded together to form a block, as in the FIG. 2 fabrication method. DETAILED DESCRIPTION OF THE INVENTION The present invention involves a fabrication method for a microstructure pattern containing star shaped cells for cellular core material, such as described and claimed in above-referenced U.S. Pat. No. 5,437,903. The microstructure star containing pattern for the sandwich core material fabricated by the present invention is illustrated in FIG. 1. As seen in FIG. 1, the microstructure pattern is composed of a combination of six pointed star shaped cells 10 and hexagonal shaped cells 11. The star shaped cell 10 include six points 12, with each point 12 formed by interconnect members 13 and 14 positioned at a 60° angle, with member 13 of one point and member 14 of an adjacent point 12 being interconnected at 15. The hexagonal cells 11 include six interconnected members or sides 16, 17, 18, 19, 20, and 21, with members or sides 16-17 and 19-20 forming points 22 and 23, with members or sides 17 and 20 forming flat surfaces between members 16-18 and 19-21. As seen in FIG. 1, either of points 22 or 23 of the hexagonal cells 11 is positioned against interconnects 15 between points 12 of star cells 10. Note that the length of the members 13 and 14 of star cells 10 are the same length as members or sides 16-21 of hexagonal cells 11. As seen in FIG. 1, each star cell 10 is surrounded by six (6) hexagonal cells 11, with two (2) hexagonal cells 10 positioned intermediate two adjacent star cells 10, and with each of the points 12 of a star cell 10 being in contact with a point 12 of an adjacent star cell 10. The microstructure composed of star shaped cells 10 and hexagonal shaped cells 11 is positioned intermediate a pair of panel faces or members which define a sandwich type structure panel as conventionally known in the art. The number of cells within the sandwich panel will vary depending on the width of the panel and the desired density of the core material. By way of example, with a sandwich panel having a thickness of 1/2 inch, the length of the members 13 and 14 forming the points 12 of the star cell 10 and the length of the members or sides 16-21 of the hexagonal cell 11 is 1/4 inch, and may be constructed of any material such as metals, ceramics, polymers, glasses, natural products, etc. Referring now to the fabrication method for producing the star cell containing microstructure of FIG. 1, reference is made to FIGS. 2 and 3, wherein sheets (flat or folded) of low density material are bonded, welded, or otherwise secured together, defined hereinafter as bonding, in both vertical and horizontal directions to form a block. The thickness of the bond or weld sections are greatly exaggerated for illustration purposes. Basically, the sheets of material, either flat (FIG. 2) or folded (FIG. 3) are bonded together to form a block, only part of which as shown, whereafter the block of sheets is expanded to form a light weight star containing configuration similar to that of FIG. 1. Referring first to FIG. 2, a partial block 30 is composed of pairs of sheets generally indicated at 31 of material constructed of aluminum, for example, with each sheet having a thickness of 0.01 mm to 10 mm, the pairs of sheets are bonded together in both a vertical and a horizontal direction. As shown, the pairs of sheets 31 are composed of vertically aligned flat sheets 32 and 33 bonded together, such as by polymeric adhesives, at each end and in the center thereof as indicated at 34, 35, 36, and are referred to hereinafter as sheet pairs. The thus bonded sheet pairs are indicated at 37, 38, 39, 40, 41, 42, and 43. The location of the center bond 35 of each sheet pair determine the length of the side members of the star shaped structure, such as members 13-14 of star cell 10. The sheet pairs 37 and 39 are bonded at 44 and 45 to sheet pair 38 and at 46 and 47 to sheet pair 40; while sheet pairs 41 and 43 are bonded at 48 and 49 to sheet pair 40 and at 50 and 51 to sheet pair 42. As indicated by bonds 52 and 53, sheet pairs 37 and 39 are bonded to adjacent sheet pairs similar to 38 and 40 not shown, but after which sheet pairs similar to sheet pairs 37 and 39 are bonded, such that the block 30 contains a series of repeated spaced sheet pairs 37-39 and 41-43, pairs 38, 40, and 42 positioned therebetween. The location of the bonds 44-51 of the adjacent pairs of sheet pairs also determines the length of the side members of star cells 10 of FIG. 1. The block 30 as illustrated in FIG. 2 is then subjected to a mechanical pull to expand the sheet pairs with respect to one another. The sheet pairs are mechanically pulled normal to the plane of the sheets 32 and 33, which expands the sheet pairs to form the star shaped cells and interconnecting cells. This can be envisioned by pulling sheet pairs 37 and 41 and sheet pairs 39 and 43, while simultaneously pulling sheet pairs 38, 40, and 42 with corresponding sheet pairs, not shown, in opposite directions. Thus when sheet pairs 37 and 39 and sheet pairs 41 and 43 are mechanically pulled with respect to each other, the area intermediate the sheet pairs 37 and 39 or sheet pairs 41 and 43 form a pattern similar to a star shaped cell indicated at 10'; and the areas on each side of sheet pair 40 form positions of interconnecting cells indicated at 11'. The interconnecting cells 11' formed by pulling the sheets of block 30 are not hexagonal in shape. Although the appearance of the cells thus formed appear different from the explicit star pattern of FIG. 1, the thus formed microstructure will still possess the advantages of the star/hexagonal structure of FIG. 1, because the layout or block 30 of FIG. 2 conforms to the star template. Following the mechanical pulling the thus formed microstructure is bonded intermediate a pair of panel faces of members, not shown. The fabrication method illustrated by FIG. 3 differs from that illustrated by FIG. 2 in utilizing a single folded sheet in place of the two flat sheets 32 and 33 for each of the sheet pairs 37-42 of FIG. 2 and the replacement of the end and center bonds 34, 35, and 36 of each sheet pair with two end bonds. As seen in FIG. 3 a partial block 30' is composed of pairs of sheets generally indicated at 31' of low density material constructed of aluminum and thickness of 0.01 mm to 10 mm, for example, with the pairs of sheets 31' each composed of a single folded sheet 55 with ends thereof bonded at 56 and 57 to a central section 58 of the folded sheet 55, and referred to hereinafter as sheet pairs. The bonds 56 and 57 may be composed of aluminum and produced by polymeric adhesives for example. The thus bonded sheet pairs are indicated at 37', 38', 39', 40', 41', 42', and 43'. As in the method illustrated by FIG. 2, the sheet pairs 37' and 39' are bonded at 44' and 45' to sheet pair 38' and at 46' and 47' to sheet pair 40'; while sheet pairs 41' and 43' are bonded at 48' and 49' to sheet pairs 40' and at 50' and 51' to sheet pair 42'. As indicated by bonds 52' and 53' sheet pairs 37', 39', 41' and 43' may be bonded to adjacent sheet pairs sheet pairs 38', 40', and 42' interposed therebetween, as described above. As pointed out above, the location of the end bonds 56 and 57 and bonds 44-51 determine the length of the side members of the star cell and the interconnecting cells, such as the hexagonal cells of FIG. 1. As set forth above with respect to the method illustrated by FIG. 2, the block 30' of FIG. 3, which when mechanically pulled normal to the plane of the sheets, expands to form star shaped cells 10' and interconnecting cells 11'. After expansion, the microstructure is bonded intermediate a pair of panel faces or members not shown to define a sandwich structure. It has thus been shown that the present invention provides a method for fabricating structural sandwich material utilizing star shaped cells. This method is carried out using either flat sheets or folded sheets bonded to form a star configuration when mechanically expanded, and thereafter positioned between panels or members to form a completed sandwich type structural material. Although the appearance of the cell forms could look quite different from the explicit six-point star pattern, the material will still possess the advantages of this configuration because the manufacturing layout conforms to the star pattern. While particular sequences of operations, materials, parameters, and structural configurations, etc., have been set forth to exemplify and explain the principles of the invention, such are not intended to be limiting. Modifications and changes may become apparent to those skilled in the art, and it is intended that the invention be limited only by the scope of the appended claims.
A method for fabricating structural sandwich materials having a core pattern which utilizes star and non-star shaped cells. The sheets of material are bonded together or a single folded sheet is used, and bonded or welded at specific locations, into a flat configuration, and are then mechanically pulled or expanded normal to the plane of the sheets which expand to form the cells. This method can be utilized to fabricate other geometric cell arrangements than the star/non-star shaped cells. Four sheets of material (either a pair of bonded sheets or a single folded sheet) are bonded so as to define an area therebetween, which forms the star shaped cell when expanded.
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CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Continuation-In-Part of copending application Ser. No. 12/620,225 filed Nov. 17, 2009, which application is a Division of copending application Ser. No. 11/439,547 filed May 24, 2006, the contents of which are hereby incorporated by reference in their entirety. FIELD OF THE INVENTION The present invention relates to a hydrothermally stable alumina, its process of manufacture and its use as a desiccant. More specifically, the present invention relates to a process of treating transition aluminas with a soluble silicon inorganic compound. The industrial activated alumina adsorbents are produced exclusively by the rapid (flash) calcination of the Bayer process derived aluminum hydroxide (Gibbsite, ATH) powder followed by wet agglomeration and thermal activation. These adsorbents exhibit X-ray diffraction patterns of transition alumina phases. They typically have high BET surface area and good adsorption properties for moisture and other contaminants. This makes them suitable for treatment of various industrial streams. Most of the adsorption processes using activated alumina require frequent thermal regeneration to remove the adsorbed water and to render the adsorbent active for the next adsorption cycle. In the course of regeneration, the adsorbent experiences the simultaneous effect of elevated temperature, pressure and high moisture content, with hot liquid water percolating through the adsorbent bed, causing hydrothermal aging and loss of adsorption performance. While the loss of performance over regeneration cycles is small in some desiccant applications and the adsorbent can last thousand of cycles, there are some severe applications resulting in much faster deterioration of performance, which are challenging even for the most stable alumina adsorbents. Natural gas drying presents the most prominent example of a severe application. Activated aluminas have been widely used for NG drying for about twenty years. However, the short lifetime caused by hydrothermal aging led to replacement of activated alumina by molecular sieves in most of the units. In spite of this, the inlet portion of the adsorbent bed still needs a protective layer of another adsorbent capable to handle the carryover of liquids and heavy hydrocarbons. Alumina quickly loses its drying performance when used as protective layer. Hence, there is a need of a hydrothermally stable alumina that will provide both protection against heavy hydrocarbons and additional drying capacity in the equilibrium portion of the bed. It is known that activated alumina is superior to molecular sieves as desiccants at high water concentrations. Another example of severe desiccant applications are some internally heated dryer for compressed air where a quick deterioration of cyclic adsorbent performance takes place. In spite of the fact that the need of improvement in the hydrothermal stability of activated alumina has been acknowledged (see the article of R. Dale Woosley “Activated Alumina Desiccants” in A LUMINA C HEMICALS —S CIENCE AND T ECHNOLOGY H ANDBOOK edited by L. D. Hart, American Ceramic Society, 1990, page 241-250), there remains a lack in reported success in preparing hydrothermally stable aluminas. U.S. Pat. No. 4,778,779 by Murrell et al. discloses a composition comprising discrete particles of bulk silica supported on the external surface of a porous gamma alumina support. Aqueous colloidal silica is claimed as a source of the silica material. Heating above 500° C. in presence of steam is required to disperse at least a portion of the silica over the alumina surface. Preparation of active cracking catalysts, not the improvement of the material stability, is the focus of the invention by Murrell et al. High temperature is needed in order for the alumina and the silica components to form an active aluminosilicate phase. U.S. Pat. No. 4,013,590 discloses that the mechanical and thermal properties of aluminum oxide are improved through their impregnation with an organic silicon compound dissolved in an organic solvent followed by thermal treatment and controlled oxidation at 500° C. Colloidal silica does not work for this purpose and it is listed in the patent as a “negative” example. The patent above and other literature sources deal with the BET surface area stability of alumina towards high temperature treatments. The focus of these prior art developments is to delay the alumina phase transformation in high temperature application such as catalysts for exhaust gas treatment. Besides cerium, rare-earth and alkaline-earth elements, silicon was also found to have stabilizing effect on alumina. The paper “Stabilization of Alumina toward Thermal Sintering by Silicon Addition” authored by Bernard Beguin et al., J. OF C ATALYSIS, 127, 595-604, (1991) studies the thermal stability of alumina toward sintering at 1050° to 1220° C. in presence of steam. The authors assume that the hydroxyl groups of alumina react with the silicon containing precursor. W. R. Grace U.S. Pat. No. 5,147,836; U.S. Pat. No. 5,304,526 and U.S. Pat. No. 6,165,351 cover preparation of silica-containing bayerite alumina which is used to obtain hydrothermally stable silica “stabilized” eta alumina. The latter may be used in preparation of catalytic compositions, especially for the catalytic cracking Sodium silicate is added to the aluminum sulfate, sodium aluminate and magnesium hydroxide which are further mixed and reacted to precipitate the bayerite alumina. Phosphorus has been also found useful for improving the thermal stability of gamma alumina with regard to sintering and phase transition to alpha alumina (see, for example, the paper from A. Stanislaus et al. “Effect of Phosphorus on the Acidity of gamma—Alumina and on the Thermal Stability of gamma-Alumina Supported Nickel-Molybdenum Hydrotreating Catalysts”, published in A PPLIED C ATALYSIS, 39, 239-253 (1988). In addition to improving the thermal stability, phosphorous alters the acidity of the source alumina. In 1992, Alcan obtained U.S. Pat. No. 5,096,871 entitled “Alumina-Alkali Metal Aluminum Silicate Agglomerate Acid Adsorbent”. This patent does not refer to improvement of hydrothermal stability of the alumina, but describes the addition of sodium silicate and sodium aluminate in the agglomeration process of alumina powder to form an alkali metal aluminum silicate coating on the internal surfaces of alumina. This alkali metal coating provides the functionality of the agglomerate to serve as an adsorbent of acid substances. SUMMARY OF THE INVENTION The present invention greatly improves the hydrothermal stability of alumina desiccants and simultaneously reduces the dust formation with activated aluminas. The modified adsorbent maintains low reactivity and is still suitable for application in reactive streams. The existing processes for manufacturing activated alumina can easily accommodate the production of the hydrothermally stable alumina described in the present invention. The additives used are inexpensive and no adverse environmental effects are expected. No heat treatment is needed as is the case in the prior art methods to prepare a thermally stable alumina carrier. The hydrothermally stable alumina desiccants of the present invention will prolong the lifetime and improve the performance of all processes employing thermal regeneration of the adsorbent. Severe regeneration applications such as natural gas drying will especially benefit from this invention. The transition alumina phases formed by rapid calcinations of aluminum hydroxide have high BET surface area and are very reactive toward water. While this feature is generally useful since it helps forming beads by agglomeration and allow for the fast pick up of moisture during adsorption, in long term, especially at severe conditions of thermal regeneration of the adsorbent, it causes irreversible re-hydration effects, which speed up the aging process of alumina. It is well known that the hydrothermal aging consists of conversion of the high surface area alumina phases to crystalline Boehmite (AlOOH) which has low BET surface area and is a poor adsorbent. The formation of crystalline Boehmite can be observed with several techniques such as X-ray diffraction, infrared spectroscopy and thermal gravimetric analysis (TGA). Activation at higher temperature increases somewhat the hydrothermal stability of alumina since it produces alumina phases, which are more stable toward re-hydration. Unfortunately, the BET surface area and the adsorption capacity decline after high temperature calcinations. On the other hand, this approach achieves only a moderate improvement of the hydrothermal stability of alumina. The present invention provides a process of making a hydrothermally stable alumina adsorbent comprising mixing together a solution containing a silica compound with a quantity of alumina powder to produce alumina particulates, curing the alumina particulates and then activating said cured alumina particulates to produce a hydrothermally stable alumina adsorbent. In the preferred embodiment of the invention, the alumina particulates are treated with water or a colloidal silica solution. The hydrothermally stable alumina adsorbent comprises silica containing alumina particles comprising a core, a shell and an outer surface. The core contains between about 0.4 to 4 wt-% silica wherein said silica is homogeneously distributed throughout the core and the shell extends up to 50 micrometers from the outer surface towards the core. Typically, the shell contains on average at least two times more silica than the core. DETAILED DESCRIPTION OF THE INVENTION In the present invention, we found that the stability of the alumina toward rehydration increases significantly by introducing silica in the course of the activated alumina manufacturing process. Surprisingly, no high temperature or activating agents are needed to achieve major improvement of the hydrothermal stability. The term “silica” as used herein refers to a variety of silicon inorganic compounds ranging from colloidal solution of silica to silicic acid or alkali metal silicates. Ullmann's E NCYCLOPEDIA OF I NDUSTRIAL C HEMISTRY , Sixth Edition, Wiley-VCH, 2003, Vol. 32, pages 411-418 lists soluble inorganic silicon compounds that are suitable for the purposes of the invention. Inorganic silicon compound with limited solubility could be also useful for the purpose of the invention since their solubility enhances upon the presence of transition alumina that has strong affinity to silicon compounds. Thus, the transfer of discrete silicon moieties from the solid inorganic compound through the surrounding liquid towards transitional alumina could be facilitated. One theory to explain the positive effect of the silica compound is that silica species tend to adhere to the most active sites on the alumina surface, which are prone to fast rehydration. Thus, the silica species will then “deactivate” such rehydration sites by preventing them from further reacting with water upon formation of unwanted hydroxyl compound of alumina. Although a mere spraying of activated alumina beads with colloidal silica improves the hydrothermal stability, a very strong improvement is achieved when a soluble silica compound is admixed to the nodulizing liquid, which is used to form alumina beads in a rotating tub, for example. The alumina particulates that are treated in this invention are powders that have a size generally in the range of about 1 to 20 microns, while the alumina beads that are eventually formed would have a formed size of about 500 to 11,200 microns, preferably from about 1,000 to 6,300 microns, corresponding to a particle size according to US Standard screen sizes from 18 to ¼″ mesh. The alumina particulates are subjected to a curing step at a temperature that can range from about 40-70° C., preferably from about 50-65° C. The duration of the curing step is for about 2-48 hours, preferably about 6 hours. It has been found that a curing step for less than 2 hours results in agglomerates being formed that have poor physical strength for use in drying natural gas. Strong improvement of both hydrothermal stability and dustiness can be attained by forming alumina particulates in presence of silica followed by spraying of the particulates with a colloidal silica solution. The amount of silica can range from 0.1 to 8 wt-%. Addition of less that 5% silica is sufficient to produce a strong improvement in the hydrothermal stability. Normally, addition of about 2% silica is adequate for producing alumina with excellent hydrothermal stability. The adsorbents of the present invention are a hydrothermally stable alumina adsorbent that comprises silica containing alumina particles comprising a core, a shell and an outer surface The core contains between about 0.4 to 4 wt-% silica with the silica homogeneously distributed throughout the core. The shell extends up to 50 micrometers from the outer surface towards the core and the shell contains on average at least two times more silica than the core. The adsorbents of the present invention can be used for thermal swing process for drying and purification of gas and liquid streams. Among the most important types of gas streams that can be treated are natural gas, process gases in a variety of industrial processes such as refining and air prepurification in the air separation industry. Pressure swing adsorption processes can be operated with these adsorbents with long-term stability towards rehydration and chemical attack combined with dust free operation. The following examples illustrate the present invention. EXAMPLE 1 Flash calcined alumina powder A-300 manufactured by UOP, Des Plaines, Ill., was fed into a 4 feet rotating tub at a rate of 0.8 lbs/min. Water at a rate of 0.5 lb/min was also continuously supplied using a pump and nozzle assembly. Small amount of 30×40 mesh alumina seed was charged first into the nodulizer in order to initiate forming of larger alumina beads. The operation continued until about 50 lbs of material (8×14 mesh nominal particle size) were accumulated. The sample was cured upon storage in a closed container. Subsequently, about 4.5 lbs of the sample was charged into a one feet pot and rotated for about 5 minutes while sprayed with about 120 cc water. The sample was then immediately activated at 400° C. for one hour using an oven with forced air circulation. We refer to this sample as to AlWW where W designates water used in both forming and additional spraying operations. EXAMPLE 2 The procedure described in Example 1 was used except that 4.5 lbs of alumina particulates were sprayed with a colloidal silica solution (Nalco 1130) to achieve addition of 0.8 mass-% SiO 2 calculated on an volatile free alumina basis. We refer to this sample as to AlWSi where Si stands for the silica used in the spraying operation. EXAMPLE 3 Flash calcined alumina powder A-300 manufactured by UOP, Des Plaines, Ill., was fed into a 4 feet rotating tub at a rate of 0.8 lbs/min while a pump and nozzle assembly continuously supplied at a rate of 0.51 lbs/min a sodium silicate solution. The solution consisted of 1 part Grade 40 sodium silicate and about 8 parts water. Small amount of 30×40 mesh alumina seed was charged first into the nodulizer in order to initiate forming of larger alumina particulates. The operation continued until about 50 lbs of material were accumulated. The particle size fraction 8×14 mesh was separated and subjected to curing in a closed container. Subsequently, about 4.5 lbs of the sample was charged into a one feet pot, sprayed with about 120 cc water and activated as described in Example 1. The silica content of this sample is about 2.2 mass-% as calculated on a volatile free alumina basis. This sample is referred to as AlSiW. EXAMPLE 4 Spherical particulates were prepared and cured as described in Example 3. Instead of water, the particulates were sprayed with a colloidal silica solution and activated as described in Example 2. This sample is referred to as AlSiSi in order to show that Si is used in both forming and final spraying stage of material preparation. The samples were tested for hydrothermal stability in an electric pressure steam sterilizer (All American, model #25×). Six portions, five grams each, of the same sample were placed into the sterilizer and subjected to steam treatment for about 17.5 hours at 17 to 20 psi (122° to 125° C.). The samples were tested after the treatment for Boehmite formation using a FTIR method. A composite sample was prepared by merging the individual samples and BET surface area was determined using the standard method with 300° C. activation step. BET surface area was also measured on the samples before the hydrothermal treatment. Table 1 compares all the data, including data for other commercial desiccants. TABLE 1 BET before BET after treatment treatment Difference Sample Description m 2 /g m 2 /g m 2 /g % Decrease AlWW Example 1 359 181 178 49.6% AlWSi Example 2 359 211 148 41.2% AlSiW Example 3 317 318 −1 −0.3% AlSiSi Example 4 305 321 −16 −5.2% CA-1 Commercial 343 200 143 41.7% alumina CA-2 Commercial 360 200 160 44.4% alumina SCA Commercial 340 264 84 24.7% Si coated alumina SA Commercial 677 512 165 24.4% silica alumina Table 1 shows that introducing colloidal silica helps to increase the hydrothermal stability—compare AlWW to AlWSi sample and the SCA sample to CA-2 sample (SCA is prepared by silica coating of alumina beads). However, a strong increase of the hydrothermal; stability is observed when Si is introduced while forming particulates—Examples 3 and 4. The samples AlSiW and AlSiSi have a higher BET surface area than do the fresh samples after hydrothermal treatment. Table 2 shows that spraying with colloidal silica is needed to reduce the dustiness of the Si nodulized alumina particulates. Nodulizing in presence of an inorganic silica compound, such as sodium silicate, followed by spraying with colloidal silica allows for strong improvements in both hydrothermal stability and dustiness. The dustiness was measured using turbidity measurements as practiced for alumina and other adsorbents. TABLE 2 Turbidity Sample Description NTU Units AlWW Example 1 44.0 AlWSi Example 2 10.6 AlSiW Example 3 107.0 AlSiSi Example 4 35.4 The data suggests that introducing up to 2-3% SiO 2 with the nodulizing liquid would strongly increase the hydrothermal stability of alumina. Treatment with colloidal silica to add additionally 1-2% SiO 2 is then needed since the Si nodulized material tends to be dustier than the water nodulized alumina. Sodium silicate was used herein because it is cheap and readily available. Other silica compounds may be used. A possible advantage of an alkali metal silicate is that it contains an alkali metal, which can “neutralize” some acid sites should active aluminosilicate form upon thermal treatment.
The hydrothermal stability of transition aluminas used as adsorbents and catalyst carriers is improved through their treatment with a soluble silicon inorganic compound such as sodium silicate wherein the silicon compound is mixed with the alumina powder at the production stage of forming particulates by liquid addition. The silicon containing particulates are activated by heating at a temperature lower than 500° C. and treated, before or after the thermal activation, by a colloidal silica solution to produce a hydrothermally stable, low dust alumina. The total silica content of the final product is typically less than 5 mass-%.
1
CROSS-REFERENCE TO RELATED APPLICATION(S) [0001] This patent application is a continuation-in-part of U.S. patent application Ser. No. 10/224,168 (Attorney Docket No. CRD1061), filed on Aug. 20, 2002, entitled, “Guidewire With Deflectable Tip,” which is a nonprovisional patent application of U.S. patent application Ser. No. 60/366,739 (Attorney Docket No. CRD1035), filed on Mar. 22, 2002, entitled, “Deflection Wire Concept.” BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a steerable guidewire having improved torque characteristics, and more particularly to a bi-directional steerable guidewire having a tip which may be very precisely “steered,” and deflected. The guidewire is particularly suitable for use in conjunction with the insertion of a catheter into a vessel of the body, or alternatively, the guidewire may be used by itself to open obstructions within a vessel or to carry a therapeutic device for removing obstructions within a vessel. [0004] 2. Description of the Prior Art [0005] For many years guidewires have included a core wire with the distal end being tapered and with a coil spring mounted on the tapered distal nd. These guidewires have been used to facilitate the insertion of a catheter into a vessel of the body. Generally, the guidewire is inserted into a vessel, a catheter is inserted over the guidewire and the catheter is then moved through the vessel until the distal end of the catheter is positioned at a desired location. The guidewire is then retracted from the catheter and the catheter is left in the vessel. Alternatively, the guidewire may be first inserted into the catheter with the distal portion of the guidewire extending beyond the distal end of the catheter. This assembly is then inserted into a vessel with the distal tip of the guidewire being used to facilitate movement of the guidewire and catheter through the vessel. Again, when the distal tip of the catheter has been placed in a desired location, the guidewire may be retracted thereby leaving the catheter in place within the vessel. [0006] Another common application for guidewires is that of using the distal tip of the guidewire for removing an obstruction within a vessel. Often times this procedure is accomplished by inserting the guidewire within a vessel, moving the distal tip of the guidewire into contact with the obstruction and then very gently tapping the distal tip of the guidewire against the obstruction until the guidewire passes through the obstruction. Alternatively, various types of devices may be placed on the distal end of a guidewire for actively opening an obstruction within the vessel. Examples of such devices which may be placed on the end of the guidewires in order to open an obstruction are disclosed in the following Robert C. Stevens U.S. Pat. Nos. 5,116,350; 5,078,722; 4,936,845; 4,923,462; and, 4,854,325. [0007] While most guidewires used today do not include a mechanism for deflecting or steering the tip of the guidewire, it is very desirable to provide tip steering in order to facilitate movement of the guidewire through the tortuous vessels of the body. There are many patents directed toward different mechanisms for deflecting the distal tip of a guidewire in order to steer the guidewire. Examples of such guidewires are disclosed in the following patents: U.S. Pat. No. 4,815,478 to Maurice Buchbinder, et al., U.S. Pat. No. 4,813,434 to Maurice Buchbinder, et al., U.S. Pat. No. 5,037,391 to Julius G. Hammerslag, et al., U.S. Pat. No. 5,203,772 to Gary R. Hammerslag, et al., U.S. Pat. No. 6,146,338 to Kenneth C. Gardeski, et al., U.S. Pat. No. 6,126,649 to Robert A. VanTassel, et al., U.S. Pat. No. 6,059,739 to James C. Baumann and U.S. Pat. No. 5,372,587 to Julius G. Hammerslag, et al. U.S. Pat. No. 4,940,062 to Hilary J. Hampton, et al., discloses a balloon catheter having a steerable tip section. All of the above-identified patents are incorporated herein by reference. [0008] While each of the latter group of patents disclose guidewires having some degree of steerability, there is a need to have a guidewire with very precise steering in a guidewire of a very small diameter which is suitable for the purposes described above. More particularly, there is an important need for a very small diameter guidewire having improved torque characteristics which includes a distal tip which may be deflected very precisely in either of two directions to enhance steerability. SUMMARY OF THE INVENTION [0009] In accordance with one aspect of the present invention, there is provided a very small diameter steerable guidewire having a deflectable tip which includes an elongated flexible tubing, a flexible helical coil attached to the distal portion of the flexible tubing, an elongated deflection member which is slidably disposed within the tubing and within the helical coil. The flexible helical coil is formed from an elongated member having a rectangular, or square cross section, and having continuous undulations wherein the undulations of adjacent turns interlock with each other, i.e., peak undulation of one turn interlocking with valley undulation of adjacent turn, to thereby enhance the rotational rigidity, referred to as torque characteristic, of the coil. The proximal portion of the deflection member is of a cylindrical configuration and the distal portion is tapered to form a deflection ribbon. Alternatively, the deflection member may take the form of a proximal cylindrical wire which is attached at its distal end to a deflection ribbon. In addition, a retaining ribbon is attached to the distal end of the flexible tubing and is oriented to extend in a plane which is generally parallel to the plane of the ribbon portion of the deflection member. An attachment member which may take the form of a rounded bead, preferably formed from epoxy, is bonded to the distal end of the helical coil, the distal end of the deflection ribbon and the distal end of the retaining ribbon so that longitudinal movement of the deflection member causes the distal end of the helical coil to be deflected. With the enhanced rotational rigidity of the coil portion or the guidewire, the entire guidewire has enhanced rotational rigidity. [0010] In accordance with another aspect of the present invention, the continuous undulations take the form of a sinusoidal wave, or alternatively a square sinusoidal wave, having positive and negative peaks and in which the positive peaks of adjacent turns of coils engage negative peaks, or valleys, of adjacent turns. [0011] In accordance with another aspect of the present invention, the retaining ribbon and the deflection ribbon are preferably pre-shaped into a curved configuration to thereby cause the flexible helical coil to be biased into a normally curved shape. [0012] In accordance with a further aspect of the present invention, the distal portion of the deflection ribbon engages the attachment member, or rounded bead, at a location offset from the center of the attachment member, and the distal portion of the retaining ribbon engages the attachment member at a location offset from the center of the attachment member. Preferably, the retaining ribbon engages the attachment member at a location offset from the center portion of the attachment member in the opposite direction from the offset location of the deflection ribbon. [0013] In accordance with still another aspect of the present invention, the deflection ribbon and the retaining ribbon are connected to each other within the attachment member. Preferably these two elements are formed as a single unitary element. In a preferred embodiment of the invention the cylindrical deflection member is flattened to form the deflection ribbon and is further flattened at its distal end to form the retaining ribbon. The retaining ribbon is bent 180 degrees with respect to the deflection ribbon to form a generally U-shaped bend to thereby establish a predetermined spacing between the ribbons and to also cause these ribbons to remain parallel to each other. BRIEF DESCRIPTION OF THE DRAWINGS [0014] [0014]FIG. 1 is an enlarged elevational view of a balloon on a guidewire having a deflectable tip and control handle in accordance with the one aspect of the present invention; [0015] [0015]FIGS. 2 and 2A are enlarged elevational sectional views showing the distal end of the balloon on a guidewire in its normal pre-shaped position; [0016] [0016]FIG. 3 is an enlarged sectional view showing the distal end of the steerable guidewire of FIG. 2 rotated 180 degrees; and, [0017] [0017]FIGS. 4 and 5 are sectional views showing the steerable guidewire deflected from its normal position to opposite extremes of deflection. DESCRIPTION OF THE PREFERRED EMBODIMENT [0018] [0018]FIG. 1 generally illustrates a steerable guidewire system 10 which embodies the present invention and comprises a steerable guidewire 12 coupled to a control handle 14 . More particularly, the steerable guidewire comprises an elongated hypotube 16 , a helical coil 18 attached to and extending from the distal end of the hypotube 16 . The helical coil 18 is of a rectangular or square cross-sectional configuration and is preferably formed from platinum tungsten with the proximal turns being wound such that adjacent turns of the proximal portion are in contact, or loosely interlocked with each other. [0019] While the preferred embodiment of the present invention includes the helical coil 18 , this element may take the form of any flexible rectangular or square cross-sectional member, such as for example a thin square metallic tube with or without portions of the tube removed, for example laser cutting, so as to form a very flexible cylindrical or square member. An elongated deflection member 20 extends from the proximal end of the control handle through the hypotube 16 and through the helical coil 18 , and is connected into an attachment member, or rounded bead 22 , which is disposed at the distal tip of the helical coil 18 . In addition, a retaining ribbon 24 is connected to the distal end of the hypotube 16 and is also connected to the rounded bead 22 . [0020] The control handle 14 generally comprises a slidable control knob 26 which may be moved longitudinally with respect to the control handle. The control handle 14 is coupled to the deflection member 20 . As will be discussed in more detail, the longitudinal movement of the slidable control knob 26 causes deflection of the distal tip of the guidewire in either an upward or downward direction. [0021] [0021]FIGS. 2, 2A and 3 illustrate in more detail the distal portion of the steerable guidewire 12 . As may be appreciated, FIG. 3 is a view of the guidewire 12 shown in FIG. 2 with the guidewire being rotated 90 degrees about its longitudinal axis. More particularly, the proximal end of the helical coil 18 is bonded, preferably by use of an epoxy, to the outer surface near the distal end of the hypotube 16 . The elongated deflection member 20 takes the form of a small diameter cylindrical deflection member 20 having an intermediate portion which is flattened to form a thin deflection ribbon 34 having a thickness of approximately 0.002 inches. The distal end of the cylindrical deflection member 20 is further flattened to a thickness of approximately 0.0015 inches and is bent back 180 degrees to form a U-shaped bend 26 a between the deflection ribbon 34 and the retaining ribbon 24 . The proximal end of the retaining ribbon 24 is bonded, preferably by use of epoxy, to the outer surface of the distal end of the hypotube 16 . The retaining ribbon 24 is aligned in a plane parallel to the plane of the deflection ribbon 34 and the U-shaped portion between the ribbons is encapsulated by the attachment member which preferably takes the form of a rounded epoxy bead 22 bonded to the distal tip of the helical coil 18 . [0022] As may be appreciated, with this unitary construction of the ribbon members, these members remain aligned so that both lie in planes parallel to each other. In addition, the U-shaped bend portion when encapsulated into the rounded bead 22 causes the retaining ribbon and deflection ribbon to be properly spaced with respect to each other. [0023] As illustrated in FIG. 2, the retaining ribbon 24 is preferably attached to the rounded bead 22 at a position offset from the center of the bead in the same direction that the retaining ribbon 24 is offset from the longitudinal axis of the steerable guidewire 12 . In addition, the deflection ribbon 34 is attached to the bead at a position offset from the center of the bead in an opposite direction from the offset of the retaining ribbon 24 . [0024] Also, as may be seen in FIG. 2, the deflection ribbon 34 and the retaining ribbon 24 are pre-shaped into an arcuate, or curved, configuration to thereby maintain the helical coil 18 in a normally curved configuration. The ribbons 24 , 34 are pre-shaped such that the distal tip of the guidewire curves away from the longitudinal axis of the guidewire in a direction toward that side of the guidewire containing the retaining ribbon 24 . [0025] The helical coil 18 is formed as an elongated member having a rectangular, or square, cross-sectional configuration and wound in a helical configuration. In addition as illustrated in FIG. 2A, the elongated member is formed with re-occurring steps, or step undulations, which when wound into a helical configuration so that adjacent turns to loosely interlock thereby preventing movement between adjacent turns. Such interlocking turns enhance the rotational rigidity or “torqueability” of the coil such that when the proximal end of the coil is rotated 180 degrees, the distal end of the coil will rotate approximately 180 degrees. Accordingly, the distal end of the coil more nearly tracks, rotationally, the proximal end of the coil thereby significantly improving the “tortional” characteristics of the coil. By improving the “tortional” characteristics of the coil, the overall “tortional” characteristics of the guidewire are significantly improved. [0026] As opposed to winding an elongated member to form the helical coil 18 , a preferred method of forming the helical coil is by laser cutting the coil from a single thin-walled tube of an alloy in the undulations locking, stepped configuration as illustrated in FIG. 2A. Such laser cutting provides a coil with precise mating surfaces to assure proper interlocking between adjacent turns of the helical coil. [0027] In operation, as previously described, the distal tip of the steerable guidewire 12 is normally biased into a downwardly curved position as illustrated in FIG. 2 because of the curve of the pre-shaped deflection ribbon 34 and the retaining ribbon 24 . When the slidable control knob 26 is moved distally as shown in FIG. 5, the deflection member 20 will be moved distally thereby causing the deflection ribbon 34 to move in a distal direction. As the deflection ribbon is moved distally, a pushing force is applied to the top portion of the rounded bead 22 . The retaining ribbon 24 is attached to the lower portion of the bead 22 to thereby maintain the bead at a fixed distance from the distal end of the hypotube 16 . As the deflection ribbon 34 is moved to the right, the tip of the guidewire is caused to deflect downwardly to a maximum deflected position. [0028] Since the deflection ribbon 34 and the retaining ribbon 24 are pre-shaped prior to any activation of the steerable guidewire, the amount of force required to deflect the guidewire in this direction is very small thereby preventing buckling of the deflection ribbon 34 as the deflection ribbon is pushed distally. As the deflection ribbon 34 is moved distally, the upper turns of the helical coil become slightly stretched and the lower turns of the coil become slightly compressed. The deflection member 20 has a diameter of about 0.0065 inches and the deflection ribbon has a thickness of about 0.002 inches to thereby provide sufficient stiffness to prevent the buckling of these elements when the deflection member 20 is pushed distally. This construction also provides sufficient stiffness to transmit the necessary force from the proximal end to the distal end of the guidewire. [0029] When the slidable control knob 26 is moved in a proximal direction as shown in FIG. 4, the deflection member 20 will be pulled to the left to thereby cause the deflection ribbon 34 to pull on the top portion of the bead 22 . Since again the retaining ribbon 24 causes the lower portion of the bead to remain at a fixed distance from the distal end of the hypotube 16 , the tip of the guidewire 12 is caused to bend in an upward direction to a maximum deflection as shown in FIG. 4. Since the deflection ribbon 34 is in tension when the deflection member 20 is pulled, there is no concern for buckling of the deflection ribbon 34 . As the deflection ribbon 34 is moved proximally, the upper coil turns become slightly compressed and the lower coil turns become somewhat stretched. [0030] As previously discussed, when the proximal end of the guidewire 12 is rotated by a physician to “steer” the distal end of the guidewire, with the interlocking turns of adjacent coils of the helical coil 18 , the distal tip will rotate on a one-to-one basis with respect to the proximal end of the hypotube 16 . In other words, there is no “play” or “lag” between rotation of the proximal end and the distal end of the guidewire. [0031] In a preferred mbodiment of the present invention, the elongated deflection member 20 , retaining ribbon 24 and deflection ribbon 34 are constructed of nitinol, but these elements may be formed from other flexible materials including polymers. The helical coil 18 preferably formed by laser cutting as previously discussed, is constructed from an alloy comprised of about 92 percent platinum and 8 percent tungsten, but this element may also be constructed from numerous other materials. It is desirable that the coil exhibit the characteristic of being radiopaque to X-rays to assist in the positioning of the distal tip of the steerable guidewire 12 . The deflection member 20 is formed from a single cylindrical nitinol wire of about 0.0065 inches in diameter having an intermediate portion which is flattened to form the deflection ribbon 34 with a thickness of about 0.002 inches, and a distal portion which is flattened to form the retaining ribbon 24 with a thickness of about 0.0015 inches. The retaining ribbon 24 is bent back 180 degrees to form a generally U-shaped bend, which is subsequently encapsulated within the rounded bead 22 . The rounded bead 22 is preferably formed with epoxy, but may be formed with soldering or by welding. [0032] It has been found that the addition of graphite between the deflection member 20 and deflection ribbon 34 , and the inner lumen of the hypotube 16 provides lubrication. Other lubricants, such as Teflon or MDX may be used for this purpose. The helical coil 18 is preferably coated with an elastomeric polymer 41 on its distal end to act as a sealant preventing the entry of blood and contrast media into the guidewire and a fluorinated polymer 39 , such as Teflon, on its proximal end for lubrication purposes. [0033] It may be seen that the guidewire as disclosed may be very easily and very precisely rotated and then deflected in either of two directions for very precise steering of the guidewire through the vessels of the body. As may be apparent, the disclosed guidewire may be used for placement of a catheter within the vasculature of the human body, it may be used by itself to cross an obstruction within the vessels or it may be used to carry a therapeutic device mounted on the distal end of the guidewire for purposes of removing obstructions which may exist within a vessel of the body. [0034] The preceding specific embodiment is illustrated of the practice of this invention. It is to be understood, however, that other variations may also be employed without departing from the spirit and scope of the invention as hereinafter claimed.
A bi-directional steerable guidewire having a deflectable distal tip which comprises a longitudinal hypotube and an interlocking spring coil attached to the distal end of the hypotube and also includes a longitudinally movable deflection member which is attached to the distal end of the spring coil and a tip retaining member which extends from the distal end of the hypotube to the distal end of the spring coil for providing very precise deflection of the distal tip.
0
BACKGROUND OF THE INVENTION This invention relates to a material or composition which is useful in the manufacture of prototype elements, and more particularly, to a ceramic feedstock composition which may be used in a ribbon or filament deposition apparatus for the manufacture or building of prototype elements. In U.S. Pat. No. 5,340,433 and U.S. Pat. No. 5,121,329, there is depicted a device or apparatus which is useful for the manufacture of prototype elements. The device feeds a filament of filled or unfilled polymer or other material through a discharge nozzle for deposition upon a platen. Either the nozzle or platen or both move in accord with a pre-programed pathway to enable the filament of material discharged from the nozzle of the device to form a prototype element. For example, gear shapes may be formed in this manner, though the particular shape formed is not a limiting feature of the invention. The subject matter of U.S. Pat. No. 5,340,433 and U.S. Pat. No. 5,121,329 is incorporated herewith by reference. Various compositions and materials have been used or are disclosed for use in a process of the type depicted in the aforesaid U.S. Patents. Further, applicants herein are co-inventors with respect to advanced type apparatus useful in the creation of prototype elements using a filament deposition technique. One of the challenges with respect to such methods and procedures is to devise a ceramic or other feedstock composition which will be especially useful in the creation of prototype elements and low volume production parts. Such a feedstock material should have adequate hardenability and toughness when formed into a desired element. The feedstock material should also be capable of use in apparatus of the type described. Such materials should also be subject to binder removal and sintering so that the element created utilizing the process may acquire both high strength and sintered density (95% of theoretical) enabling it to be used in a test or low volume ceramic parts production environment. Thus there has remained a need to provide an improved feedstock composition useful for the manufacture of prototype elements using ribbon deposition type apparatus and techniques. SUMMARY OF THE INVENTION Briefly, the present invention comprises a ceramic or metal feedstock composition for the manufacture of prototype elements using a filament or ribbon deposition apparatus wherein the composition comprises the combination of the four primary materials including: (a) a ceramic or metal powder or powder mix; (b) an ethylenejacrylate based copolymer binder (i.e. polyethylene-co-ethyl acrylate, polyethylene-co-butyl acrylate); (c) wax (i.e. microcrystalline polyethylene wax, paraffin wax, beeswax, carnauba wax, amide wax, or combinations thereof); and (d) liquid plasticizer. These materials are mixed together and upon appropriate compounding, may be used in a prototype machine having a discharge nozzle which discharges a molten filament or ribbon in a pattern to form prototype elements. A wide variety of Group II, III, and IV and transition metal carbide, nitride, and oxide ceramic powders are useable in the invention as well as ferrous and nonferrous alloy powders. The ceramic or metal powder is typically ball milled either dry or in a solvent vehicle to disperse, deagglomerate, and uniformly mix the ceramic powders. Hexane is a preferred liquid vehicle for ball milling, but other liquids may be used. The hexane is then stripped from the material, e.g., by distillation, so that the ceramic powder remains. The powder is then mixed in combination with the other materials cited above. The combined materials have preferred ranges or amounts. The ceramic or metal powder, for example, comprises in the range of 75 to 93 weight % of the composition. The binder comprises 4.5 to 14 weight percent of the composition. The wax comprises 1.5 to 6 weight percent of the composition and the plasticizer comprises 1 to 5 weight percent of the composition. Typically, the green feedstock composition is fed into a prototype machine wherein a nozzle discharges a filament or ribbon in a specific pattern as described above. The prototype element is then debindered and sintered. In this manner a prototype element is created. It should also be noted that the feedstock may be utilized to manufacture a molded prototype product which is formed, fired and/or sintered. Thus it is an object of the invention to provide an improved feedstock composition useful for the manufacture of prototype elements. It is a further object of the invention to provide a ceramic feedstock composition which has minimal shrinkage and cracking densification of the debindered prototype element. Yet another object of the invention is to provide a green ceramic feedstock composition which may be utilized to manufacture prototype elements wherein the elements are uniform in appearance and structure even following sintering thereof. Another object of the invention is to provide a green ceramic feedstock composition which may be used to manufacture prototype elements wherein the fired elements have a density greater than 95% and possess high strength. These and other objects, advantages and features of the invention will be set forth in the detailed description which follows. DESCRIPTION OF THE PREFERRED EMBODIMENT The ceramic feedstock of the invention may be utilized in prototype machines of the type described in U.S. Pat. No. 5,340,433 and U.S. Pat. No. 5,121,329 and pending U.S. application Ser. No. 08/825,893 filed Apr. 2, 1997, entitled, "Method and Apparatus for In-Situ Formation of Three-Dimensional Solid Objects By Extrusion of Polymeric Materials." Other element forming machines may also be utilized in the practice of the invention. That is, the ceramic feedstock material may be used for feeding into a machine of the general nature described to thereby create a three-dimensional object from such feedstock. The feedstock is comprised of four basic components: (1) ceramic or metal powders; (2) polyethylene-co-acrylate copolymer binder; (3) wax; and (4) liquid plasticizer. These four materials may be utilized with certain additional additives. For example, additives such as coloring agents may be utilized. Advantageously, the powders which may be used to provide a feedstock include ceramic oxides, ceramic carbides, ceramic nitrides, ceramic borides, suicides, and metals or mixtures thereof. Preferred powders for use in that composition include aluminum oxide, barium oxide, barium titanate, beryllium, oxide, calcium oxide, cobalt oxide, chromium, oxide, dysprosium oxide and other rare oxides, lanthanum oxide, magnesium oxide, manganese oxide, niobium oxide, nickel oxide, aluminum phosphate and other phosphates, lead oxide, lead titanate, lead zirconate, silicon oxide and silicates, thorium oxide, titanium oxide and titanates, uranium oxide, yttrium oxide, yttrium aluminate, zirconium oxide and its alloys, boron carbide, iron carbide, hafnium carbide, molybdenum carbide, silicon carbide, tantalum carbide, titanium carbide, uranium carbide, tungsten carbide, zirconium carbide, aluminum nitride, boron nitride, silicon nitride, titanium nitride, uranium nitride, yttrium nitride, zirconium nitride, aluminum boride, hafnium boride, molybdenum boride, titanium boride, zirconium boride, molybdenum disilicide, as well as nickel, iron, chromium, cobalt, or their alloys, aluminum, beryllium, boron, copper, gold, hafnium, iridium, magnesium, manganese, molybdenum, niobium, palladium, platinum, rhenium, silver, tantalum, titanium, tungsten, zinc and zirconium. The binder used in the invention is a homopolymer or copolymer of ethylene and acrylic acid or its ester. Examples of useable copolymer binders include polyethylene-co-ethylacrylate, polyethylene-co-butylacrylate and polybutylacrylate where polyethylene-co-ethylacrylate is the preferred polymer binder in this invention. A wide variety of natural and synthetic waxes may be used in this formulation which impart dimensional rigidity upon cooling to the dispensed molten feedstock filament or ribbon material. These waxes include, but are not limited to, microcrystalline polyethylene wax, beeswax, paraffin wax, carnauba wax, Montan wax, and amide wax where microcrystalline polyethylene is the preferred material in the invention formulation. A liquid plasticizer is also an ingredient of the invention and serves as a processing aid that reduces the melt viscosity of the feedstock composition, as well as increases the flexibility and toughness of its polymer binder component. These liquid plasticizers may be esters of fatty acids (i.e. butyl oleate), esters of phthalic acid (i.e. dibutyl phthalate, dioctylphthalate), or hydrocarbon oils (i.e. Heavy White Mineral Oil). In any event, the feedstock formulation can be processed as a rod or as a small diameter (e.g. 0.070" diameter) filament forms. The rod feedstock is readily processed using high pressure extrusion heads of the type described in Application Ser. No. 08/825,893. Filament feedstock can be utilized in apparatus of the type disclosed in U.S. Pat. No. 5,340,433 and U.S. Pat. No. 5,121,329. The filament feedstock is very flexible and will not fracture after repeated flexure. This phenomenon is observed despite the fact that the filament is greater than 50% by volume ceramic material. The material is fabricated or mixed and then processed in the apparatus of the type described, for example, to form a turbine blade, rotor blade or gear. The formed components are then heated in an oven to remove their organic phase. Test materials did not crack or warp after such treatment indicating that the binder is uniformly removed from the parts during the heating operation. The parts also have been sintered without any pressure to density the material and observations are that at least 80% of these sintered parts make distortion-free ceramic prototype elements. The density of such sintered materials is greater than 95% of its theoretical density. The sintered part also exhibits high strength. Following is a specific example of the formulation of the feedstock composition and the protocol or procedure make such a feedstock: EXAMPLE ONE A silicon nitride powder is first ball milled in a hexane solvent to disperse, deagglomerate and uniformly mix with other ceramic powders, specifically yttrium oxide and aluminum oxide. Other solvents (e.g. ethanol, isopropanol) may be used. The composition of the mixture is as follows: 49.1 wt. % (H.C. Starck M11) Silicon Nitride 5.12 wt. % Yttrium Oxide (Molycorp Inc.) 1.68 wt. % Aluminum Oxide (Ceralox Corp.) 43.2 wt. % Hexane (A.C.S. Reagent or HPLC Grade) 0.9 wt. % Ethomeen C-12 Dispersant (Akzo Nobel Chemicals, Inc. fatty aminoalcohol) Subsequent to the mixing of the composition, the hexane is stripped from the mixture by a distillation process. The ceramic powders remain after the stripping operation. The ceramic powders are then batched with the other materials comprising the feedstock composition in a Brabender High Torque mixer to formulate the green ceramic feedstock composition. Following is a summary of the mix in the green feedstock composition: 82.5 wt. % ceramic powder 11.7 wt. % polyethylene-co-ethylacrylate binder (Union Carbide Corp. DPDA 6182) 3.45 wt. % BASF AL3 Microcrystalline Polyethylene Wax 2.35 wt. % Butyl oleate Plasticizer (Witco Corp. Kemester 4000) Following the mixing of the material and to create the green ceramic feedstock, the materials are fed as a filament into a machine of the type disclosed in U.S. Pat. No. 5,340,433 and U.S. Pat. No. 5,121,329 or U.S. application Ser. No. 08/825,893. The extruded materials thus define a complex shaped prototype element in accord with the teachings herein. The element is then debindered to eliminate the organic phase. Thereafter, the parts are sintered in an inert nitrogen atmosphere. The observed parts were described above. EXAMPLE TWO The same formulation procedure was followed as in Example 1 but with different components as set forth below: 80.8 wt. % Si 3 N 4 (milled in hexane with Al 2 O 3 and Y 2 O 3 sintering aids → same ratio as in Ex. 1.) 11.6 wt. % polyethylene-co-ethylacrylate copolymer 2.8 wt. % BASF AL3 Microcrystalline Polyethylene Wax 3.0 wt. % Beeswax (N.F. Refined) 1.8 wt. % Butyl oleate EXAMPLE THREE Again, the same formulation procedure as in Example One was followed: 80.7 wt. % Si 3 N 4 milled powder (w/Al 2 O 3 and Y 2 O 3 as in Ex. 1.) 11.6 wt. % polyethylene-co-ethylacrylate copolymer 5.9 wt. % Beeswax (N.F. Refined) 1.8 wt. % Butyl oleate EXAMPLE FOUR A pre-mixed stainless steel powder is batched with the other materials comprising the feedstock composition using a Brabender High Torque mixer to formulate the green ceramic feedstock composition. The following is a summary of the mix in the green feedstock composition: 92.69 wt. % ANVAL 17-4 PH Stainless Steel Powder 4.89 wt. % polyethylene-co-ethylacrylate copolymer 1.46 wt. % BASF AL3 Microcrystalline Polyethylene Wax 0.95 wt. % Butyl oleate Plasticizer (WitcoCorp.Kemester 4000) The materials were, following binder removal and sintering, successfully formed as prototype elements using the described techniques. Various other formulations and combinations of the particular elements set forth are possible. Thus the invention is to be limited only by the following claims and equivalent thereof
A ceramic or metal feedstock composition useful for manufacture of prototype elements using a filament or ribbon deposition apparatus, includes a ceramic or metal powder, a binder of ethylene/acrylate copolymer or homopolymer, a wax and liquid plasticizer mixed together in the form of a ribbon or rod which may then be used in a prototyping device.
2
BACKGROUND [0001] Whipstocks are well known to the hydrocarbon industry as devices providing a hardened diverter face useful to cause a milling tool run into the downhole environment either behind (single trip) or after (multiple trips) the whipstock to track through a wall of a borehole whether that hole be cased or open. The ability to cause such “side tracks” is important in that it is the basis for multilateral wellbore technology. Multilateral technology has dramatically enhanced the ability of operators to recover hydrocarbon materials from subsurface formations by accessing multiple reservoir areas from a single surface location. This reduces the cost involved with recovering the hydrocarbon materials and in addition, reduces the footprint of a well system at the surface. [0002] Inherent in the milling of either a casing or the formation or both is the production of debris. Debris in the wellbore is undesirable because it tends to cause malfunctions in well equipment resulting in delays and additional costs in running the well operation. In order to avoid debris falling down the wellbore, debris barrier devices have been employed by the industry. Unfortunately, an effective debris barrier has eluded the art. SUMMARY [0003] A self adjusting debris excluder sub includes a cup; a cone configured to bias the cup to a sealed position; and a support having an end supporting the cup and an end mounted in the sub to allow lateral movement of the end that supports the cup. [0004] A self adjusting excluder sub includes a first subassembly; a second subassembly with respect to which the first subassembly is axially movable; and a support disposed at the second subassembly and when actuated being resiliently disposed against the first subassembly while being laterally movable relative to the first and second subassemblies jointly. [0005] A debris excluder includes a cup having a first perimetrical dimension smaller than a tubular member in which it is intended to be run; and a cone in operable communication with the cup to selectively increase the cup to a second perimetrical dimension. [0006] A method for milling a window while excluding debris includes shifting a second subassembly relative to a first subassembly in a self adjusting excluder sub; and expanding a cup of the first subassembly with a cone of the second subassembly, the cone mounted on a support articulated from the second assembly. BRIEF DESCRIPTION OF THE DRAWINGS [0007] Referring now to the drawings wherein like elements are numbered alike in the several Figures: [0008] FIG. 1 is a cross-sectional view of a debris catcher for use with a whipstock as disclosed herein. DETAILED DESCRIPTION [0009] It has been discovered by the inventors hereof that whipstock debris catchers of the prior art have been thwarted by properties inherent in the whipstock assembly. Because whipstock assemblies are pushed to a side of the primary borehole in which they are anchored opposite of the side of the borehole at which an exit is being milled by the milling tool, debris excluding devices of the prior art can fail to catch all the debris. Further, because the greatest concentration of debris is generated on the side of the whipstock that is being pushed away from the borehole wall, generally, therefore also being the side of the whipstock where a prior art debris catcher is most vulnerable, debris generally escapes capture. [0010] Referring to FIG. 1 , a debris catcher arrangement 10 is illustrated that accommodates the lateral movement of the whipstock inherent in milling the casing or open hole wall. The arrangement 10 includes a bottom sub 12 that is configured to be received in an anchor of the prior art (not shown). The bottom sub 12 includes at least one, and as shown, a series of ports 14 to prevent a swabbing effect of the tool as it is tripped into or out of the hole. A downhole end of the bottom sub 12 is, as noted above, configured for receipt by a conventional anchor (not shown) in the wellbore. This, then, is also the pivot point about which the arrangement 10 and a whipstock (not shown) attached thereto (at a top sub introduced later herein) pivot when the whipstock is urged laterally during a milling operation as discussed above. The bottom sub 12 is attached at an uphole end 16 thereof to each of a collet 18 , a mandrel 20 and a spring retainer 22 . The collet and the spring retainer are fixedly attached to the bottom sub 12 at affixation 24 and 26 , respectively, while the mandrel 20 is axially slidably received at the bottom sub 12 . A torque transmissive coupling 28 is provided between the mandrel and the bottom sub for two specific reasons. The first is to allow torque generated as a byproduct of the milling operation to be borne through the arrangement to the anchor (not shown) so that the whipstock (not shown) will remain in the orientation in which it is intended to exist. The second is to provide a stroke length that is designed into the tool and ensures that a fluid bypass closing operation (discussed more fully hereunder) takes place reliably. In one embodiment, the stroke length is about 1.5 inches although it is to be appreciated that other lengths can be designed in for particular applications. [0011] The collet 18 cooperates with the mandrel 20 through a resiliency of the collet occasioned by one or more slits 30 therein, a series of slits 30 being illustrated. The collet 18 includes a profile 32 thereon complementarily shaped to a recess 34 in the mandrel 20 . The profile 32 is disposed downhole of the recess 34 during run in and prior to actuation of the debris seal arrangement 10 and resides in the recess 34 after such actuation. It is to be appreciated that it is the mandrel that moves downhole rather than the collet moving uphole during actuation. The collet 18 is axially fixed. In one embodiment, the collet 18 is configured to provide a deflection force of about 20,000 pounds. This means that the collet can be snapped in for actuation and snapped out for deactivation of the arrangement 10 by using a set down weight of about 20,000 or a pull of about 20,000 pounds. Other amounts of force can be designed in. In the embodiment discussed, this rating is selected to be between the typical setting range of about 12,000 to about 15,000 pounds for the anchor (not shown) and about 40,000 pounds for the milling bit to whipstock release member (not shown but well known commercially available configuration). This will ensure that the arrangement 10 actuates at the appropriate time. In addition, it is to be appreciated that the collet as disclosed herein, in combination with the other components, disclosed results in an arrangement that does not utilize one time release members such as shear screws thereby enabling the arrangement to be snapped in/snapped out numerous times if necessary or desired for some reason. Debris excluding configurations of the prior art do not possess such capability. [0012] Consequent movement of the mandrel 20 , at least one opening 36 or a series of openings 36 as illustrated, are blocked during the actuation phase of the arrangement 10 . The openings 36 are necessary to allow fluid to flow from an annular area of the wellbore 40 through the arrangement 10 and through ports 14 back to the annular area when the arrangement is being run in or retrieved from the hole, a fluid bypass arrangement. After the arrangement 10 is landed in the anchor (not shown), blocking the openings 36 closes a potential debris path. In order to ensure that the bypass is closed, the stroke of the mandrel must be a substantially fixed dimension. As noted above, in one embodiment, the length is 1.5 inches. Were the arrangement 10 to stop stroking the mandrel 20 prior to achieving the full design stroke (of for example 1.5 inches), the blocking of the bypass might well be ineffective leading to potential migration of debris through the arrangement 10 . As this would be contrary to the point of the arrangement 10 , it is undesirable. Therefore, it is important to achieve a full stroke. Potentially impeding the gratification of full stroke, however, is the relative unknown of the casing or open hole inside dimension. If the debris excluding arrangement encounters resistance to the stroke due to contact with the casing or open hole wall, the full stroke can be in jeopardy. To alleviate this potential occurrence, resiliency in the arrangement is also provided (discussed further hereunder). [0013] Also, consequent movement of mandrel 20 , a debris catch system 42 of the arrangement 10 , is actuated. The debris catch system 10 comprises a cup thimble 44 (through which openings 36 extend) fixedly attached to the mandrel 20 . A cup 46 is nested within the cup thimble 44 and further anchored to the mandrel at shoulder 48 . Cup 46 may be constructed of a number of different materials providing they have a debris exclusionary effect. Materials include but are not limited to a resilient material such as rubber or plastic, a wire brush comprising metal or other material capable of withstanding the environment in which it is intended to be deployed, etc. The material is to act as a debris catch with the casing or open hole wall to exclude debris from falling downhole of the arrangement 10 when actuated. In one embodiment as illustrated, the cup 46 is a frustoconical structure that grows in diametrical dimension in a downhole direction. This provides an advantage for retrieval of the arrangement 10 because debris cannot collect in the concavity defined by the frustocone. Such debris would interfere with dimensional reduction of the cup 46 when retrieving the arrangement 10 , an undesirable occurrence. Prior to actuation (including during run in) the system 42 is a clearance fit within the borehole so that the cup 46 does not experience significant wear during the run in and so that the tool avoids “float” in the bore related to too small of an annular space around the cup 46 for fluid to easily pass during the run in. [0014] Once the arrangement 10 is in place in the borehole, it is actuated whereby the cup 46 is radially displaced, to effect a debris catch. Displacement in one embodiment is by a cone 50 . The cone 50 is fixedly mounted upon a support 52 , for example, a sleeve as illustrated, which is itself disposed about the mandrel 20 but not in contact therewith. The cone 50 acts as a wedge against the cup 46 to cause the cup 46 to grow in outside dimension. The sleeve 52 is axially moveably mounted about the mandrel 20 with a clearance annulus 54 . Clearance annulus 54 is disposed between an inside dimension surface 56 of the sleeve 52 and an outside dimension surface 58 of the mandrel 20 . This annulus, provided within the arrangement 10 , is important in that it allows the cone 50 to remain relatively centralized in the borehole even when the whipstock (not shown) is urged off center thereby causing the arrangement 10 to pivot about the anchor point at a downhole end of the bottom sub 12 . The centralized position of the cone causes the cup 46 to be pushed into contact with the wall of the casing or open hole even though the whipstock is out of center. Because of the arrangement 10 , debris exclusion is enhanced. In one embodiment, the cone 50 is mounted at one axial end of the sleeve while the other axial end of the sleeve is mounted to the mandrel 20 allowing the end of the sleeve supporting the cone to move laterally relative to the arrangement 10 . [0015] Further to the foregoing, the sleeve 52 includes at a downhole end thereof a radially thickened section 60 with a stop surface 62 . The stop surface 62 is cooperable with a stop flange 64 . Sleeve 52 further includes an end 66 that is limited in movement by a shoulder 68 of mandrel 20 . Total axial movement of the sleeve 52 and therefore cone 50 is limited to the illustrated distance between end 66 and shoulder 68 . Promoting articulation of the sleeve 52 about its thickened section 60 is a ridge 70 which spaces the thickened section 60 of the sleeve from the mandrel 20 providing an articulation point. [0016] The cone 50 is biased by a resilient member 70 , such as a spring, as illustrated. The resilient member 70 is protected by a cover 72 . The bias drives the cone into the cup 46 in order to expand the same when the sleeve 52 is driven in a downhole direction by the movement of the arrangement 10 . Further, the member 70 serves another purpose for the arrangement 10 and that is to allow resiliency in the system 42 when the cup 46 contacts the borehole wall prior to the mandrel fully stroking the designed in distance. For example then, assuming the cup 46 contacts the borehole wall early in the stroke of the mandrel, the mandrel will not be prevented from achieving a full stroke because the member 70 deflects to facilitate full stroke of the mandrel. In other words, because after the cup 46 contacts the borehole wall, the cone cannot significantly more move into cup 46 , something has to give or the mandrel will stop its stroke. What gives in the illustrated embodiment is the member 70 to allow the rest of the stroke to occur. It is to further be appreciated that while no seal is shown at the bypass, one could easily be created by providing seals such as o-rings on the collet straddling the openings 36 . Because the arrangement is primarily a debris catcher, sealing is unnecessary. It is well to note, however, the sealing potential of the arrangement 10 if needed for a particular application. [0017] Initial downhole movement of the arrangement comprises a downhole motion of a first sub assembly of the arrangement 10 comprising the mandrel 20 , cup 46 , cup thimble 44 , a top sub 62 (all of which are fixed relative to each other) and other components (not shown) attached uphole of the components illustrated relative to a second subassembly comprising the bottom sub 12 , the collet 18 , the spring retainer 22 , the sleeve 52 , the cone 50 and the resilient member 70 . When the mandrel moves downhole, the collet 18 deflects and moves the profile 32 into the recess 34 . Due to the retainer 22 being fixedly attached to bottom sub 12 , the resilient member 60 cannot move downhole but rather is compressed axially both facilitating stroke for the mandrel 20 , as noted above and resulting in a rebound force that is used to force the cup 46 to open. The rebound force facilitates the maintenance of the cup 46 in a position to effectively exclude debris even when the arrangement 10 is pivoted out of position due to the whipstock being urged off center into a wall of the borehole opposite the exit window being milled. [0018] While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
A self adjusting excluder sub includes a first subassembly; a second subassembly with respect to which the first subassembly is axially movable; and a support disposed at the second subassembly and when actuated being resiliently disposed against the first subassembly while being laterally movable relative to the first and second subassemblies jointly and method.
4
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of application Ser. No. 07/683,974 by the same inventor and assignee herein, filed Apr. 11, 1991, now abandoned. BACKGROUND OF THE INVENTION This invention relates generally to coin handling machines, and specifically to coin handling machines with rotating coin bowls. Referring to FIG. 1, shown is a plan view of a conventional coin handling machine having a coin bowl 10 which may be at an angle to horizontal and is typically rotated. Coins are typically loaded into the machine through a fixed coin hopper 20 and fall gravitationally, or are pushed into the coin bowl. (Coin 12a is shown leaving the coin bowl, while coin 12b is shown lodged in a coin receiving space.) The coins form a tumbling coin mass and coin lifters 14 attached to a rotating drum wheel disk 16 help direct coins through coin receiving holes 17 of the drum wheel disk when the coin level is low and into the space between the back side of the drum wheel disk and a stationary surface which is parallel and spaced from the drum wheel disk. The drum wheel disk forms the bottom of the coin bowl 10 and carries ejector pins 19 on its back side which direct the coins to an exit chute 18. A coin stripper 22, mounted on a stationary back surface 24 and positioned behind the drum wheel disk, engages an edge of a coin as it is pushed along by the ejector pins and directs the coins into chute 18 and out of the machine. The coins impinge on a coin stripper edge 22a, which is usually a hard steel or plastic surface. Ejector pins 19 exert forces on the coins which act both parallel and perpendicular to the coin stripper edge. A hub 25 on the back side of drum wheel disk 16 may also be included to help guide the flow of coins toward coin holes 17. Other coin handling machines which operate along the lines discussed above are known. U.S. Pat. No. Reissue No. 28,557 shows a disk dispensing apparatus. U.S. Pat. No. 902,067 (Froberg) discloses a rotating coin receiver designed to receive a mass of coins, preferably inclined so that the coins slide toward a lower portion of the coin receiver, where openings allow the coins to be driven out of the receiver by reciprocating slides. Similarly, U.S. Pat. No. 918,273 (Brewster) discloses a coin counter having a plurality of coin separating disks which rotate around a spindle and in which a hopper rotates via a hand wheel crank. U.S. Pat. No. 1,080,533 (Bach) discloses a rotating coin hopper, but coins are guided only by rotation of the hopper. Other relevant patents include U.S. Pat. No. 1,095,981, which shows a lifting plate for discharging coins; U.S. Pat. No. 3,757,805, which shows an annular ring which defines an adjustable space for coins of different thicknesses; U.S. Pat. Nos. 4,557,282 and 4,620,559, which disclose rotating coin hoppers; and U.S. Pat. No. 4,570,655 which shows coin guides. Most prior art coin handling machines suffer frequent failures which take them out of service. Failures are typically due to a coin wedging against a stationary coin bowl ring or other surface which is stationary or relatively slower moving. Other failures typically occur because of improper or lack of adequate agitation of the coin mass by the rotating drum wheel disk and the coin lifters attached to the drum wheel disk, inadequate guidance of the coins as they are moved toward the discharge chute, or the accumulation of "coin dust" in these machines, with no apparent way of removing it. SUMMARY OF THE INVENTION In accordance with the present invention, a coin handling machine is provided for sequentially dispensing individual coins from a coin mass. The machine includes a frame, a stationary back plate assembly mounted to the frame and having a face which is angularly inclined relative to the vertical, and a disk parallel to and spaced from the stationary back plate assembly for defining a generally annular coin moving space between the disk and the stationary back plate assembly. The disk generally includes a plurality of circumferentially spaced coin-receiving holes of a diameter sufficient to permit passage of the coin from a side of the disk facing away from the stationary back plate assembly into the coin moving space. One novel feature is a set of coin pushers associated with each coin hole, the pushers being radially spaced and the stationary back plate assembly including a plurality of spaced-apart circular grooves positioned and formed to coincide with the positions of the coin pushers. The coin pushers extend from the disk into the associated grooves of the back plate, with the leading edges of the pushers in the direction of rotation of the disk trailing the associated coin hole in the disk. As the pushers move coins along an arcuate path through the space as the disk is rotated, a stripper means traversing the arcuate path intercepts the coins, thereafter moving them transversely to the direction of rotation of the disk from the space to a coin discharge area which is beyond a periphery of the disk. Preferred embodiments include those wherein the radially innermost of each set of pushers is closest to the associated coin hole in the disk and the radially outermost pusher is furthest removed from the associated coin hole in the disk so that the forces applied by the pushers to a coin engaged by the stripper means act generally in the direction of the transverse movement of a coin to the discharge area. Another aspect of the invention includes a pressure pad located proximate to and upstream of the stripper means in the direction of disk rotation, the pressure pad being movably mounted to the stationary back plate assembly and including means for biasing the pressure pad toward the disk which gently presses a coin overlying the pad against the disk to thereby stabilize the coin in the space immediately prior to its engagement by the stripper means. Further aspects of the invention will become apparent from the description which follows. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a prior art apparatus presented to illustrate the state of the art; FIG. 2 is a side elevation and section of a coin handling machine constructed in accordance with the present invention; FIG. 3 is an elevation, with parts broken away, of the coin handling machine shown in FIG. 2 and is taken on line 3--3 of FIG. 2; FIG. 4 is a section taken on line 4--4 of FIG. 3, and shows how the pressure pad holds a coin against the back side of the drum wheel disk; FIG. 5 is a section taken along line 5--5 of FIG. 3 showing an embodiment of an assembly allowing the adjustment of the separation between the stationary back plate assembly and the drum wheel disk; FIG. 6 shows an exploded perspective view of a second embodiment of the stationary back plate assembly, pressure pad, and coin guide; FIG. 7 shows an embodiment of a pressure pad wherein the pad comprises two individual pressure pads; and FIG. 8 shows a perspective view of the coin handling machine having a baffle plate useful for high coin levels, reducing the effective weight of the coin mass and thus the strain on the means for rotating the drum wheel disk. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 2 and 3 (similar reference numerals are used throughout FIGS. 2-8), a coin handling machine 2 constructed in accordance with the present invention generally comprises an upright frame 4 adapted to be supported on a flat surface (not separately shown) which has an inclined face 6 to which a stationary back plate assembly 8 is secured. (As used herein the term "stationary" means not rotating, with axial movement allowable.) A drive motor 10 is mounted to the frame on the side of face 6 opposite from the back plate assembly and it includes a shaft 12 which protrudes through an appropriate bore in the back plate assembly. A drum wheel disk 14, mounted to the free end of the motor shaft for rotation therewith, is spaced from the stationary back plate assembly, as is further discussed below, and includes a central hub 48 and a plurality of circumferentially spaced-apart coin receiving holes 17 of a diameter sufficient to permit passage of the coins being handled by the machine. A cylindrical drum 18 is attached to the disk along its periphery and rotates with the disk when driven by the motor. Cylindrical drum 18 and disk 14 rotate in a counterclockwise fashion as designated by the arrow ω (FIG. 3), although it will be appreciated by those skilled in the art that clockwise rotation may be used with associated changes in the structure in the coin handling machine. A coin hopper 19, which may be made of molded plastic material, is attached to the back plate assembly, surrounds the disk and the cylinder drum and holds a mass of coins (not shown). Referring specifically to FIG. 3, this figure shows a section taken along the line 3--3 of FIG. 2. A coin stripper 20 is disposed in a suitably shaped recess of the back plate assembly 8 with threaded bolts 22, for example. The stripper includes a coin stripping edge 24 which protrudes from surface 26 of the back plate assembly, that is, it protrudes into a space 28 between disk 14 and back plate assembly 8. (See FIG. 4, a section taken along the line 4--4 of FIG. 3.) The coin stripping edge extends transversely (but not radially) to the direction of rotation of the disk from the vicinity of disk hub 48 toward the periphery of the back plate assembly and a coin discharge area 30 where coins are introduced into a suitable coin chute (not shown) for delivery to a desired coin pay-out location (not shown). Just upstream (in the counterclockwise direction of rotation of drum wheel disk 14 of the stripper 20 is a pressure pad 32 which gently biases a coin 33 (shown in FIG. 4) toward the back side of drum wheel disk 14. In the preferred embodiment of the invention, the stationary back plate assembly 8 is formed of a stationary back plate 34 and a stationary ring 36 secured, for example, bolted thereto. The stationary ring includes a cutout 38 shaped to slidably receive the pressure pad to that it can move in the cutout in a direction perpendicular to the faces of the stationary ring. One or more springs 40 anchored in bores 42 in the back plate bias the pressure pad toward drum wheel disk 14, thereby pressing coin 33 against the back side of the disk, as is best illustrated in FIG. 4, and stabilizing it. Pressure pad 32 may be in two or more parts, as shown in FIG. 7, or may be one solid plate, the choice depending on whether a staged coin exit is to be achieved or not. The back side of drum wheel disk 14 includes a set of circularly arcuate, radially spaced-apart, rib-shaped coin pushers 44 which project into correspondingly shaped and arranged, circular, spaced-apart grooves 46 in stationary ring 36. A set of such pushers trails (in the direction of disk rotation) each coin receiving hole 17 in the disk to form a pocket for a coin which is recessed from hole 17. It is the function of the pushers to move any coin in space 28 through the space and toward stripper 20 as the disk is rotated while the coin is retained in the pocket. As perhaps better seen in the section of FIG. 5, taken along the line 5--5 of FIG. 3, coin pushers 44 track in the stationary ring grooves 46 in stationary ring 36. Thus, as drum wheel disk 14 rotates as shown in FIG. 3, coins deposited in coin holes 17 and lodged in coin receiving space 28 will be moved toward pressure pad 32 by coin pushers 44. As the drum wheel disk is rotated in the counterclockwise fashion, the pushers exert a force on the coins which tends to move the coins tangentially toward the drum wheel disk periphery. Upstream of coin stripper 20 and pressure pad 32 and generally near the top of stationary ring 36 is a pivotally mounted coin guide 64, as shown in FIGS. 3, 4, and 6, which stabilizes and directs the coin in space 28 towards hub 48 before the coin encounters the pressure pad 32 and contacts coin stripping edge 24. Coin guide 64 in effect exerts a force which counteracts the tendency of the coin to move tangentially toward the periphery of the drum wheel disk. Referring to FIGS. 3 and 4, as the coins approach coin stripper 20 they are stabilized by pressure pad 32. Pressure pad 32 is located strategically above, i.e., just upstream of coin stripping edge 24 and it gently presses the coin against the back side of the disk, thereby eliminating any play and looseness of the coin in the space and preventing a coin from gravitationally and uncontrollably dropping onto the coin stripping edge 24. Pressure pad 32 ensures the positive guidance of the coin and its controlled advance through space 28 as it is being pushed by pushers 44 of the rotating drum wheel disk. The stripper edge 24 is defined by stripper ribs 25 (FIG. 3) on coin stripper 20 and they are spaced apart to accommodate coin pushers 44 on the back side of drum wheel disk 14. Once the coin contacts stripper edge 24 its motion is redirected by the edge while the pushers continue to apply a moving force to the coin to advance it transversely to the direction of rotation along the stripper edge and out of space 28 toward coin discharge area 30. As the coin moves along the stripper edge, the coin periphery is engaged by successively radially more outward pushers of the set. The geometry of the coin periphery, the stripper edge and the pushers of the set are such that the contact point between the coin periphery and the pushers remain in the general vicinity of the centerline of the coin which is parallel to the stripper edge 24. This minimizes the force component applied by the pushers to the coin which acts transverse, i.e. relatively perpendicular to the stripper edge. The increasingly trailing position of the leading edges of the radially more outward pushers facilitates this reduction of the transverse force component. The small force which presses the coin against the stripper edge 24 minimizes wear and tear of the edge, the pushers, and the coins. It also reduces the generation of undesirable coin dust within the machine. Referring now to FIG. 3, stationary ring 36 has the same number of spaced-apart grooves 46 as there are coin pushers 44 on drum wheel disk 14. Spaced-apart grooves 46 also serve the function of collecting "coin dust" which is generated by the coin mass as it tumbles in the coin bowl. Such "coin dust" typically includes metal shavings from coins, fibers, paper fragments and other assorted dirt and rubbed off particles which may be detrimental to the smooth operation of the coin handling machine. To remove the coin dust from the machine, stationary ring 36 preferably has one or more through-holes 80 at spaced apart locations in the grooves. Coin dust eventually accumulates in the grooves and is swept by the moving pushers 44 to the holes where it drops out of the machine. Referring to FIG. 5, a modification of the apparatus allows the separation between stationary ring 36 and drum wheel disk 14 to be adjusted for handling coins of different thicknesses with the same machine. For this purpose an adjustable nut and screw assembly 52 is attached (e.g. welded) to back plate 34, having a main separation adjustment screw 54 and a spring 62. One or more adjusting springs 56 support stationary ring 36 in a firm but elastic manner on the back plate 34. A bolt and washer assembly 60 connects adjustable nut and screw assembly 52 to stationary ring 36. When main adjustment screw 54 is rotated clockwise by hand or with a suitable tool the separation between the back surface of drum wheel disk 14 and front surface of stationary ring 36 is decreased as the stationary ring moves axially toward the disk, with the opposite rotation of screw 54 effecting an increase in separation. Referring now to FIG. 6, there is shown an exploded perspective view of the stationary back plate assembly, pressure pad, and coin guide. Coin guide 64 is pivotally mounted to the stationary ring 36 with a pivot defined by a pin 70 and a journal 72. A spring 66 which is anchored in bores 68, 69 in the back plate and the coin guide, respectively, biases coin guide 64 toward the center of ring 36. Referring to FIGS. 4 and 6, an embodiment of pressure pad 32 is shown which is shaped to help position a coin properly relative to the stripper edge. The pressure pad includes a first surface 35 facing the drum wheel disk which is substantially parallel thereto, and a second surface 37 which is contiguous with and located in the direction of disk rotation upstream of the first surface 35. Second surface 37 slopes away from the disk in a direction opposite to the direction of disk rotation to facilitate the engagement of the coin by the pressure pad 32 as the coin is advanced toward the stripper edge 24. Springs 40 urge the pressure pad or pads through aperture 38 in ring 36 against the backside of disk 14 or, when a coin overlies the pad, against the coin, thereby urging the coin against the back side of the disk to stabilize it as it continues to move toward engagement with the stripper edge. In addition to stabilizing the coins moving over the pressure pad, the pad, when no coin is present, rests flush against the back side of the disk and for that purpose it includes grooves which are shaped and positioned to correspond to the grooves in ring 36 so that the pushers on the back side of the disk can move therethrough. When the pad is flush against the back side of the disk, it prevents the entry of a fresh coin from the hopper into a coin opening 17 located upstream but in the vicinity of the stripper edge. If a coin were permitted to enter the opening at such a location, it might only partially enter space 28 between the disk and the back plate and remain partially in the opening, with one part of the coin in the space between the disk and the back plate and the other part on the hopper side of the disk. If the inner part of such a coin were permitted to contact the stripper edge, the coin would become wedged between the edge and the coin opening 17 in the disk. This would arrest the rotation of the disk and render the entire machine inoperative. Biasing the pressure pad 32 flush against the back side of the disk prevents such an occurrence. FIG. 7 shows another embodiment of a pressure pad 32 comprising in two parts 32a and 32b. The advantage of having the configuration and number of pads as shown in FIG. 7 is that it may be shaped to extend a substantial length across the coin stripping edge 24 of coin stripper 20. This enhances the control over and guidance of the coin as it approaches and then moves along the stripper edge. Referring to FIG. 8, in another embodiment the hopper 19 of the coin handling machine of the present invention includes a baffle plate 82 attached (e.g., welded or bolted) to the inside of the hopper 19, e.g., at 83. The baffle plate covers a major portion of the side of disk 14 facing the interior of the hopper and includes a cutout 85, in the lower portion of the baffle plate, which is defined by an upright, generally vertical edge 87 and an upper, horizontal edge 89. The baffle plate prevents a substantial and, depending on the height of the coin mass, even a major part of the coins from contacting the rotating disk, thereby reducing wear and tear, friction and, surprisingly, facilitating the pickup of fresh coins in coin holes 17 of the disk. Coin lifters 91 (see FIG. 3) in the form of small blocks bolted to the periphery of disk 14 may be provided for agitating the coin mass overlying cutout 85 in the baffle plate to facilitate the positioning of coins in each coin opening 17 as it passes the cutout and moves towards coin stripper 20. The coin lifter has a height less than the spacing between the disk and baffle plate 82 to prevent any interference between them. The hub, drum wheel disk, and cylindrical coin bowl may be made out of any material which can withstand the physical conditions existing in the hopper. Since the hopper will usually handle metal coins, materials of construction typically include various steels and steel alloys. Thermoplastics, such as TEFLON®, may also be used, as well as thermo-setting compression molded resins such as phenol-formaldehyde-type resins. Coin guide 64 can be fabricated using either metal or high-wear plastic. Preferably steel with a high surface hardness is used. Pressure pad 32 is preferably made of either metal or high-wear resistant plastic and may be fabricated by methods well known in the art, such as simple injection molding of a thermoplastic such as nylon or TEFLON®. Turning now to the operation of the coin handling machine of the present invention, and referring to the drawings, coins are initially placed inside hopper 19 and motor 10 is energized to rotate disk 14. As coin openings 17 sweep past cutout 85 in baffle plate 82, coins drop into coin opening 17 and become positioned in annular space 28 between the disk and the back plate 34. Pushers 44 advance the coins as the disk rotates towards stripper 20. The coins will typically move radially outward toward and frequently into engagement with skirt 50 of the disk which forms the peripheral boundary for annular space 28. When a given coin reaches coin guide 64, in the typical, inclined installation of the machine shown in FIG. 2 at the top of the back plate, the spring loaded guide urges the coin radially inward toward and into engagement with hub 48. At this time the spring biased pressure pad 32 engages the side of the coin facing the back plate and urges the coin against the back side of the disk, thereby stabilizing it and preventing the coin from uncontrollably moving, e.g., gravitationally dropping downwardly onto stripper edge 24. Instead, the coin is moved by pushers 44 and once it engages the stripper edge, its direction of movement changes and its motion continues along the stripper edge until the coin is entirely outside the annular space 28 between the disk and the back plate and in coin discharge area 30 for further movement toward a payout location (not shown). It has been surprisingly shown that the apparatus of the present invention not only reduces static friction within the rotating coin bowl and reduces failure due to static friction, but improves the flow of coins through the hopper, which is to a large extent due to the reduction of static friction between coins and stationary or slow moving parts of the hopper, and stabilization of the coins in the coin receiving space as they approach the coin stripper and exit the coin handling machine. The features described herein in accordance with the invention can also be retrofitted into existing machines to improve coin flow and reduce hopper failures.
An improved coin handling machine of the type having a rotating coin bowl and coin stripper is presented which allows a coin to be stabilized prior to exiting the machine, reducing jamming of the machine and subsequent maintenance. Improvements include the provision of a set of coin pushers on the underside of the drum wheel disk, a coin guide for helping the coins remain in their respective coin receiving spaces and one or more pressure pads placed strategically above the coin stripper for discharging the coins out of the machine, the pressure pad(s) preventing the coins from gravitationally dropping over the coin stripper as the coins move toward the coin exit chute.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for making titanium alloy products having high strength and ductility. 2. Description of the Related Arts Titanium alloys have been widely used in aerospace applications for their advantages of high ductility and strength. In recent years, they have also been introduced in consumer product applications. High-strength type titanium alloys, typical of which is Ti-6Al-4V, however, have a disadvantage of high working cost due to their poor workability in general. To overcome such a disadvantage, a superplastic forming/diffusion bonding method has been developed and used as a new forming method ("A Study on Fabrication Method of Integrated Light Titanium Sheet Metal Structure by Superplastic Forming/Diffusion Bonding", Makoto Ohsumi et al., Mitsubishi Heavy Industries Technical Review Vol. 20, No. 4, (1983-7), hereinafter called Prior Art 1). This forming method is to heat a titanium alloy to a predetermined temperature in α+β-phase, and to form it at a low strain rate, by which a component of a Final product shape or its similar shape can be formed. However, the above-described forming method has problems as described below. For the most widely used Ti-6Al-4V alloy, the structure becomes coarse due to grain growth during superplastic forming because the superplastic forming temperature is as high as a temperature from 900° to 950° C., so that deterioration in mechanical properties (for example, decrease in strength and ductility) occurs. For the Ti-6Al-4V alloy, the strength can be increased by rendering heat treatment of solution treatment and aging, but rapid cooling such as water quenching is needed in cooling after solution treatment. Therefore, it is almost impossible to apply this alloy to superplastically formed components. The superplastic forming is mainy applied to thin sheets. If a sheet component undergoes water quenching, quenching strains due to thermal stresses are developed, so that the component cannot function as a product. Further, for the Ti-6Al-4V alloy, the reduction in forming cost is limited because of its high forming temperature. Therefore, the development of a titanium alloy which allows superplastic forming at lower temperatures has been attempted ("Enhanced Superplasticity and Strength in Modified Ti-6Al-4V Alloys", J. A. Wert and N. E. Paton, Metallurgical Transactions A, Volume 14A, December 1983, p.2535-2544, hereinafter called Prior Art 2). In accordance with the requirements shown in Prior Art 2, some of the inventors of the present invention have developed a titanium alloy for superplastic forming which has a superplastic forming temperature 100° C. or more lower than that of the above-described Ti-6Al-4V alloy (Japanese Unexamined Patent Publication Laid-Open No. 3-274238, hereinafter called Prior Art 3). Specifically, the use of an alloy, whose typical composition is Ti-4.5Al-3V-2Mo-2Fe, remarkedly decreases the superplastic forming temperature. In the above-mentioned Prior Arts 1 to 3, however, the following four problems remain to be solved. Firstly, quenching strains are developed in solution treatment after superplastic forming, and high strength and ductility cannot necessarily be obtained by solution treatment and subsequent heat treatment. Secondly, in terms of cost, it is undesirable to repeat the solution treatment on a superplastic component. Therefore, the establishment of an alternative, efficient manufacturing technique is expected. Thirdly, deterioration in material properties takes place due to superplastic forming, so that their strength and ductility are prone to decrease. Fourthly, the establishment of a superplastic forming/diffusion bonding process is expected so that it can achieve excellent diffusion bonding strength. SUMMARY OF THE INVENTION It is the first object of the invention to provide a method for making α+β-titanium alloy products having high strength and ductility, which has a composition without generation of quenching strains after superplastic forming and without the need for solution treatment, by properly establishing the cooling conditions after superplastic forming and the subsequent heat treatment conditions. It is the second object of the invention to provide a method for making α+β-titanium alloy products, which can efficiently obtain the superplastically formed products having high strength and high ductility. It is the third object of the invention to provide a method for making α+β-titanium alloy products which produces less deterioration in material properties due to superplastic forming and has much higher strength and ductility. It is the fourth object of the invention to provide a method for making α+β-titanium alloy products, which includes a diffusion bonding process capable of achieving excellent diffusion bonding strength. From the viewpoint described below, the target value of the strength after superplastic forming was set at 105 kgf/mm 2 , 5 percent higher than the strength of Ti-6Al-4V alloy, preferably 110 kgf/mm 2 , 10 percent higher The above-mentioned Prior Art 1 describes a fact that for the Ti-6Al-4V alloy, the strength decreases by 5 to 10 percent in superplastic forming, and the tensile strength after superplastic forming is about 100 kgf/mm 2 . Normally, in order for a new material or new process to be used, it is said that the enhancement in properties by 5 percent to 10 percent or more is needed. Therefore, in this application, tentative target properties were set at 5 to 10 percent improvement on the strength of the Ti-6Al-4V alloy. To attain the above-mentioned objects, the present invention provides a method for making titanium alloy products comprising the steps of: superplastic forming α+β-titanium alloy at a predetermined temperature, said α+β-titanium alloy consisting essentially of 3.45 to 5 wt. % Al, 2.1 to 5 wt. % V, 0.85 to 2.85 wt. % Mo, 0.85 to 3.15 wt. % Fe, 0.01 to 0.25 wt. % 0 and the balance being titanium; cooling the superplastically formed titanium alloy at a cooling rate of 0.05 to 5° C./sec; and aging the cooled titanium alloy at a temperature of 400° to 600° C. The present invention provides another method for making titanium alloy products comprising the steps of: superplastic forming α+β-titanium alloy at a predetermined superplastic-forming temperature, said α+β-titanium alloy consisting essentially of 3.45 to 5 wt. % Al, 2.1 to 5 wt. % V, 0.85 to 2.85 wt. % Mo, 0.85 to 3.15 wt. % Fe, 0.01 to 0.25 wt. % 0 and the balance being titanium; heating the superplastically formed titanium alloy to a temperature ranging from the superplastic-forming temperature plus 5° C. to less than β-transus; cooling the heated titanium alloy at a cooling rate of 0.05° to 5° C./sec; and aging the cooled titanium alloy at a temperature of 400° to 600° C. The present invention provides still another method for making titanium alloy products comprising the steps of: superplastic forming α+β-titanium alloy at a predetermined superplastic-forming temperature, said α+β-titanium alloy consisting essentially of 3.45 to 5 wt. % Al, 2.1 to 5 wt. % V, 0.85 to 2.85 wt. % Mo, 0.85 to 3.15 wt. % Fe, 0.01 to 0.25 wt. % 0 and the balance being titanium; heating the superplastically formed titanium alloy to a temperature ranging from the superplastic-forming temperature plus 5° C. to less than β-transus; diffusion-bonding the heated titanium alloy; cooling the diffusion-bonded titanium alloy at a cooling rate of 0.05° to 5° C./sec; and aging the cooled titanium alloy at a temperature of 400° to 600° C. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows the effect of cooling rate after superplastic forming on tensile properties after aging treatment; FIG. 2 shows the effect of aging treatment temperature on tensile strength of superplastically formed product; FIG. 3 shows a method of measuring thermal strain of superplastically formed product after cooling; FIG. 4 shows the effect of heating temperature after superplastic forming on tensile properties after aging treatment; FIG. 5 shows the effect of diffusion bonding temperature after superplastic forming on diffusion bonding strength after aging treatment; and FIG. 6 shows the effect of diffusion bonding temperature after superplastic forming on tensile properties after aging treatment. DESCRIPTION OF THE PREFERRED EMBODIMENT The inventors obtained the following knowledge as a result of repeated studies made earnestly to find an alloy having such properties and its manufacturing conditions. We found that some of the α+β-titanium alloys having the chemical composition disclosed in the above-mentioned Prior Art 3 are alloys having a component suitable for solving the above problems. We also found that a technique for manufacturing a superplastically formed component having much higher strength and ductility than before can be established by performing heat treatment by a method described below after these alloys are superplastically formed, and a formed component having excellent strength in diffusion bonding can be manufactured. As a result of further detailed studies made focusing on this point, we found that there exists a composition which is not included in Prior Art 3 but can achieve the same effect. Specifically, it was found that the above first and second problems can be solved by specifying a chemical composition from the above viewpoint, by performing cooling after solution treatment at a proper cooling rate which can offer high strength and ductility after aging treatment without giving thermal strains to the formed component after superplastic forming, and subsequently by performing aging treatment in a proper temperature range. Also, it was found that the third problem can be solved by heating the formed component to a predetermined temperature without being cooled to room temperature after forming is performed at an optimum superplastic forming temperature at which the structure does not become coarse during the superplastic forming and by subsequently performing the above-mentioned heat treatment, and even higher strength can be attained. Furthermore, it as found that for the fourth problem, both of the bonding strength and the strength of the formed component can be improved at the same time by increasing the temperature of the formed component to perform diffusion bonding after superplastic forming, and a superplastic forming/diffusion bonding process can be established. Next, the present invention .ill be described in detail. First, the reasons why the chemical composition is limited as described above in the present invention .ill be described. Al (aluminum): Al is one of α stabilizing elements, and the clement indispensable to the α+β-titanium alloy. If Al content is less than 3.45 wt %, sufficient strength cannot be obtained. If Al content exceeds 5 wt %, the workability, especially at low temperatures, significantly deteriorates, and the fatigue life strength worsens. Therefore, Al content was specified at the range from 3.45 to 5 wt %. O (oxygen): Oxygen content equal to that of the ordinary α+β-titanium alloy is desirable. If oxygen content is less than 0.01 wt %, the contribution to the increase in strength is insufficient, and if oxygen content exceeds 0.25 wt %, the ductility decreases. Therefore, oxygen content .as specified at the range from 0.01 to 0.25 wt %. V (vanadium): V has little effect of stabilizing β-phase, but it is an important element to reduce the β-transus. However, if V content is less than 2 1 wt % the reduction in β-transus is insufficient, and the effect of stabilizing β- phase cannot be achieved. If V content exceeds 5.0 wt %, the stability of β-phase becomes too high, so that the increase in strength due to aging treatment cannot be obtained sufficiently, and the cost becomes high because V is an expensive element. Therefore, V content was specified at the range from 2.1 to 5.0 wt. %. Mo (molybdenum): Mo has effects of stabilizing β-phase and retarding grain growth. However, if Mo content is less than 0.85 wt %, crystal grains become coarse in annealing, so that the desired effect cannot be achieved. If Mo content exceeds 2.85 wt %, the stability of β-phase becomes too high, so that the increase in strength due to aging treatment cannot be obtained. Therefore, Mo content was specified at 0.85 to 2.85 wt. %. Fe (iron): Fe stabilizes β-phase, especially strengthening β-phase, and greatly contributes to the increase in strength after solution and aging treatment. Also, because Fe has a high diffusivity in titanium, it has an effect of reducing the deformation resistance in superplastic forming, and improves diffusion bonding properties. If Fe content is less than 0.85 wt %, the effect of strengthening is insufficient, and both of the effect of reducing the deformation resistance in superplastic forming and the effect of improving the diffusion bonding properties are insufficient. If Fe content exceeds 3.15 wt %, the stability of β-phase becomes too high, so that the superplastic properties deteriorate, and the increase in strength in aging treatment cannot be obtained. Therefore, Fe content was specified at 0.85 to 3.15 wt %. Impurity elements normally contained in the α+β-titanium alloy and other additional elements which have no influence on the effects of the present invention are allowed. Next, the reasons why the cooling conditions and heat treatment conditions after superplastic forming are limited are described below. The cooling rate after superplastic forming must be one which is not too high in order to prevent thermal strains and must be one which is not too low in order to obtain a sufficient increase in strength after aging treatment. If the cooling rate is too high, the strength after aging treatment becomes too high, the ductility being lost, so that the formed component cannot be used as a practical component. Therefore, the cooling rate after superplastic forming was specified at 0.05° to 5 ° C./sec in consideration of above factors. FIG. 1 shows tensile properties of superplastically formed components at room temperature. The superplastically formed components were manufactured as follows: After a Ti-4.38% Al-3.02%V-2.03%Mo-1.91%Fe-0.085%0 alloy was superplastically formed at 795° C., the formed component was cooled to room temperature at different cooling rates, and subsequently aging treatment was performed at 510° C. for 6 hours. As seen from FIG. 1, if the cooling rate is lower than 0.05° C./sec, the increase in strength after aging treatment cannot be obtained. If the cooling rate exceeds 5° C./sec, a decrease in ductility is found though the strength is high, the elongation being less than 5%, which presents a problem in practical use. Also, at cooling rates exceeding 5° C./sec, large thermal strains were produced on the formed body after superplastic forming. In case that the cooling rate is 0.05° to 1° C./sec, more preferable elongation is obtained. In case that the cooling rate is 1° to 5° C./sec, more preferable strength is obtained, The cooling rate of 0.3° to 1° C./sec is more desirable in elongation and strength. If the aging treatment temperature is lower than 400° C., the temperature is too low to improve the strength after aging treatment. If the aging treatment temperature exceeds 600° C., the strength enhancement is undesirably lost due to "over-aging". Therefore, the aging treatment temperature was specified at the range from 400° to 600° C. In case that aging treatment temperature is 400° to 500° C., more preferable tensile strength is obtained. In case that aging treatment temperature is 500° to 600° C., more preferable elongation is obtained. In case that aging treatment temperature is 450° to 550° C., more preferable 0.2% proof stress and tensile strength are obtained. A α+β-titanium alloy having high strength and ductility can be obtained under the above conditions. In this case, the deterioration in material properties due to superplastic forming is inhibited, so that much higher strength can be obtained, by increasing the temperature of the formed body in a predetermined range after superplastic forming, and then by performing cooling and aging treatment under the above conditions. At this time, if the increased temperature range is less than 5° C., the effect is not found, and if the increased temperature is not lower than the β-transus of that material, the microstructure becomes coarse, so that the mechanical properties after aging treatment, especially the ductility, deteriorate. Therefore, the temperature increased at this time was specified at a temperature which is 5° C. or more higher than the superplastic forming temperature and lower than the β-transus. To further increase the strength, it is preferable that the increased temperature be 25° C. or more higher than the superplastic forming temperature. In this case, it is desirable that the heating treatment is performed in a superplastic forming apparatus without cooling the formed component to room temperature. Sufficient bonding strength can be obtained even if diffusion bonding is performed at the superplastic forming temperature after superplastic forming. Also, far higher bonding strength can be obtained by increasing the temperature of the superplastically formed component in a predetermined range to perform diffusion bonding after superplastic forming, and then by performing cooling and aging treatment under the above conditions. At this time, if the increased temperature range is less than 5° C., the effect is not found, and if the increased temperature is not lower than the β-transus of that material, the microstructure becomes coarse, so that the mechanical properties after aging treatment, especially the ductility, deteriorate. Therefore, the temperature increased at this time was specified at a temperature which is 5° C. or more higher than the superplastic forming temperature and lower than the β-transus. To further increase the strength, it is preferable that the increased temperature be 25° C. or more higher than the superplastic forming temperature. In this case too, it is desirable that the heating treatment is performed in a superplastic forming apparatus without cooling the formed component to room temperature. The superplastic forming is carried out at a temperature of at most β-transus. The temperature of 750° to 825° C. is more preferable. EXAMPLE Next, the examples of the present invention will be described in detail. Example-1 After an ingot of α+β-titanium alloy which contains 4.38 wt % Al, 3.02 wt % V, 2.03 wt % Mo, 1.91 wt % Fe, 0.085 wt % 0, 0.01 wt % C, 0.006 wt % N, and 0.0085 wt % H, and has a β-transus of 895° C. was heated to β-phase region and forged, the forged material was heated to α+β-phase region, and formed into a 2 mm-thick sheet by hot rolling. After being superplastically formed at 795° C., this sheet material was cooled to room temperature at a cooling rate of 0.005° to 30° C./sec, and then underwent aging treatment at 510° C. for 6 hours. The relationship between the cooling rate and the tensile properties at room temperature for this example is shown in Table 1 and FIG. 1. TABLE 1______________________________________ Thermal Tensile Tensile strainCooling strength after strength after Elongation afterrate cooling aging after aging cooling(°C./sec) (kgf/mm.sup.2) (kgf/mm.sup.2) (%) (%)______________________________________0.005 101.5 102.8 16.4 <10.03 100.8 101.2 16.0 <10.1 99.8 105.2 13.6 <10.3 100.4 111.5 11.8 <11 101.8 120.5 8.4 <13 99.5 129.4 7.3 <110 98.3 130.5 4.9 1.630 98.0 130.2 4.6 3.2______________________________________ From Table 1 and FIG. 1, it is seen that if the cooling rate after superplastic forming is lower than 0.05° C./sec, the increase in strength cannot be obtained, and if the cooling rate exceeds 5° C./sec, the elongation is less than 5% though high strength can be obtained, which presents a problem in practical use. It is found that if the cooling rate is in the range of 0.05° to 5° C./sec, both of the strength and the elongation take satisfactory values. Table 1 also shows the relationship between the thermal strain and the cooling rate for the formed component after superplastic forming and cooling. If the cooling rate exceeds 5° C./sec, the occurrence of remarkable thermal strain is found. The thermal strain was evaluated by using a value obtained by dividing the maximum value of the floating height from a surface plate by the length of side of the formed component. The floating height was measured with the superplastically formed component being placed on a surface plate as shown in FIG. 3. Next, after being superplastically formed at 795° C. in the same manner as described above, a titanium alloy sheet having the above chemical composition was cooled to room temperature at a cooling rate of 1° C./sec, and then underwent aging treatment in the temperature range of 300° to 700° C. for 1 hour to evaluate the tensile properties at room temperature. The results are shown in Table 2 and FIG. 2. As seen from Table 2 and FIG. 2, if the aging treatment temperature is lower than 400° C., aging hardening is insufficient, and if the temperature exceeds 600° C., softening due to overaging occurs, so that the target strength not lower than 110 kgf/mm 2 cannot be obtained. TABLE 2______________________________________Agingtreatment 0.2% proof stress Tensile strength Elongationtemperature (kgf/mm.sup.2) (kgf/mm.sup.2) (%)______________________________________300° C. 99.7 104.3 18.5400° C. 100.1 110.6 16.4480° C. 108.3 127.5 10.1510° C. 106.0 122.4 12.2560° C. 105.2 114.1 13.5600° C. 102.4 109.9 15.8700° C. 95.4 100.6 17.9______________________________________ Example 2 After an ingot of α+β-titanium alloy which contains 4.52 wt % Al, 3.21 wt % V, 1.89 wt % Mo, 2.07 wt % Fe, 0.114 wt % 0, 0.01 wt % C, 0.008 wt % N, and 0.0045 wt % H, and has a β-transus of 905° C. was heated to β-phase region and forged, the forged material was heated to α+β-phase region, and formed into a 3 mm-thick sheet by hot rolling. After this sheet material is superplastically formed at 775° C., the formed body was heated to temperatures from 778° C. (superplastic forming temperature +3° C.) to 915° C. (β-transus+10° C.), cooled to room temperature at a cooling rate of 0.5° C./sec and successively underwent aging treatment at 480° C. for 3 hours. The relationship between the heating temperature after superplastic forming and the tensile properties after aging treatment for this example is shown in Table 3 and FIG. 4. The tensile properties of a material which was cooled to room temperature at a cooling rate of 0.5° C./sec without being heated after superplastic forming and underwent aging treatment at 480° C. for 3 hours are shown in Table 3 for comparison. From Table 3 and FIG. 4, it is seen that the increase in strength can be obtained by heating the formed body by 5° C. or more at a temperature which is lower than the β-transus. Particularly for the formed component heated to a temperature not lower than the superplastic forming temperature plus 25° C., much higher strength can be obtained. TABLE 3______________________________________Heating 0.2% proof stress Tensile Strength ElongationTemperature (kgf/mm.sup.2) (kgf/mm.sup.2) (%)______________________________________775° C. 109.2 128.0 9.6778° C. 109.3 128.1 9.5785° C. 110.8 129.9 9.0810° C. 112.6 131.8 7.6840° C. 114.5 132.7 7.0870° C. 114.8 133.0 6.6915° C. 114.6 132.9 3.5______________________________________ Example 3 The titanium alloy sheet (3 mm thickness) shown in Example 2 is superplastically formed at 810° C., successively subjected to diffusion bonding at that temperature, then cooled to room temperature at 1° C./sec, and underwent aging treatment at 510° C. for 6 hours. The tensile properties of the superplastically formed portion at this time is shown in Table 4. From this result, it is found that the same effects as those of Example 2 can be obtained even when diffusion bonding is performed after superplastic forming. TABLE 4______________________________________ 0.2% proof stress Tensile strength Elongation (kgf/mm.sup.2) (kgf/mm.sup.2) (kgf/mm.sup.2)______________________________________As cooled 94.0 100.7 12.8After aging 110.4 120.0 8.3treatment______________________________________ Example 4 The titanium alloy sheet (2 mm thickness) shown in Example 1 is superplastically formed at 795° C., successively heated to 820° C., subjected to diffusion bonding at that temperature, then cooled to room temperature at 1° C./sec, and underwent aging treatment at 510° C. for 6 hours. The tensile properties of the superplastically formed portion for this example is shown in Table 5. As seen from Table 5, the same effects as those of Example 2 can be obtained even when heating and diffusion bonding are performed after superplastic forming. TABLE 5______________________________________ 0.2% proof stress Tensile strength Elongation (kgf/mm.sup.2) (kgf/mm.sup.2) (kgf/mm.sup.2)______________________________________As cooled 94.9 101.5 11.7After aging 112.5 122.3 7.9treatment______________________________________ Example 5 The titanium alloy sheet (2 mm thickness) shown in Example 1 is superplastically formed at 775° C., successively heated to temperatures from 778° to 910° C., subjected to diffusion bonding at those temperatures, then cooled to room temperature at 0.5° C./sec, and underwent aging treatment at 510° C. for 6 hours. The relationship between the diffusion bonding temperature and the bonding strength of the diffusion bonded portion is shown in Table 6 and FIG. 5, and the relationship between the diffusion bonding temperature and the strength of the superplastically formed portion is shown in Table 7 and FIG. 6. TABLE 6______________________________________ Shearing strength of diffusion bonded portionHeating temperature (kgf/mm.sup.2)______________________________________775° C. 53.2778° C. 53.3785° C. 57.0810° C. 61.6840° C. 63.1870° C. 63.5915° C. 58.9______________________________________ TABLE 7______________________________________Heating 0.2% proof stress Tensile strength ElongationTemperature (kgf/mm.sup.2) (kgf/mm.sup.2) (%)______________________________________775° C. 100.9 118.4 10.2778° C. 101.3 118.3 10.1785° C. 104.5 120.2 9.0810° C. 106.3 122.5 7.6840° C. 108.4 125.0 6.7870° C. 108.6 125.8 5.9915° C. 106.9 124.7 3.5______________________________________ From the figures in the tables above, it is found that both of the bonding strength and the strength of the superplastic-formed portion are increased by performing heating and diffusion bonding after superplastic forming.
A method for making titanium alloy products comprises the steps of: superplastic-forming α+β-titanium alloy at a predetermined temperature, said α+β-titanium alloy consisting essentially of 3.45 to 5 wt. % Al, 2.1 to 5 wt. % V, 0.85 to 2.85 wt. % Mo, 0.85 to 3.15 wt. % Fe, 0.01 to 0.25 wt. % 0 and the balance being titanium; cooling the superplastically formed titanium alloy at a cooling rate of 0.05 to 5° C./sec; and aging the cooled titanium alloy at a temperature of 400° to 600° C. The superplastically formed titanium alloy can be diffusion-bonded, thereafter the diffusion-bonded titanium alloy can be cooled and aged.
2
This application is a continuation of application Ser. No. 09/883,734, filed Jun. 18, 2001, now U.S. Pat. No. 6,830,828, which is a continuation-in-part of application Ser. No. 09/274,609, filed Mar. 23, 1999 (now abandoned); application Ser. No. 09/452,346, filed Dec. 1, 1999 (now abandoned); and application Ser. No. 09/311,126, filed May 13, 1999 (now abandoned). This application is also a division of application Ser. No. 10/171,235, filed Jun. 13, 2002, now U.S. Pat. No. 6,902,830, which is a division of application Ser. No. 09/883,734, filed Jun. 18, 2001, now U.S. Pat. No. 6,830,828, which is a continuation-in-part of application Ser. No. 09/452,346, filed Dec. 1, 1999 (now abandoned). GOVERNMENT RIGHTS This invention was made with Government support under Contract No. F33615-94-1-1414 awarded by DARPA. The government has certain rights in this invention. FIELD OF INVENTION The present invention is directed to organic light emitting devices (OLEDs) comprised of emissive layers that contain an organometallic phosphorescent compound. BACKGROUND OF THE INVENTION Organic light emitting devices (OLEDs) are comprised of several organic layers in which one of the layers is comprised of an organic material that can be made to electroluminesce by applying a voltage across the device, C. W. Tang et al., Appl. Phys. Lett. 1987, 51, 913. Certain OLEDs have been shown to have sufficient brightness, range of color and operating lifetimes for use as a practical alternative technology to LCD-based full color flat-panel displays (S. R. Forrest, P. E. Burrows and M. E. Thompson, Laser Focus World, February 1995). Since many of the thin organic films used in such devices are transparent in the visible spectral region, they allow for the realization of a completely new type of display pixel in which red (R), green (G), and blue (B) emitting OLEDs are placed in a vertically stacked geometry to provide a simple fabrication process, a small R-G-B pixel size, and a large fill factor, International Patent Application No. PCT/US95/15790. A transparent OLED (TOLED), which represents a significant step toward realizing high resolution, independently addressable stacked R-G-B pixels, was reported in International Patent Application No. PCT/US97/02681 in which the TOLED had greater than 71% transparency when turned off and emitted light from both top and bottom device surfaces with high efficiency (approaching 1% quantum efficiency) when the device was turned on. The TOLED used transparent indium tin oxide (ITO) as the hole-injecting electrode and a Mg—Ag-ITO electrode layer for electron-injection. A device was disclosed in which the ITO side of the Mg—Ag-ITO electrode layer was used as a hole-injecting contact for a second, different color-emitting OLED stacked on top of the TOLED. Each layer in the stacked OLED (SOLED) was independently addressable and emitted its own characteristic color. This colored emission could be transmitted through the adjacently stacked, transparent, independently addressable, organic layer or layers, the transparent contacts and the glass substrate, thus allowing the device to emit any color that could be produced by varying the relative output of the red and blue color-emitting layers. The PCT/US95/15790 application disclosed an integrated SOLED for which both intensity and color could be independently varied and controlled with external power supplies in a color tunable display device. The PCT/US95/15790 application, thus, illustrates a principle for achieving integrated, full color pixels that provide high image resolution, which is made possible by the compact pixel size. Furthermore, relatively low cost fabrication techniques, as compared with prior art methods, may be utilized for making such devices. Because light is generated in organic materials from the decay of molecular excited states or excitons, understanding their properties and interactions is crucial to the design of efficient light emitting devices currently of significant interest due to their potential uses in displays, lasers, and other illumination applications. For example, if the symmetry of an exciton is different from that of the ground state, then the radiative relaxation of the exciton is disallowed and luminescence will be slow and inefficient. Because the ground state is usually anti-symmetric under exchange of spins of electrons comprising the exciton, the decay of a symmetric exciton breaks symmetry. Such excitons are known as triplets, the term reflecting the degeneracy of the state. For every three triplet excitons that are formed by electrical excitation in an OLED, only one symmetric state (or singlet) exciton is created. (M. A. Baldo, D. F. O'Brien, M. E. Thompson and S. R. Forrest, Very high-efficiency green organic light-emitting devices based on electrophosphorescence, Applied Physics Letters, 1999, 75, 4–6.) Luminescence from a symmetry-disallowed process is known as phosphorescence. Characteristically, phosphorescence may persist for up to several seconds after excitation due to the low probability of the transition. In contrast, fluorescence originates in the rapid decay of a singlet exciton. Since this process occurs between states of like symmetry, it may be very efficient. Many organic materials exhibit fluorescence from singlet excitons. However, only a very few have been identified which are also capable of efficient room temperature phosphorescence from triplets. Thus, in most fluorescent dyes, the energy contained in the triplet states is wasted. However, if the triplet excited state is perturbed, for example, through spin-orbit coupling (typically introduced by the presence of a heavy metal atom), then efficient phosphoresence is more likely. In this case, the triplet exciton assumes some singlet character and it has a higher probability of radiative decay to the ground state. Indeed, phosphorescent dyes with these properties have demonstrated high efficiency electroluminescence. Only a few organic materials have been identified which show efficient room temperature phosphorescence from triplets. In contrast, many fluorescent dyes are known (C. H. Chen, J. Shi, and C. W. Tang, “Recent developments in molecular organic electroluminescent materials,” Macromolecular Symposia, 1997, 125, 1–48; U. Brackmann, Lambdachrome Laser Dyes (Lambda Physik, Gottingen, 1997)) and fluorescent efficiencies in solution approaching 100% are not uncommon. (C. H. Chen, 1997, op. cit.) Fluorescence is also not affected by triplet-triplet annihilation, which degrades phosphorescent emission at high excitation densities. (M. A. Baldo, et al., “High efficiency phosphorescent emission from organic electroluminescent devices,” Nature, 1998, 395, 151–154; M. A. Baldo, M. E. Thompson, and S. R. Forrest, “An analytic model of triplet-triplet annihilation in electrophosphorescent devices,” 1999). Consequently, fluorescent materials are suited to many electroluminescent applications, particularly passive matrix displays. To understand the different embodiments of this invention, it is useful to discuss the underlying mechanistic theory of energy transfer. There are two mechanisms commonly discussed for the transfer of energy to an acceptor molecule. In the first mechanism of Dexter transport (D. L. Dexter, “A theory of sensitized luminescence in solids,” J. Chem. Phys., 1953, 21, 836–850), the exciton may hop directly from one molecule to the next. This is a short-range process dependent on the overlap of molecular orbitals of neighboring molecules. It also preserves the symmetry of the donor and acceptor pair (E. Wigner and E. W. Wittmer, Uber die Struktur der zweiatomigen Molekelspektren nach der Quantenmechanik, Zeitschrift fur Physik, 1928, 51, 859–886; M. Klessinger and J. Michl, Excited states and photochemistry of organic molecules (VCH Publishers, New York, 1995)). Thus, the energy transfer of Eq. (1) is not possible via Dexter mechanism. In the second mechanism of Förster transfer (T. Förster, Zwischenmolekulare Energiewanderung and Fluoreszenz, Annalen der Physik, 1948, 2, 55–75; T. Förster, Fluoreszenz organisciler Verbindugen (Vandenhoek and Ruprecht, Gottinghen, 1951), the energy transfer of Eq. (1) is possible. In Förster transfer, similar to a transmitter and an antenna, dipoles on the donor and acceptor molecules couple and energy may be transferred. Dipoles are generated from allowed transitions in both donor and acceptor molecules. This typically restricts the Förster mechanism to transfers between singlet states. Nevertheless, as long as the phosphor can emit light due to some perturbation of the state such as due to spin-orbit coupling introduced by a heavy metal atom, it may participate as the donor in Förster transfer. The efficiency of the process is determined by the luminescent efficiency of the phosphor (F Wilkinson, in Advances in Photochemistry (eds. W. A. Noyes, G. Hammond, and J. N. Pitts), pp. 241–268, John Wiley & Sons, New York, 1964), i.e., if a radiative transition is more probable than a non-radiative decay, then energy transfer will be efficient. Such triplet-singlet transfers were predicted by Förster (T. Förster, “Transfer mechanisms of electronic excitation,” Discussions of the Faraday Society, 1959, 27, 7–17) and confirmed by Ermolaev and Sveshnikova (V. L. Ermolaev and E. B. Sveshnikova, “Inductive-resonance transfer of energy from aromatic molecules in the triplet state,” Doklady Akademii Nauk SSSR, 1963, 149, 1295–1298), who detected the energy transfer using a range of phosphorescent donors and fluorescent acceptors in rigid media at 77K or 90K. Large transfer distances are observed; for example, with triphenylamine as the donor and chrysoidine as the acceptor, the interaction range is 52 Å. The remaining condition for Förster transfer is that the absorption spectrum should overlap the emission spectrum of the donor assuming the energy levels between the excited and ground state molecular pair are in resonance. In one example of this application, we use the green phosphor fac tris(2-phenylpyridine)iridium (Ir(Ppy) 3 ; M. A. Baldo, et al., Appl. Phys. Lett., 1999, 75, 4–6) and the red fluorescent dye [2-methyl-6-[2-(2,3,6,7-tetrahydro-1H,5H-benzo[ij]quinolizin-9-yl) ethenyl]-4H-pyran-ylidene]propane-dinitrile] (DCM2“; C. W. Tang, S. A. VanSlyke, and C. H. Chen, “Electroluminescence of doped organic films,” J. Appl. Phys., 1989, 65, 3610–3616). DCM2 absorbs in the green, and, depending on the local polarization field (V. Bulovic, et al., “Bright, saturated, red-to-yellow organic light-emitting devices based on polarization-induced spectral shifts,” Chem. Phys. Lett., 1998, 287, 455–460), it emits at wavelengths between λ=570 nm and λ=650 nm. It is possible to implement Förster energy transfer from a triplet state by doping a fluorescent guest into a phosphorescent host material. Unfortunately, such systems are affected by competitive energy transfer mechanisms that degrade the overall efficiency. In particular, the close proximity of the host and guest increase the likelihood of Dexter transfer between the host to the guest triplets. Once excitons reach the guest triplet state, they are effectively lost since these fluorescent dyes typically exhibit extremely inefficient phosphorescence. To maximize the transfer of host triplets to fluorescent dye singlets, it is desirable to maximize Dexter transfer into the triplet state of the phosphor while also minimizing transfer into the triplet state of the fluorescent dye. Since the Dexter mechanism transfers energy between neighboring molecules, reducing the concentration of the fluorescent dye decreases the probability of triplet-triplet transfer to the dye. On the other hand, long range Förster transfer to the singlet state is unaffected. In contrast, transfer into the triplet state of the phosphor is necessary to harness host triplets, and may be improved by increasing the concentration of the phosphor. Devices whose structure is based upon the use of layers of organic optoelectronic materials generally rely on a common mechanism leading to optical emission. Typically, this mechanism is based upon the radiative recombination of a trapped charge. Specifically, OLEDs are comprised of at least two thin organic layers separating the anode and cathode of the device. The material of one of these layers is specifically chosen based on the material's ability to transport holes, a “hole transporting layer” (HTL), and the material of the other layer is specifically selected according to its ability to transport electrons, an “electron transporting layer” (ETL). With such a construction, the device can be viewed as a diode with a forward bias when the potential applied to the anode is higher than the potential applied to the cathode. Under these bias conditions, the anode injects holes (positive charge carriers) into the hole transporting layer, while the cathode injects electrons into the electron transporting layer. The portion of the luminescent medium adjacent to the anode thus forms a hole injecting and transporting zone while the portion of the luminescent medium adjacent to the cathode forms an electron injecting and transporting zone. The injected holes and electrons each migrate toward the oppositely charged electrode. When an electron and hole localize on the same molecule, a Frenkel exciton is formed. Recombination of this short-lived state may be visualized as an electron dropping from its conduction potential to a valence band, with relaxation occurring, under certain conditions, preferentially via a photoemissive mechanism. Under this view of the mechanism of operation of typical thin-layer organic devices, the electroluminescent layer comprises a luminescence zone receiving mobile charge carriers (electrons and holes) from each electrode. As noted above, light emission from OLEDs is typically via fluorescence or phosphorescence. There are issues with the use of phosphorescence. It has been noted that phosphorescent efficiency decreases rapidly at high current densities. It may be that long phosphorescent lifetimes cause saturation of emissive sites, and triplet-triplet annihilation may produce efficiency losses. Another difference between fluorescence and phosphorescence is that energy transfer of triplets from a conductive host to a luminescent guest molecule is typically slower than that of singlets; the long range dipole-dipole coupling (Förster transfer) which dominates energy transfer of singlets is (theoretically) forbidden for triplets by the principle of spin symmetry conservation. Thus, for triplets, energy transfer typically occurs by diffusion of excitons to neighboring molecules (Dexter transfer); significant overlap of donor and acceptor excitonic wavefunctions is critical to energy transfer. Another issue is that triplet diffusion lengths are typically long (e.g., >1400 Å) compared with typical singlet diffusion lengths of about 200 Å. Thus, if phosphorescent devices are to achieve their potential, device structures need to be optimized for triplet properties. In this invention, we exploit the property of long triplet diffusion lengths to improve external quantum efficiency. Successful utilization of phosphorescence holds enormous promise for organic electroluminescent devices. For example, an advantage of phosphorescence is that all excitons (formed by the recombination of holes and electrons in an EL), which are (in part) triplet-based in phosphorescent devices, may participate in energy transfer and luminescence in certain electroluminescent materials. In contrast, only a small percentage of excitons in fluorescent devices, which are singlet-based, result in fluorescent luminescence. An alternative is to use phosphorescence processes to improve the efficiency of fluorescence processes. Fluorescence is in principle 75% less efficient due to the three times higher number of symmetric excited states. Because one typically has at least one electron transporting layer and at least one hole transporting layer, one has layers of different materials, forming a heterostructure. The materials that produce the electroluminescent emission are frequently the same materials that function either as the electron transporting layer or as the hole transporting layer. Such devices in which the electron transporting layer or the hole transporting layer also functions as the emissive layer are referred to as having a single heterostructure. Alternatively, the electroluminescent material may be present in a separate emissive layer between the hole transporting layer and the electron transporting layer in what is referred to as a double heterostructure. The separate emissive layer may contain the emissive molecule doped into a host or the emissive layer may consist essentially of the emissive molecule. That is, in addition to emissive materials that are present as the predominant component in the charge carrier layer, that is, either in the hole transporting layer or in the electron transporting layer, and that function both as the charge carrier material as well as the emissive material, the emissive material may be present in relatively low concentrations as a dopant in the charge carrier layer. Whenever a dopant is present, the predominant material in the charge carrier layer may be referred to as a host compound or as a receiving compound. Materials that are present as host and dopant are selected so as to have a high level of energy transfer from the host to the dopant material. In addition, these materials need to be capable of producing acceptable electrical properties for the OLED. Furthermore, such host and dopant materials are preferably capable of being incorporated into the OLED using starting materials that can be readily incorporated into the OLED by using convenient fabrication techniques, in particular, by using vacuum-deposition techniques. The exciton blocking layer used in the devices of the present invention (and previously disclosed in U.S. appl. Ser. No. 09/153,144, now U.S. Pat. No. 6,097,147) substantially blocks the diffusion of excitons, thus substantially keeping the excitons within the emission layer to enhance device efficiency. The material of blocking layer of the present invention is characterized by an energy difference (“band gap”) between its lowest unoccupied molecular orbital (LUMO) and its highest occupied molecular orbital (HOMO). In accordance with the present invention, this band gap substantially prevents the diffusion of excitons through the blocking layer, yet has only a minimal effect on the turn-on voltage of a completed electroluminescent device. The band gap is thus preferably greater than the energy level of excitons produced in an emission layer, such that such excitons are not able to exist in the blocking layer. Specifically, the band gap of the blocking layer is at least as great as the difference in energy between the triplet state and the ground state of the host. It is desirable for OLEDs to be fabricated using materials that provide electroluminescent emission in a relatively narrow band centered near selected spectral regions, which correspond to one of the three primary colors, red, green and blue so that they may be used as a colored layer in an OLED or SOLED. It is also desirable that such compounds be capable of being readily deposited as a thin layer using vacuum deposition techniques so that they may be readily incorporated into an OLED that is prepared entirely from vacuum-deposited organic materials. Co-pending application U.S. Ser. No. 08/774,087, filed Dec. 23, 1996, now U.S. Pat. No. 6,048,630, is directed to OLEDs containing emitting compounds that produce a saturated red emission. SUMMARY OF THE INVENTION The present invention is directed to organic light emitting devices wherein the emissive layer comprises an emissive molecule, optionally with a host material (wherein the emissive molecule is present as a dopant in said host material), which molecule is adapted to luminesce when a voltage is applied across the heterostructure, wherein the emissive molecule is selected from the group of phosphorescent organometallic complexes. The emissive molecule may be further selected from the group of phosphorescent organometallic platinum, iridium or osmium complexes and may be still further selected from the group of phosphorescent cyclometallated platinum, iridium or osmium complexes. A specific example of the emissive molecule is fac tris(2-phenylpyridine)iridium, denoted (Ir(ppy) 3 ) of formula [In this, and later figures herein, we depict the dative bond from nitrogen to metal (here, Ir) as a straight line.] The general arrangement of the layers is hole transporting layer, emissive layer, and electron transporting layer. For a hole conducting emissive layer, one may have an exciton blocking layer between the emissive layer and the electron transporting layer. For an electron conducting emissive layer, one may have an exciton blocking layer between the emissive layer and the hole transporting layer. The emissive layer may be equal to-the-hole transporting layer (in which case the exciton blocking layer is near or at the anode) or to the electron transporting layer (in which case the exciton blocking layer is near or at the cathode). The emissive layer may be formed with a host material in which the emissive molecule resides as a guest or the emissive layer may be formed of the emissive molecule itself. In the former case, the host material may be a hole-transporting material selected from the group of substituted tri-aryl amines. The host material may be an electron-transporting material selected from the group of metal quinoxolates, oxadiazoles and triazoles. An example of a host material is 4,4′-N,N′-dicarbazole-biphenyl (CBP), which has the formula: The emissive layer may also contain a polarization molecule, present as a dopant in said host material and having a dipole moment, that affects the wavelength of light emitted when said emissive dopant molecule luminesces. A layer formed of an electron transporting material is used to transport electrons into the emissive layer comprising the emissive molecule and the (optional) host material. The electron transporting material may be an electron-transporting matrix selected from the group of metal quinoxolates, oxadiazoles and triazoles. An example of an electron transporting material is tris-(8-hydroxyquinoline)aluminum (Alq 3 ). A layer formed of a hole transporting material is used to transport holes into the emissive layer comprising the emissive molecule and the (optional) host material. An example of a hole transporting material is 4,4′-bis[N-(1-naphthyl)-N-phenyl-amino]biphenyl [“α-NPD”]. The use of an exciton blocking layer (“barrier layer”) to confine excitons within the luminescent layer (“luminescent zone”) is greatly preferred. For a hole-transporting host, the blocking layer may be placed between the luminescent layer and the electron transport layer. An example of a material for such a barrier layer is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (also called bathocuproine or BCP), which has the formula: For a situation with a blocking layer between a hole-conducting host and the electron transporting layer (as is the case in Example 2 below), one seeks the following characteristics, which are listed in order of relative importance. 1. The difference in energy between the LUMO and HOMO of the blocking layer is greater than the difference in energy between the triplet and ground state singlet of the host material. 2. Triplets in the host material are not quenched by the blocking layer. 3. The ionization potential (IP) of the blocking layer is greater than the ionization potential of the host. (Meaning that holes are held in the host.) 4. The energy level of the LUMO of the blocking layer and the energy level of the LUMO of the host are sufficiently close in energy such that there is less than 50% change in the overall conductivity of the device. 5. The blocking layer is as thin as possible subject to having a thickness of the layer that is sufficient to effectively block the transport of excitons from the emissive layer into the adjacent layer. That is, to block excitons and holes, the ionization potential of the blocking layer should be greater than that of the HTL, while the electron affinity of the blocking layer should be approximately equal to that of the ETL to allow for facile transport of electrons. [For a situation in which the emissive (“emitting”) molecule is used without a hole transporting host, the above rules for selection of the blocking layer are modified by replacement of the word “host” by “emitting molecule.”] For the complementary situation with a blocking layer between a electron-conducting host and the hole-transporting layer one seeks characteristics (listed in order of importance): 1. The difference in energy between the LUMO and HOMO of the blocking layer is greater than the difference in energy between the triplet and ground state singlet of the host material. 2. Triplets in the host material are not quenched by the blocking layer. 3. The energy of the LUMO of the blocking layer is greater than the energy of the LUMO of the (electron-transporting) host. (Meaning that electrons are held in the host.) 4. The ionization potential of the blocking layer and the ionization potential of the host are such that holes are readily injected from the blocker into the host and there is less than a 50% change in the overall conductivity of the device. 5. The blocking layer is as thin as possible subject to having a thickness of the layer that is sufficient to effectively block the transport of excitons from the emissive layer into the adjacent layer. [For a situation in which the emissive (“emitting”) molecule is used without an electron transporting host, the above rules for selection of the blocking layer are modified by replacement of the word “host” by “emitting molecule.”] The present invention covers articles of manufacture comprising OLEDs comprising a new family of phosphorescent materials, which can be used as dopants in OLEDs, and methods of manufacturing the articles. These phosphorescent materials are cyclometallated platinum, iridium or osmium complexes, which provide electroluminiscent emission at a wavelength between 400 nm and 700 nm. The present invention is further directed to OLEDs that are capable of producing an emission that will appear blue, that will appear green, and that will appear red. More specifically, OLEDs of the present invention comprise, for example, an emissive layer comprised of platinum (II) complexed with Bis[2-(2-phenyl)pyridinato-N,C2], Bis[2-(2′-thienyl)pyridinato-N,C3], and Bis[benzo(h)quinolinato-N,C]. The compound cis-Bis[2-(2′-thienyl)pyridinato-N,C3] Pt(II) gives a strong orange to yellow emission. The invention is further directed to emissive layers wherein the emissive molecule is selected from the group of phosphorescent organometallic complexes, wherein the emissive molecule contains substituents selected from the class of electron donors and electron acceptors. The emissive molecule may be further selected from the group of phosphorescent organometallic platinum, iridium or osmium complexes and may be still further selected from the group of phosphorescent cyclometallated platinum, iridium or osmium complexes, wherein the organic molecule contains substituents selected from the class of electron donors and electron acceptors. The invention is further directed to an organic light emitting device comprising a heterostructure for producing luminescence, wherein the emissive layer comprises a host material, an emissive molecule, present as a dopant in said host material, adapted to luminesce when a voltage is applied across the heterostructure, wherein the emissive molecule is selected from the group consisting of cyclometallated platinum, iridium or osmium complexes and wherein there is a polarization molecule, present as a dopant in the host material, which polarization molecule has a dipole moment and which polarization molecule alters the wavelength of the luminescent light emitted by the emissive dopant molecule. The polarization molecule may be an aromatic molecule substituted by electron donors and electron acceptors. The present invention is directed to OLEDs, and a method of fabricating OLEDs, in which emission from the device is obtained via a phosphorescent decay process wherein the phosphorescent decay rate is rapid enough to meet the requirements of a display device. More specifically, the present invention is directed to OLEDs comprised of a material that is capable of receiving the energy from an exciton singlet or triplet state and emitting that energy as phosphorescent radiation. The OLEDs of the present invention may be used in substantially any type of device which is comprised of an OLED, for example, in OLEDs that are incorporated into a larger display, a vehicle, a computer, a television, a printer, a large area wall, theater or stadium screen, a billboard or a sign. The present invention is also directed to complexes of formula L L′ L″ M, wherein L, L′, and L″ are distinct bidentate ligands and M is a metal of atomic number greater than 40 which forms an octahedral complex with the three bidentate ligands and is preferably a member of the third row (of the transition series of the periodic table) transition metals, most preferably Ir and Pt. Alternatively, M can be a member of the second row transition metals, or of the main group metals, such as Zr and Sb. Some of such organometallic complexes electroluminesce, with emission coming from the lowest energy ligand or MLCT state. Such electroluminescent compounds can be used in the emitter layer of organic light emitting diodes, for example, as dopants in a host layer of an emitter layer in organic light emitting diodes. This invention is further directed to organometallic complexes of formula L L′ L″ M, wherein L, L′, and L″ are the same (represented by L 3 M) or different (represented by L L′ L″ M), wherein L, L′, and L″ are bidentate, monoanionic ligands, wherein M is a metal which forms octahedral complexes, is preferably a member of the third row of transition metals, more preferably Ir or Pt, and wherein the coordinating atoms of the ligands comprise sp 2 hybridized carbon and a heteroatom. The invention is further directed to compounds of formula L 2 MX, wherein L and X are distinct bidentate ligands, wherein X is a monoanionic bidentate ligand, wherein L coordinates to M via atoms of L comprising sp 2 hybridized carbon and heteroatoms, and wherein M is a metal forming an octahedral complex, preferably iridium or platinum. It is generally expected that the ligand L participates more in the emission process than does X. The invention is directed to meridianal isomers of L 3 M wherein the heteroatoms (such as nitrogen) of two ligands L are in a trans configuration. In the embodiment in which M is coordinated with an sp 2 hybridized carbon and a heteroatom of the ligand, it is preferred that the ring comprising the metal M, the sp 2 hybridized carbon and the heteroatom contains 5 or 6 atoms. These compounds can serve as dopants in a host layer which functions as a emitter layer in organic light emitting diodes. Furthermore, the present invention is directed to the use of complexes of transition metal species M with bidentate ligands L and X in compounds of formula L 2 MX in the emitter layer of organic light emitting diodes. A preferred embodiment is compounds of formula L 2 IrX, wherein L and X are distinct bidentate ligands, as dopants in a host layer functioning as an emitter layer in organic light emitting diodes. The present invention is also directed to an improved synthesis of organometallic molecules which function as emitters in light emitting devices. These compounds of this invention can be made according to the reaction: L 2 M(μ-Cl) 2 ML 2 +XH→L 2 MX+HCl wherein L 2 M(μ-Cl) 2 ML 2 is a chloride bridged dimer with L a bidentate ligand, and M a metal such as Ir; XH is a Bronsted acid which reacts with bridging chloride and serves to introduce a bidentate ligand X, where XH can be, for example, acetylacetone, 2-picolinic acid, or N-methylsalicyclanilide, and H represents hydrogen. The method involves combining the L 2 M(μ-Cl) 2 ML 2 chloride bridged dimer with the XH entity. The resultant product of the form L 2 MX has approximate octahedral disposition of the bidentate ligands L, L, and X about M. The resultant compounds of formula L 2 MX can be used as phosphorescent emitters in organic light emitting devices. For example, the compound wherein L=(2-phenylbenzothiazole), X=acetylacetonate, and M=Ir (the compound abbreviated as BTIr) when used as a dopant in 4,4′-N,N′-dicarbazole-biphenyl (CBP) (at a level 12% by mass) to form an emitter layer in an OLED shows a quantum efficiency of 12%. For reference, the formula for CBP is: The synthetic process to make L 2 MX compounds of the present invention may be used advantageously in a situation in which L, by itself, is fluorescent but the resultant L 2 MX is phosphorescent. One specific example of this is where L=coumarin-6. The synthetic process of the present invention facilitates the combination of L and X pairs of certain desirable characteristics. For example, the present invention is further directed to the appropriate selection of L and X to allow color tuning of the complex L 2 MX relative to L 3 M. For example, Ir(ppy) 3 and (ppy) 2 Ir(acac) both give strong green emission with a λ max of 510 nm (ppy denotes phenyl pyridine). However, if the X ligand is formed from picolinic acid instead of from acetylacetone, there is a small blue shift of about 15 nm. Furthermore, the present invention is also directed to a selection of X such that it has a certain HOMO level relative to the L 3 M complex so that carriers (holes or electrons) might be trapped on X (or on L) without a deterioration of emission quality. In this way, carriers (holes or electrons) which might otherwise contribute to deleterious oxidation or reduction of the phosphor would be impeded. The carrier that is remotely trapped could readily recombine with the opposite carrier either intramolecularly or with the carrier from an adjacent molecule. The present invention, and its various embodiments, are discussed in more detail in the examples below. However, the embodiments may operate by different mechanisms. Without limitation and without limiting the scope of the invention, we discuss the different mechanisms by which various embodiments of the invention may operate. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 . Electronic absorbance spectra of Pt(thpy) 2 , Pt(thq) 2 , and Pt(bph)(bpy). FIG. 2 . Emission spectra of Pt(thpy) 2 , Pt(thq) 2 , and Pt(bph)(bpy). FIG. 3 . Energy transfer from polyvinylcarbazole (PVK) to Pt(thpy) 2 in the solid film. FIG. 4 . Characteristics of OLED with Pt(thpy) 2 dopant: (a) I-V characteristic; (b) Light output curve. FIG. 5 . Quantum efficiency dependence on applied voltage for OLED with Pt(thpy) 2 dopant. FIG. 6 . Characteristics of the OLED device with Pt(thpy) 2 dopant: (a) normalized electroluminescence (EL) spectrum of the device at 22 V (b) CIE diagram based on normalized EL spectrum. FIG. 7 . Proposed energy level structure of the electrophosphorescent device of Example 2. The highest occupied molecular orbital (HOMO) energy and the lowest unoccupied molecular orbital (LUMO) energy are shown (see I. G. Hill and A. Kahn, J. Appl. Physics (1999)). Note that the HOMO and LUMO levels for fr(ppy) 3 are not known. The bottom portion of FIG. 7 shows structural chemical formulae for: (a) Ir(ppy) 3 ; (b) CBP; and (c) BCP. FIG. 8 . The external quantum efficiency of OLEDs using Ir(ppy) 3 : CBP luminescent layers. Peak efficiencies are observed for a mass ratio of 6% Ir(ppy) 3 to CBP. The 100% lr(ppy) 3 device has a slightly different structure than shown in FIG. 7 . In it, the Ir(ppy) 3 layer is 300 A thick and there is no BCP blocking layer. The efficiency of a 6% Ir(ppy) 3 : CBP device grown without a BCP layer is also shown. FIG. 9 . The power efficiency and luminance of the 6% Ir(ppy) 3 : CBP device. At 100 cd/m 2 , the device requires 4.3 V and its power efficiency is 19 lm/W. FIG. 10 . The electroluminescent spectrum of 6% Ir(ppy) 3 : CBP. Inset: The Commission Internationale de L'Eclairage (CIE) chromaticity coordinates of Ir(ppy) 3 in CBP are shown relative to fluorescent green emitters Alq 3 and poly(p-phenylenevinylene) (PPV). FIG. 11 . Expected structure of L 2 IrX complexes along with the structure expected for PPIr. Four examples of X ligands used for these complexes are also shown. The structure shown is for an acac derivative. For the other X type ligands, the O—O ligand would be replaced with an N—O ligand. FIG. 12 . Comparison of facial and meridianal isomers of L 3 M. FIG. 13 . Molecular formulae of mer-isomers disclosed herewith: mer-Ir(ppy) 3 and mer-Ir(bq) 3 . PPY (or ppy) denotes phenyl pyridyl and BQ (or bq) denotes 7,8-benzoquinoline. FIG. 14 . Models of mer-Ir(ppy) 3 (left) and (ppy) 2 Ir(acac) (right). FIG. 15 . (a) Electroluminescent device data (quantum efficiency vs. current density) for 12% by mass “BTIr” in CBP. BTIr stands for bis (2-phenylbenzothiazole)iridium acetylacetonate; (b) Emission spectrum from same device FIG. 16 . Representative molecule to trap holes (L 2 IrX complex). FIG. 17 . Emission spectrum of Ir(3-MeOppy) 3 . FIG. 18 . Emission spectrum of tpyIrsd. FIG. 19 . Proton NMR spectrum of tpyIrsd (=typIrsd). FIG. 20 . Emission spectrum of thpyIrsd. FIG. 21 . Proton NMR spectrum of thpyIrsd. FIG. 22 . Emission spectrum of btIrsd. FIG. 23 . Proton NMR spectrum of btIrsd. FIG. 24 . Emission spectrum of BQIr. FIG. 25 . Proton NMR spectrum of BQIr. FIG. 26 . Emission spectrum of BQIrFA. FIG. 27 . Emission spectrum of THIr (=thpy; THPIr). FIG. 28 . Proton NMR spectrum of THPIr. FIG. 29 . Emission spectra of PPIr. FIG. 30 . Proton NMR spectrum of PPIr. FIG. 31 . Emission spectrum of BTHPIr (=BTPIr). FIG. 32 . Emission spectrum of tpyIr. FIG. 33 . Crystal structure of tpyIr showing trans arrangement of nitrogen. FIG. 34 . Emission spectrum of C6. FIG. 35 . Emission spectrum of C6Ir. FIG. 36 . Emission spectrum of PZIrP. FIG. 37 . Emission spectrum of BONIr. FIG. 38 . Proton NMR spectrum of BONIr. FIG. 39 . Emission spectrum of BTIr. FIG. 40 . Proton NMR spectrum of BTIr. FIG. 41 . Emission spectrum of BOIr. FIG. 42 . Proton NMR spectrum of BOIr. FIG. 43 . Emission spectrum of BTIrQ. FIG. 44 . Proton NMR spectrum of BTIrQ. FIG. 45 . Emission spectrum of BTIrP. FIG. 46 . Emission spectrum of BOIrP. FIG. 47 . Emission spectrum of btIr-type complexes with different ligands. FIG. 48 . Proton NMR spectrum of mer-Irbq. FIG. 49 . Other suitable L and X ligands for L 2 MX compounds. In all of these ligands listed, one can easily substitute S for O and still have a good ligand. FIG. 50 . Examples of L L′ L″ M compounds. In the listed examples of L L′ L″ M and L L′ M X compounds, the compounds would be expected to emit from the lowest energy ligand or the MLCT state, involving the bq or thpy ligands. In the listed example of an L M X X′ compound, emission therefrom is expected from the ppy ligand. The X and X′ ligands will modify the physical properties (for example, a hole trapping group could be added to either ligand). DETAILED DESCRIPTION OF THE INVENTION The present invention is generally directed to emissive molecules, which luminesce when a voltage is applied across a heterostructure of an organic light-emitting device and which molecules are selected from the group of phosphorescent organometallic complexes, and to structures, and correlative molecules of the structures, that optimize the emission of the light-emitting device. The term “organometallic” is as generally understood by one of ordinary skill, as given, for example, in “Inorganic Chemistry” (2nd edition) by Gary L. Miessler and Donald A. Tarr, Prentice-Hall (1998). The invention is further directed to emissive molecules within the emissive layer of an organic light-emitting device which molecules are comprised of phosphorescent cyclometallated platinum, iridium or osmium complexes. On electroluminescence, molecules in this class may produce emission which appears red, blue, or green. Discussions of the appearance of color, including descriptions of CIE charts, may be found in H. Zollinger, Color Chemistry, VCH Publishers, 1991 and H. J. A. Dartnall, J. K. Bowmaker, and J. D. Mollon, Proc. Roy. Soc. B (London), 1983, 220, 115–130. The present invention will now be described in detail for specific preferred embodiments of the invention, it being understood that these embodiments are intended only as illustrative examples and the invention is not to be limited thereto. Synthesis of the Cyclometallated Platinum Complexes We have synthesized a number of different Pt cyclometallated complexes. Numerous publications, reviews and books are dedicated to the chemistry of cyclometallated compounds, which also are called intramolecular-coordination compounds. (I. Omae, Organometallic Intramolecular-coordination compounds. N.Y. 1986. G. R. Newkome, W. E. Puckett, V. K. Gupta, G. E. Kiefer, Chem. Rev. 1986,86,451. A. D. Ryabov, Chem. Rev. 1990, 90, 403). Most of the publications depict mechanistical aspects of the subject and primarily on the cyclometallated compounds with one bi- or tri-dentate ligand bonded to metal by C—M single bond and having cycle closed with one or two other X—M bonds where X may be N, S, P, As, O. Not so much literature was devoted to bis- or tris-cyclometallated complexes, which do not possess any other ligands but C,N type bi-dentate ones. Some of the subject of this invention is in these compounds because they are not only expected to have interesting photochemical properties as most cyclometallated complexes do, but also should exhibit increased stability in comparison with their monocyclometallated analogues. Most of the work on bis-cyclopaladated and bis-cycloplatinated compounds was performed by von Zelewsky et al. (For a review see: M. Maestri, V. Balzani, Ch.Deuschel-Cornioley, A. von Zelewsky, Adv. Photochem. 1992 17, 1. L. Chassot, A. Von Zelewsky, Helv. Chim. Acta 1983, 66, 243. L. Chassot, E. Muler, A. von Zelewsky, Inorg. Chem. 1984, 23, 4249. S Bonafede, M. Ciano, F. Boletta, V. Balzani, L. Chassot, A. von Zelewsky, J Phys. Chem. 1986, 90, 3836. L. Chassot, A. von Zelewsky, D. Sandrini, M. Maestri, V. Balzani, J. Am. Chem. Soc. 1986, 108, 6084. Ch. Cornioley-Deuschel, A. von Zelewsky, Inorg. Chem. 1987, 26, 3354. L. Chassot, A. von Zelewsky, Inorg. Chem. 1987, 26, 2814. A. von Zelewsky, A. P. Suckling, H. Stoeckii-Evans, Inorg. Chem. 1993, 32, 4585. A. von Zelewsky, P. Belser, P. Hayoz, R. Dux, X. Hua, A. Suckling, H. Stoeckii-Evans, Coord. Chem. Rev. 1994, 132, 75. P. Jolliet, M. Gianini, A. von Zelewsky, G. Bernardinelli, H. Stoeckii-Evans, Inorg. Chem. 1996, 35, 4883. H. Wiedenhofer, S. Schutzenmeier, A. von Zelewsky, H. Yersin, J. Phys. Chem. 1995, 99, 13385. M. Gianini, A. von Zelewsky, H. Stoeckii-Evans, Inorg. Chem. 1997, 36, 6094.) In one of their early works, (M. Maestri, D. Sandrini, V. Balzani, L. Chassot, P. Jolliet A. von Zelewsky, Chem. Phys. Lett. 1985,122,375) luminescent properties of three bis-cycloplatinated complexes were investigated in detail. The summary of the previously reported results on Pt bis-cyclometallated complexes important for our current research is as follows: i. in general, cyclometallated complexes having a 5-membered ring formed between the metal atom and C,X ligand are more stable. ii. from the point of view of stability of resulting compounds, complexes not containing anionic ligands are preferred; thus, bis-cyclometallated complexes are preferred to mono-cyclometallated ones. iii. a variety of Pt(Pd) cyclometallated complexes were synthesized, homoleptic (containing similar C,X ligands), heteroleptic (containing two different cyclometallating C,X ligands) and complexes with one C,C cyclometallating ligand and one N,N coordinating ligand. iv. most bis-cyclometallated complexes show M + ions upon electron impact ionization in their mass spectra; this can be a base for our assumption on their stability upon vacuum deposition. v. on the other hand, some of the complexes are found not to be stable in certain solvents; they undergo oxidative addition reactions leading to Pt(IV) or Pd(IV) octahedral complexes. vi. optical properties are reported only for some of the complexes; mostly absorption data is presented. Low-energy electron transitions observed in both their absorption and emission spectra are assigned to MLCT transitions. vii. reported luminescent properties are summarized in Table 1. Used abbreviations are explained in Scheme 1. Upon transition from bis-cyclometalated complexes with two C,N ligands to the complexes with one C,C and one N,N ligand batochromic shift in emission was observed. (M. Maestri, D. Sandrini, V. Balzani, A. von Zelewsky, C. Deuschel-Cornioley, P. Jolliet, Helv. Chim. Acta 1988, 71, 1053. TABLE 1 Absorption and emission properties of several cycloplatinated complexes. Reproduced from A.von Zelewsky et. al (Chem. Phys. Lett., 1985, 122, 375 and Helv. Chim. Acta 1988, 17, 1053). Abbreviation explanations are given in Scheme 1. emission spectra absorption 77 K 293 K solvent λmax(ε) λmax(τ) λmax(τ) Pt(Phpy) 2 (1) CH 3 CN 402(12800) 491(4.0) — 291(27700) Pt(Thpy) 2 (2) CH 3 CN 418(10500)  570(12.0) 578(2.2) 303(26100) Pt(Bhq) 2 (3) CH 3 CN 421(9200)  492(6.5) — 367(12500) 307(15000) Pt(bph)(bpy)(4) We synthesized different bis-cycloplatinated complexes in order to investigate their optical properties in different hosts, both polymeric and molecular, and utilize them as dopants in corresponding hosts for organic light-emitting diodes (OLEDs). Usage of the complexes in molecular hosts in OLEDs prepared in the vacuum deposition process requires several conditions to be satisfied. The complexes should be sublimable and stable at the standard deposition conditions (vacuum ˜10 −6 torr). They should show emission properties interesting for OLED applications and be able to accept energy from host materials used, such as Alq 3 or NPD. On the other hand, in order to be useful in OLEDs prepared by wet techniques, the complexes should form true solutions in conventional solvents (e.g., CHCl 3 ) with a wide range of concentrations and exhibit both emission and efficient energy transfer from polymeric hosts (e.g., PVK). All these properties of cycloplatinated complexes were tested. In polymeric hosts we observe efficient luminescence from some of the materials. Syntheses Proceeded as Follows: 2-(2-thienyl)pyridine. Synthesis is shown in Scheme 2, and was performed according to procedure close to the published one (T. Kauffmann, A. Mitschker, A. Woltermann, Chem. Ber. 1983, 116, 992). For purification of the product, instead of recommended distillation, zonal sublimation was used (145–145–125° C., 2–3 hours). Light brownish white solid (yield 69%). Mass-spec: m/z: 237(18%), 161 (100%, M + ), 91 (71%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 6.22–6.28 (d. of d., 1H), 6.70–6.80 (d. of d., 1H), 6.86–7.03 (m,3H), 7.60–7.65 (m,1H). 13 C NMR (250 MHZ, DMSO-d 6 ): 118.6, 122.3, 125.2, 128.3, 128.4, 137.1, 144.6, 149.4, 151.9. 2-(2-thienyl)quinoline. Synthesis is displayed in Scheme 3, and was made according to published procedure (K. E. Chippendale, B. Iddon, H. Suschitzky, J. Chem. Soc. 1949, 90, 1871). Purification was made exactly following the literature as neither sublimation nor column chromatography did not give as good results as recrystallizations from (a) petroleum ether, and (b) EtOH-H 2 O (1:1) mixture. Pale yellow solid, gets more yellow with time (yield 84%). Mass-spec: m/z: 217 (32%), 216 (77%), 215 (83%), 214 (78%), 213 (77%), 212 (79%), 211(100%, M + ), 210 (93%), 209 (46%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 7.18–7.24 (d. of d.,1H), 7.48–7.58 (d. of d. of d.,1H), 7.67–7.78 (m,2H), 7.91–7.97 (m,3H), 8.08–8.11 (d,1H), 2-(2′-bromophenyl)pyridine. Synthesis was performed according to literature (D. H. Hey, C. J. M. Stirling, G. H. Williams, J. Chem. Soc. 1955, 3963; R. A. Abramovich, J. G. Saha, J. Chem. Soc. 1964, 2175). It is outlined in Scheme 4. Literature on the subject was dedicated to the study of aromatic substitution in different systems, including pyridine, and study of isomeric ratios in the requiting product. Thus in order to resolve isomer mixtures of different substituted phenylpyridines, not 2-(2′-bromophenyl)pyridine, the authors utilized 8 ft.×¼ in. column packed with ethylene glycol succinate (10%) on Chromosorb W at 155° C. and some certain helium inlet pressure. For resolving the reaction mixture we obtained, we used column chromatography with hexanes:THF (1:1) and haxanes:THF:PrOH-1 (4:4:1) mixtures as eluents on silica gel because this solvent mixture gave best results in TLC (three well resolved spots). Only the first spot in the column gave mass spec major peak corresponding to n-(2′-bromophenyl)pyridines (m/z: 233, 235), in the remaining spots this peak was minor. Mass spec of the first fraction: m/z: 235 (97%), 233 (100%, M + ), 154 (86%), 127 (74%). 1 H NMR of the first fraction (250 MHZ, DMSO-d6) δ, ppm: 7.27–7.51 (m,4H), 7.59–7.96 (m,2H), 8.57–8.78 (m,2H). Sublimation of the 1 st fraction product after column did not lead to disappearance of the peaks of contaminants in 1 H NMR spectrum, and we do not expect the sublimation to lead to resolving the isomers if present. 2-phenylpyridine. Was synthesized by literature procedure (J. C. W. Evans, C. F. H. Allen, Org. Synth. Cell. 1943, 2, 517) and is displayed in Scheme 5. Pale yellow oil darkening in the air (yield 48%). 1 H NMR (250 MHZ, DMSO-d 6 ) of the product after vacuum distillation: δ,ppm: 6.70–6.76 (m,1H), 6.92–7.10 (m,3H), 7.27–7.30 (m,1H), 7.36–7.39 (q,1H), 7.60–7.68 (m,2H), 8.16–8.23 (m,1H)). 2,2′-diaminobiphenyl. Was prepared by literature method (R. E. Moore, A. Furst, J. Org. Chem. 1958, 23, 1504) (Scheme 6). Pale pink solid (yield 69%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 5.72–5.80 (t. of d.,2H), 5.87–5.93 (d. of d., 2H), 6.03–6.09 (d. of d.,2H), 6.13–6.23 (t. of d.,2H). Mass spec: m/z: 185 (40%), 184 (100%, M + ), 183 (73%), 168 (69%), 167 (87%), 166(62%), 139 (27%). Scheme 6: Synthesis of 2,2′-dibromobiphenyl from 2,2′-dinitrobiphenyl 2,2′-dibromobiphenyl. (Scheme 6) (A. Uehara, J. C. Bailar, Jr., J. Organomet. Chem. 1982, 239,1). 2,2′-dibromo-1,1′-binaphthyl. Was synthesized according to literature (H. Takaya, S. Akutagawa, R. Noyori, Org. Synth. 1989, 67,20) (Scheme 7). trans-Dichloro-bis-(diethyl sulfide) platinum (II). Prepared by a published procedure (G. B. Kauffman, D. O. Cowan, Inorg. Synth. 1953, 6, 211) (Scheme 8). Bright yellow solid (yield 78%). cis-Dichloro-bis-(diethyl sulfide)platinum (II). Prepared by a published procedure (G. B. Kauffman, D. O. Cowan, Inorg. Synth. 1953, 6, 211). (Scheme 8). Yellow solid (63%). cis-Bis[2-(2-thienyl)pyridinato-N,C 5′ platinum (II). Was synthesized according to literature methods (L. Chassot, A. von Zelewsky, Inorg. Chem. 1993, 32, 4585). (Scheme 9). Bright red crystals (yield 39%). Mass spec: m/z: 518 (25%), 517 (20%), 516 (81%), 513 (100%,M + ), 514 (87%), 481 (15%), 354 (23%). cis-Bis[2-(2′-thienyl)quinolinato-N,C 3 ) platinum (II). Was prepared following published procedures (P. Jolliet, M. Gianini, A. von Zelewsky, G. Bernardinelli, H. Stoeckii-Evans, Inorg. Chem. 1996, 35, 4883). (Scheme 10). Dark red solid (yield 21%). Absorption spectra were recorded on AVIV Model 14DS-UV-Vis-IR spectrophotometer and corrected for background due to solvent absorption. Emission spectra were recorded on PTI QuantaMaster Model C-60SE spectrometer with 1527 PMT detector and corrected for detector sensitivity inhomogeneity. Vacuum deposition experiments were performed using standard high vacuum system (Kurt J. Lesker vacuum chamber) with vacuum ˜10 −6 torr. Quartz plates (ChemGlass Inc.) or borosilicate glass-IndiumTin Oxide plates (ITO, Delta Technologies,Lmtd.), if used as substrates for deposition, were pre-cleaned according to the published procedure for the later (A. Shoustikov, Y. You, P. E. Burrows, M. E. Thomspon, S. R. Forrest, Synth.Met. 1997, 91, 217). Thin film spin coating experiments were done with standard spin coater (Specialty Coating Systems, Inc.) with regulatable speed, acceleration speed, and deceleration speed. Most films were spun coat with 4000 RPM speed and maximum acceleration and deceleration for 40 seconds. Optical properties of the Pt cyclometallated complexes: are shown above in Table 1. Optical Properties in Solution: Absorbance spectra of the complexes Pt(thpy) 2 , Pt(thq) 2 and Pt(bph)(bpy) in solution (CHCl 3 or CH 2 Cl 2 ) were normalized and are presented in FIG. 1 . Absorption maximum for Pt(phpy) 2 showed a maximum at ca. 400 nm, but because the complex apparently requires further purification, the spectrum is not presented. Normalized emission spectra are shown in FIG. 2 . Excitation wavelengths for Pt(thpy) 2 , Pt(thq) 2 and Pt(bph)(bpy) are correspondingly 430 nm, 450 nm, and 449 nm (determined by maximum values in their excitation spectra). Pt(thpy) 2 gives strong orange to yellow emission, while Pt(thq) 2 gives two lines at 500 and 620 nm. The emission form these materials is due to efficient phosphorescence. Pt(bph)(bpy) gives blue emission, centered at 470 nm. The emission observed for Pt(bph)(bpy) is most likely due to fluorescence and not phosphorescence. Emission lifetimes and quantum yields in solution: Pt(thPy) 2 : 3.7 μs (CHCl 3 , deoxygenated for 10 min) 0.27 Pt(thq) 2 : 2.6 μs (CHCl 3 , deoxygenated for 10 min) not measured Pt(bph)(bpy): not in μs region (CH 2 O 2 , deoxygenated not measured for 10 min) Optical properties in PS solid matrix: Pt(thpy) 2 : Emission maximum is at 580 nm (lifetime 6.5 μs) upon excitation at 400 nm. Based on the increased lifetime for the sample in polystyrene we estimate a quantum efficiency in polystyrene for Pt(thpy) 2 of 0.47. Pt(thq) 2 : Emission maximum at 608 nm (lifetime 7.44 μs) upon excitation at 450 nm. Optical Properties of the complexes in PVK Film: These measurements were made for Pt(thpy) 2 only. Polyvinylcarbazole (PVK) was excited at 250 nm and energy transfer from PVK to Pt(thpy) 2 was observed ( FIG. 3 ). The best weight PVK:Pt(thpy) 2 ratio for the energy transfer was found to be ca. 100:6.3. EXAMPLES OF LIGHT EMITTING DIODES Example 1 ITO/PVK:PBD.Pt(thpy) 2 (100:40:2)/Ag:Mg/Ag Pt(thpy) 2 does not appear to be stable toward sublimation. In order to test it in an OLED we have fabricated a polymer blended OLED with Pt(thpy) 2 dopant. The optimal doping level was determined by the photoluminescence study described above. The emission from this device comes exclusively from the Pt(thpy) 2 dopant. Typical current-voltage characteristic and light output curve of the device are shown in FIG. 4 . Quantum efficiency dependence on applied voltage is demonstrated in FIG. 5 . Thus, at 22 V quantum efficiency is ca. 0.11%. The high voltage required to drive this device is a result of the polymer blend OLED structure and not the dopant. Similar device properties were observed for a polymer blend device made with a coumarin dopant in place of Pt(thpy) 2 . In addition, electroluminescence spectrum and CIE diagram are shown in FIG. 6 . Example 2 In this example, we describe OLEDs employing the green, electrophosphorescent material fac tris(2-phenylpyridine)iridium (Ir(ppy) 3 ). This compound has the following formulaic representation: The coincidence of a short triplet lifetime and reasonable photoluminescent efficiency allows Ir(ppy) 3 -based OLEDs to achieve peak quantum and power efficiencies of 8.0% (28 cd/A) and ˜30 lm/W respectively. At an applied bias of 4.3V, the luminance reaches 100 cd/m 2 and the quantum and power efficiencies are 7.5% (26 cd/A) and 19 lm/W, respectively. Organic layers were deposited by high vacuum (10 −6 Torr) thermal evaporation onto a cleaned glass substrate precoated with transparent, conductive indium tin oxide. A 400 A thick layer of 4,4′-bis(N-(1-naphthyl)-N-phenyl-amino)biphenyl (α-NPD) is used to transport holes to the luminescent layer consisting of Ir(ppy) 3 in CBP. A 200 A thick layer of the electron transport material tris-(8-hydroxyquinoline)aluminum (Alq 3 ) is used to transport electrons into the Ir(ppy) 3 :CBP layer, and to reduce Ir(ppy) 3 luminescence absorption at the cathode. A shadow mask with 1 mm diameter openings was used to define the cathode consisting of a 1000 A thick layer of 25:1 Mg:Ag, with a 500 A thick Ag cap. As previously (O'Brien, et al., App. Phys. Lett. 1999, 74,.442–444), we found that a thin (60 A) barrier layer of 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (bathocuproine, or BCP) inserted between the CBP and the Alq 3 was necessary to confine excitons within the luminescent zone and hence maintain high efficiencies. In O'Brien et al., Appl. Phys. Lett. 1999, 74, 442–444, it was argued that this layer prevents triplets from diffusing outside of the doped region. It was also suggested that CBP may readily transport holes and that BCP may be required to force exciton formation within the luminescent layer. In either case, the use of BCP clearly serves to trap excitons within the luminescent region. The molecular structural formulae of some of the materials used in the OLEDs, along with a proposed energy level diagram, is shown in FIG. 7 . FIG. 8 shows the external quantum efficiencies of several Ir(ppy) 3 -based OLEDs. The doped structures exhibit a slow decrease in quantum efficiency with increasing current. Similar to the results for the Alq 3 :PtOEP system the doped devices achieve a maximum efficiency (˜8%) for mass ratios of Ir(ppy) 3 :CBP of approximately 6–8%. Thus, the energy transfer pathway in Ir(ppy) 3 :CBP is likely to be similar to that in PtOEP:Alq 3 (Baldo, et al., Nature, 1998, 395, 151; O'Brien, 1999, op. cit.) i.e. via short range Dexter transfer of triplets from the host. At low Ir(ppy) 3 concentrations, the lumophores often lie beyond the Dexter transfer radius of an excited Alq 3 molecule, while at high concentrations, aggregate quenching is increased. Note that dipole-dipole (Förster) transfer is forbidden for triplet transfer, and in the PtOEP:Alq 3 system direct charge trapping was not found to be significant. Example 3 In addition to the doped device, we fabricated a heterostructure where the luminescent region was a homogeneous film of Ir(ppy) 3 . The reduction in efficiency (to ˜0.8% ) of neat Ir(ppy) 3 is reflected in the transient decay, which has a lifetime of only ˜100 ns, and deviates significantly from mono-exponential behavior. A 6% Ir(ppy) 3 :CBP device without a BCP barrier layer is also shown together with a 6% Ir(ppy) 3 :Alq 3 device with a BCP barrier layer. Here, very low quantum efficiencies are observed to increase with current. This behavior suggests a saturation of nonradiative sites as excitons migrate into the Alq 3 , either in the luminescent region or adjacent to the cathode. Example 4 In FIG. 9 we plot luminance and power efficiency as a function of voltage for the device of Example 2. The peak power efficiency is ˜30 lm/W with a quantum efficiency of 8%, (28 cd/A). At 100cd/m 2 , a power efficiency of 19 lm/W with a quantum efficiency of 7.5% (26 cd/A) is obtained at a voltage of 4.3V. The transient response of Ir(ppy) 3 in CBP is a mono-exponential phosphorescent decay of ˜500 ns, compared with a measured lifetime (e.g., King, et al., J. Am. Chem. Soc., 1985, 107, 1431–1432) of 2 μs in degassed toluene at room temperature. These lifetimes are short and indicative of strong spin-orbit coupling, and together with the absence of Ir(ppy) 3 fluorescence in the transient response, we expect that Ir(ppy) 3 possesses strong intersystem crossing from the singlet to the triplet state. Thus all emission originates from the long lived triplet state. Unfortunately, slow triplet relaxation can form a bottleneck in electrophosphorescence and one principal advantage of Ir(ppy) 3 is that it possesses a short triplet lifetime. The phosphorescent bottleneck is thereby substantially loosened. This results in only a gradual decrease in efficiency with increasing current, leading to a maximum luminance of ˜100,000 cd/m 2 . Example 5 In FIG. 10 , the emission spectrum and Commission Internationale de L'Eclairage (CIE) coordinates of Ir(ppy) 3 are shown for the highest efficiency device. The peak wavelength is λ=510 nm and the full width at half maximum is 70 nm. The spectrum and CIE coordinates (x=0.27,y=0.63) are independent of current. Even at very high current densities (˜100 mA/cm 2 ) blue emission from CBP is negligible—an indication of complete energy transfer. Other techniques known to one-of ordinary skill may be used in conjunction with the present invention. For example, the use of LiF cathodes (Hung, et al., Appl. Phys. Lett., 1997, 70, 152–154), shaped substrates (G. Gu, et al., Optics Letters, 1997, 22, 396–398), and novel hole transport materials that result in a reduction in operating voltage or increased quantum efficiency (B. Kippelen, et al., MRS (San Francisco, Spring, 1999) are also applicable to this work. These methods have yielded power efficiencies of ˜20 lm/W in fluorescent small molecule devices (Kippelen, Id.). The quantum efficiency in these devices (Kido and Iizumi, App. Phys. Lett., 1998, 73, 2721) at 100 cd/m 2 is typically ≦4.6% (lower than that of the present invention), and hence green-emitting electrophosphorescent devices with power efficiencies of >40 lm/W can be expected. Purely organic materials (Hoshino and Suzuki, Appl. Phys. Lett., 1996, 69, 224–226) may sometimes possess insufficient spin orbit coupling to show strong phosphorescence at room temperature. While one should not rule out the potential of purely organic phosphors, the preferred compounds may be transition metal complexes with aromatic ligands. The transition metal mixes singlet and triplet states, thereby enhancing intersystem crossing and reducing the lifetime of the triplet excited state. The present invention is not limited to the emissive molecule of the examples. One of ordinary skill may modify the organic component of the Ir(ppy) 3 (directly below) to obtain desirable properties. One may have alkyl substituents or alteration of the atoms of the aromatic structure. These molecules, related to Ir(ppy) 3 , can be formed from commercially available ligands. The R groups can be alkyl or aryl and are preferably in the 3, 4, 7 and/or 8 positions on the ligand (for steric reasons). The compounds should give different color emission and may have different carrier transport rates. Thus, the modifications to the basic Ir(ppy) 3 structure in the three molecules can alter emissive properties in desirable ways. Other possible emitters are illustrated below, by way of example. This molecule is expected to have a blue-shifted emission compared to Ir(ppy) 3 . R and R′ can independently be alkyl or aryl. Organometallic compounds of osmium may also be used in this invention. Examples include the following. These osmium complexes will be octahedral with 6 d electrons (isoelectronic with the Ir analogs) and may have good intersystem crossing efficiency. R and R′ are independently selected from the group consisting of alkyl and aryl. They are believed to be unreported in the literature. Herein, X can be selected from the group consisting of N or P. R and R′ are independently selected from the group alkyl and aryl. The molecule of the hole-transporting layer of Example 2 is depicted below. The present invention will work with other hole-transporting molecules known by one of ordinary skill to work in hole transporting layers of OLEDs. The molecule used as the host in the emissive layer of Example 2 is depicted below. The present invention will work with other molecules known by one of ordinary skill to work as hosts of emissive layers of OLEDs. For example, the host material could be a hole-transporting matrix and could be selected from the group consisting of substituted tri-aryl amines and polyvinylcarbazoles. The molecule used as the exciton blocking layer of Example 2 is depicted below. The invention will work with other molecules used for the exciton blocking layer, provided they meet the requirements listed in the summary of the invention. Molecules which are suitable as components for an exciton blocking layer are not necessarily the same as molecules which are suitable for a hole blocking layer. For example, the ability of a molecule to function as a hole blocker depends on the applied voltage, the higher the applied voltage, the less the hole blocking ability. The ability to block excitons is roughly independent of the applied voltage. This invention is further directed to the synthesis and use of certain organometallic molecules of formula L 2 MX which may be doped into a host phase in an emitter layer of an organic light emitting diode. Optionally, the molecules of formula L 2 MX may be used at elevated concentrations or neat in the emitter layer. This invention is further directed to an organic light emitting device comprising an emitter layer comprising a molecule of the formula L 2 MX wherein L and X are inequivalent, bidentate ligands and M is a metal, preferably selected from the third row of the transition elements of the periodic table, and most preferably Ir or Pt, which forms octahedral complexes, and wherein the emitter layer produces an emission which has a maximum at a certain wavelength λ max . The general chemical formula for these molecules which are doped into the host phase is L 2 MX, wherein M is a transition metal ion which forms octahedral complexes, L is a bidentate ligand, and X is a distinct bidentate ligand. Examples of L are 2-(1-naphthyl)benzoxazole)), (2-phenylbenzoxazole), (2-phenylbenzothiazole), (2-phenylbenzothiazole), (7,8-benzoquinoline), coumarin, (thienylpyridine), phenylpyridine, benzothienylpyridine, 3-methoxy-2-phenylpyridine, thienylpyridine, and tolylpyridine. Examples of X are acetylacetonate (“acac”), hexafluoroacetylacetonate, salicylidene, picolinate, and 8-hydroxyquinolinate. Further examples of L and X are given in FIG. 49 and still further examples of L and X may be found in Comprehensive Coordination Chemistry, Volume 2, G. Wilkinson (editor-in-chief), Pergamon Press, especially in chapter 20.1 (beginning at page 715) by M. Calligaris and L. Randaccio and in chapter 20.4 (beginning at page 793) by R. S. Vagg. Synthesis of Molecules of Formula L 2 MX The compounds of formula L 2 MX can be made according to the reaction: L 2 M(μ-Cl) 2 ML 2 +XH→L 2 MX+HCl wherein L 2 M(μ-Cl) 2 ML 2 is a chloride bridged dimer with L a bidentate ligand, and M a metal such as Ir; XH is a Bronsted acid which reacts with bridging chloride and serves to introduce a bidentate ligand X, wherein XH can be, for example, acetylacetone, hexafluoroacetylacetone, 2-picolinic acid, or N-methylsalicyclanilide; and L 2 MX has approximate octahedral disposition of the bidentate ligands L, L, and X about M. L 2 Ir(μ-Cl) 2 IrL 2 complexes were prepared from IrCl 3 .nH 2 O and the appropriate ligand by literature procedures (S. Sprouse, K. A. King, P. J. Spellane, R. J. Watts, J. Am. Chem. Soc., 1984, 106, 6647–6653; for general reference: G. A. Carlson, et al., Inorg. Chem., 1993, 32, 4483; B. Schmid, et al., Inorg. Chem., 1993, 33, 9; F. Garces, et al.; Inorg. Chem., 1988, 27, 3464; M. G. Colombo, et al., Inorg. Chem., 1993, 32, 3088; A. Mamo, et al., Inorg. Chem., 1997, 36, 5947; S. Serroni, et al.; J. Am. Chem. Soc., 1994, 116, 9086; A. P. Wilde, et al., J. Phys. Chem., 1991, 95, 629; J. H. van Diemen, et al., Inorg. Chem., 1992, 31, 3518; M. G. Colombo, et al., Inorg. Chem., 1994, 33, 545), as described below. Ir(3-MeOppy) 3 . Ir(acac) 3 (0.57 g, 1.17 mmol) and 3-methoxy-2-phenylpyridine (1.3 g, 7.02 mmol) were mixed in 30 ml of glycerol and heated to 200° C. for 24 hrs under N 2 . The resulting mixture was added to 100 ml of 1 M HCl. The precipitate was collected by filtration and purified by column chromatography using CH 2 Cl 2 as the eluent to yield the product as bright yellow solids (0.35 g, 40%). MS (EI): m/z (relative intensity) 745 (M + , 100), 561 (30), 372 (35). Emission spectrum in FIG. 17 . tpyIrsd. The chloride bridge dimer (tpyIrCl) 2 (0.07 g, 0.06 mmol), salicylidene (0.022 g, 0.16 mmol) and Na 2 CO 3 (0.02 g, 0.09 mmol) were mixed in 10 ml of 1,2-dichloroethane and 2 ml of ethanol. The mixture was refluxed under N 2 for 6 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the solvent evaporated. The excess salicylidene was removed by gentle heating under vacuum. The residual solid was redissolved in CH 2 Cl 2 and the insoluble inorganic materials were removed by filtration. The filtrate was concentrated and column chromatographed using CH 2 Cl 2 as the eluent to yield the product as bright yellow solids (0.07 g, 85%). MS (EI): m/z (relative intensity) 663 (M + , 75), 529 (100), 332 (35). The emission spectrum is in FIG. 18 and the proton NMR spectrum is in FIG. 19 . thpyIrsd. The chloride bridge dimer (thpyIrCl) 2 (0.21 g, 0.19 mmol) was treated the same way as (tpyIrCl) 2 . Yield: 0.21 g, 84%. MS (EI): m/z (relative intensity) 647 (M + , 100), 513 (30), 486 (15), 434 (20), 324 (25). The emission spectrum is in FIG. 20 and the proton NMR spectrum is in FIG. 21 . btIrsd. The chloride bridge dimer (btIrCl) 2 (0.05 g, 0.039 mmol) was treated the same way as (tpyIrCl) 2 . Yield: 0.05 g, 86%. MS (EI): m/z (relative intensity) 747 (M + , 100), 613 (100), 476 (30), 374 (25), 286 (32). The emission spectrum is in FIG. 22 and the proton NMR spectrum is in FIG. 23 . Ir(bq) 2 (acac), BQIr. The chloride bridged dimer (Ir(bq) 2 Cl) 2 (0.091 g, 0.078 mmol), acetylacetone (0.021 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: bright yellow solids (yield 91%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.93 (d,2H), 8.47 (d,2H), 7.78 (m,4H), 7.25 (d,2H), 7.15 (d,2H), 6.87 (d,2H), 6.21 (d,2H), 5.70 (s,1H), 1.63 (s,6H). MS, e/z: 648 (M+,80%), 549 (100%). The emission spectrum is in FIG. 24 and the proton NMR spectrum is in FIG. 25 . Ir(bq) 2 (Facac), BQIrFA. The chloride bridged dimer (Ir(bq) 2 Cl) 2 (0.091 g, 0.078 mmol), hexafluoroacetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solids (yield 69%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.99 (d,2H), 8.55 (d,2H), 7.86 (m,4H), 7.30 (d,2H), 7.14 (d,2H), 6.97 (d,2H), 6.13 (d,2H), 5.75 (s,1H). MS, e/z: 684 (M+,59%), 549 (100%). Emission spectrum in FIG. 26 . Ir(thpy) 2 (acac), THPIr. The chloride bridged dimer (Ir(thpy) 2 Cl) 2 (0.082 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow-orange solid (yield 80%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.34 (d,2H), 7.79 (m,2H), 7.58 (d,2H), 7.21 (d,2H), 7.15 (d,2H), 6.07 (d,2H), 5.28 (s,1H), 1.70 (s,6H). MS, e/z: 612 (M+,89%), 513 (100%). The emission spectrum is in FIG. 27 (noted “THIr”) and the proton NMR spectrum is in FIG. 28 . Ir(ppy) 2 (acac), PPIr. The chloride bridged dimer (Ir(ppy) 2 Cl) 2 (0.080 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solid (yield 87%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.54 (d,2H), 8.06 (d,2H), 7.92 (m,2H), 7.81 (d,2H), 7.35 (d,2H), 6.78 (m,2H), 6.69 (m,2H), 6.20 (d,2H), 5.12 (s,1H), 1.62 (s,6H). MS, e/z: 600 (M+,75%), 501 (100%). The emission spectrum is in FIG. 29 and the proton NMR spectrum is in FIG. 30 . Ir(bthpy) 2 (acac), BTPIr. The chloride bridged dimer (Ir(bthpy) 2 Cl) 2 (0.103 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solid (yield 49%). MS, e/z: 712 (M+,66%), 613 (100%). Emission spectrum is in FIG. 31 . [Ir(ptpy) 2 Cl] 2 . A solution of IrCl 3 .xH 2 O (1.506 g, 5.030 mmol) and 2-(p-tolyl)pyridine (3.509 g, 20.74 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 25 hours. The yellow-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried. The product was obtained as a yellow powder (1.850 g, 65%). [Ir(ppz) 2 Cl] 2 . A solution of IrCl 3 .xH 2 O (0.904 g, 3.027 mmol) and 1-phenylpyrazole (1.725 g, 11.96 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 21 hours. The gray-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried. The product was obtained as a light gray powder (1.133 g, 73%). [Ir(C6) 2 Cl] 2 . A solution of IrCl 3 .xH 2 O (0.075 g, 0.251 mmol) and coumarin C6 [3-(2-benzothiazolyl)-7-(diethyl)coumarin] (Aldrich) (0.350 g, 1.00 mmol) in 2-ethoxyethanol (15 mL) was refluxed for 22 hours. The dark red mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol. The product was dissolved in and precipitated with methanol. The solid was filtered and washed with methanol until no green emission was observed in the filtrate. The product was obtained as an orange powder (0.0657 g, 28%). Ir(ptpy) 2 (acac) (tpyIr). A solution of [Ir(ptpy) 2 Cl] 2 (1.705 g, 1.511 mmol), 2,4-pentanedione (3.013 g, 30.08 mmol) and (1.802 g, 17.04 mmol) in 1,2-dichloroethane (60 mL) was refluxed for 40 hours. The yellow-green mixture was cooled to room temperature and the solvent was removed under reduced pressure. The product was taken up in 50 mL of CH 2 Cl 2 and filtered through Celite. The solvent was removed under reduced pressure to yield orange crystals of the product (1.696 g, 89%). The emission spectrum is given in FIG. 32 . The results of an x-ray diffraction study of the structure are given in FIG. 33 . One sees that the nitrogen atoms of the tpy (“tolyl pyridyl”) groups are in a trans configuration. For the x-ray study, the number of reflections was 4663 and the R factor was 5.4%. Ir(C6) 2 (acac) (C6Ir). Two drops of 2,4-pentanedione and an excess of Na 2 CO 3 was added to solution of [Ir(C6) 2 Cl] 2 in CDCl 3 . The tube was heated for 48 hours at 50° C. and then filtered through a short plug of Celite in a Pasteur pipet. The solvent and excess 2,4-pentanedione were removed under reduced pressure to yield the product as an orange solid. Emission of C6 in FIG. 34 and of C6Ir in FIG. 35 . Ir(ppz) 2 picolinate (PZIrp). A solution of [Ir(Ppz) 2 Cl] 2 (0.0545 g, 0.0530 mmol) and picolinic acid (0.0525 g, 0.426 mmol) in CH 2 Cl 2 (15 mL) was refluxed for 16 hours. The light green mixture was cooled to room temperature and the solvent was removed under reduced pressure. The resultant solid was taken up in 10 mL of methanol and a light green solid precipitated from the solution. The supernatant liquid was decanted off and the solid was dissolved in CH 2 Cl 2 and filtered through a short plug of silica. The solvent was removed under reduced pressure to yield light green crystals of the product (0.0075 g, 12%). Emission in FIG. 36 . 2-(1-naphthyl)benzoxazole, (BZO-Naph). (11.06 g, 101 mmol) of 2-aminophenol was mixed with (15.867 g, 92.2 mmol) of 1-naphthoic acid in the presence of polyphosphoric acid. The mixture was heated and stirred at 240° C. under N 2 for 8 hrs. The mixture was allowed to cool to 100° C., this was followed by addition of water. The insoluble residue was collected by filtration, washed with water then reslurried in an excess of 10% Na 2 CO 3 . The alkaline slurry was filtered and the product washed thoroughly with water and dried under vacuum. The product was purified by vacuum distillation. BP 140° C./0.3 mmHg. Yield 4.8 g (21%). Tetrakis(2-(1-naphthyl)benzoxazoleC 2 ,N′)(μ-dichloro)diiridium. ((Ir 2 (BZO-Naph) 4 Cl) 2 ). Iridium trichloride hydrate (0.388 g) was combined with 2-(1-naphthyl)benzoxazole (1.2 g, 4.88 mmol). The mixture was dissolved in 2-ethoxyethanol (30 mL) then refluxed for 24 hrs. The solution was cooled to room temperature, the resulting orange solid product was collected in a centrifuge tube. The dimer was washed with methanol followed by chloroform through four cycles of centrifuge/redispersion cycles. Yield 0.66 g. Bis(2-(1-naphthyl)benzoxazole)acetylacetonate, Ir(BZO-Naph) 2 (acac), (BONIr). The chloride bridged dimer (Ir 2 (BZO-Naph) 4 Cl) 2 (0.66 g, 0.46 mmol), acetylacetone (0.185 g) and sodium carbonate (0.2 g) were mixed in 20 ml of dichloroethane. The mixture was refluxed under N 2 for 60 hrs. The reaction was then cooled and the orange/red precipitate was collected in centrifuge tube. The product was washed with water/methanol (1:1) mixture followed by methanol wash through four cycles of centrifuge/redispersion cycles. The orange/red solid product was purified by sublimation. SP 250° C./2×10 −5 torr, yield 0.57 g (80%). The emission spectrum is in FIG. 37 and the proton NMR spectrum is in FIG. 38 . Bis(2-phenylbenzothiazole)Iridium acetylacetonate (BTIr). 9.8 mmol (0.98 g, 1.0 mL) of 2,4-pentanedione was added to a room-temperature solution of 2.1 mmol 2-phenylbenzothiazole Iridium chloride dimer (2.7 g) in 120 mL of 2-ethoxyethanol. Approximately 1 g of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath for several hours. Reaction mixture was cooled to room temperature, and the orange precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 75% yield. The emission spectrum is in FIG. 39 and the proton NMR spectrum is in FIG. 40 . Bis(2-phenylbenzooxazole)Iridium acac (BOIr). 9.8 mmol (0.98 g, 1.0 mL) of 2,4-pentanedione was added to a room-temperature solution of 2.4 mmol 2-phenylbenzoxazole Iridium chloride dimer (3.0 g) in 120 mL of 2-ethoxyethanol. Approximately 1 g of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath overnight (˜16 hrs.). Reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 60% yield. The emission spectrum is in FIG. 41 and the proton NMR spectrum is in FIG. 42 . Bis(2-phenylbenzothiazole)Iridium (8-hydroxyquinolate) (BTIrQ). 4.7 mmol (0.68 g) of 8-hydroxyquinoline was added to a room-temperature solution of 0.14 mmol 2-phenylbenzothiazole Iridium chloride dimer (0.19 g) in 20 mL of 2-ethoxyethanol. Approximately 700 mg of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath overnight (23 hrs.). Reaction mixture was cooled to room temperature, and the red precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 57% yield. The emission spectrum is in FIG. 43 and the proton NMR spectrum is in FIG. 44 . Bis(2-phenylbenzothiazole)Iridium picolinate (BTIrP). 2.14 mmol (0.26 g) of picolinic acid was added to a room-temperature solution of 0.80 mmol 2-phenylbenzothiazole Iridium chloride dimer (1.0 g) in 60 mL of dichloromethane. The mixture was heated to reflux under nitrogen in an oil bath for 8.5 hours. The reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations yielded about 900 mg of impure product. Emission spectrum is in FIG. 45 . Bis(2-phenylbenzooxazole)Iridium picolinate (BOIrP). 0.52 mmol (0.064 g) of picolinic acid was added to a room-temperature solution of 0.14 mmol 2-phenylbenzoxazole Iridium chloride dimer (0.18 g) in 20 mL of dichloromethane. The mixture was heated to reflux under nitrogen in an oil bath overnight (17.5 hrs.). Reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The precipitate was dissolved in dichloromethane and transferred to a vial, and the solvent was removed. Emission spectrum is in FIG. 46 . Comparative emission spectra for different L′ in btIr complexes are shown in FIG. 47 . These syntheses just discussed have certain advantages over the prior art. Compounds of formula PtL 3 cannot be sublimed without decomposition. Obtaining compounds of formula IrL 3 can be problematic. Some ligands react cleanly with Ir(acac) 3 to give the tris complex, but more than half of the ligands we have studied do not react cleanly in the reaction: 3 L+Ir(acac) 3 →L 3 Ir+(acac)H; typically 30% yield, L=2-phenylpyridine, benzoquinoline, 2-thienylpyridine. A preferred route to Ir complexes can be through the chloride-bridged dimer L 2 M(μ-Cl) 2 ML 2 via the reaction: 4 L+IrCl 3 .nH 2 O→L 2 M(μ-Cl) 2 ML 2 +4 HCl Although fewer than 10% of the ligands we have studied failed to give the Ir dimer cleanly and in high yield, the conversion of the dimer into the tris complex IrL 3 is problematic working for only a few ligands. L 2 M(μ-Cl) 2 ML 2 +2Ag + +2L→L 3 Ir+2AgCl. We have discovered that a far more fruitful approach to preparing phosphorescent complexes is to use chloride bridged dimers to create emitters. The dimer itself does not emit strongly, presumably because of strong self quenching by the adjacent metal (e.g., iridium) atoms. We have found that the chloride ligands can be replaced by a chelating ligand to give a stable, octahedral metal complex through the chemistry: L 2 M(μ-Cl) 2 ML 2 +XH→L 2 MX+HCl We have extensively studied the system wherein M=iridium. The resultant iridium complexes emit strongly, in most cases with lifetimes of 1–3 microseconds (“μsec”). Such a lifetime is indicative of phosphorescence (see Charles Kittel, Introduction to Solid State Physics). The transition in these materials is a metal ligand charge transfer (“MLCT”). In the discussion that follows below, we analyze data of emission spectra and lifetimes of a number of different complexes, all of which can be characterized as L 2 MX (M=Ir), where L is a cyclometallated (bidentate) ligand and X is a bidentate ligand. In nearly every case, the emission in these complexes is based on an MLCT transition between Ir and the L ligand or a mixture of that transition and an intraligand transition. Specific examples are described below. Based on theoretical and spectroscopic studies, the complexes have an octahedral coordination about the metal (for example, for the nitrogen heterocycles of the L ligand, there is a trans disposition in the Ir octahedron). Specifically, in FIG. 11 , we give the structure for L 2 IrX, wherein L=2-phenyl pyridine and X=acac, picolinate (from picolinic acid), salicylanilide, or 8-hydroxyquinolinate. A slight variation of the synthetic route to make L 2 IrX allows formation of meridianal isomers of formula L 3 Ir. The L 3 Ir complexes that have been disclosed previously all have a facial disposition of the chelating ligands. Herewith, we disclose the formation and use of meridianal L 3 Ir complexes as phosphors in OLEDs. The two structures are shown in FIG. 12 . The facial L 3 Ir isomers have been prepared by the reaction of L with Ir(acac) 3 in refluxing glycerol as described in equation 2 (below). A preferred route into L 3 Ir complexes is through the chloride bridged dimer (L 2 Ir(μ-Cl) 2 IrL 2 ), equation 3+4 (below). The product of equation 4 is a facial isomer, identical to the one formed from Ir(acac) 3 . The benefit of the latter prep is a better yield of facial-L 3 Ir. If the third ligand is added to the dimer in the presence of base and acetylacetone (no Ag + ), a good yield of the meridianal isomer is obtained. The meridianal isomer does not convert to the facial one on recrystallization, refluxing in coordinating solvents or on sublimation. Two examples of these meridianal complexes have been formed, mer-Irppy and mer-Irbq ( FIG. 13 ); however, we believe that any ligand that gives a stable facial-L 3 Ir can be made into a meridianal form as well. 3 L+Ir(acac) 3 →facial-L 3 Ir+acacH  (2) typically 30% yield, L=2-phenylpyridine, bezoquinoline, 2-thienylpyridine 4 L+IrCl 3 .nH 2 O→L 2 Ir(μ-Cl) 2 IrL 2 +4 HCl  (3) typically >90% yield, see attached spectra for examples of L, also works well for all ligands that work in equation (2) L 2 Ir(μ-Cl) 2 IrL 2 +2 Ag + +2 L→2 facial-L 3 Ir+2 AgCl  (4) typically 30% yield, only works well for the same ligands that work well for equation (2) L 2 Ir(μ-Cl) 2 IrL 2 +XH+Na 2 CO 3 +L→merdianal-L 3 Ir  (5) typically >80% yield, XH=acetylacetone Surprisingly, the photophysics of the meridianal isomers is different from that of the facial forms. This can be seen in the details of the spectra discussed below, which show a marked red shift and broadening in the meridianal isomer relative to its facial counterpart. The emission lines appear as if a red band has been added to the band characteristic of the facial-L 3 Ir. The structure of the meridianal isomer is similar to those of L 2 IrX complexes, with respect, for example, to the arrangement of the N atoms of the ligands about Ir. Specifically, for L=ppy ligands, the nitrogen of the L ligand is trans in both mer-Ir(ppy) 3 and in (ppy) 2 Ir(acac) further, one of the L ligands for the mer-L 3 Ir complexes has the same coordination as the X ligand of L 2 IrX complexes. In order to illustrate this point a model of mer-Ir(ppy) 3 is shown next to (Ppy) 2 Ir(acac) in FIG. 14 . One of the ppy ligands of mer-Ir(ppy) 3 is coordinated to the Ir center in the same geometry as the acac ligand of (ppy) 2 Ir(acac). The HOMO and LUMO energies of these L 3 Ir molecules are clearly affected by the choice of isomer. These energies are very important is controlling the current-voltage characteristics and lifetimes of OLEDs prepared with these phosphors. The syntheses for the two isomers depicted in FIG. 13 are as follows. Syntheses of Meridianal Isomers mer-Irbq: 91 mg (0.078 mmol) of [Ir(bq) 2 Cl] 2 dimer, 35.8 mg (0.2 mmol) of 7,8-benzoquinoline, 0.02 ml of acetylacetone (ca. 0.2 mmol) and 83 mg (0.78 mmol) of sodium carbonate were boiled in 12 ml of 2-ethoxyethanol (used as received) for 14 hours in inert atmosphere. Upon cooling yellow-orange precipitate forms and is isolated by filtration and flash chromatography (silica gel, CH 2 Cl 2 ) (yield 72%). 1H NMR (360 MHz, dichloromethane-d2), ppm: 8.31 (q,1H), 8.18 (q,1H), 8.12 (q,1H), 8.03(m,2H), 7.82 (m, 3H), 7.59 (m,2H), 7.47 (m,2H), 7.40 (d,1H), 7.17 (m,9), 6.81 (d,1H), 6.57 (d,1H). MS, e/z: 727 (100%, M+). NMR spectrum in FIG. 48 . mer-Ir(tpy) 3 : A solution of IrCl 3 .xH 2 O (0.301 g, 1.01 mmol), 2-(p-tolyl)pyridine (1.027 g, 6.069 mmol), 2,4-pentanedione (0.208 g, 2.08 mmol) and Na 2 CO 3 (0.350 g, 3.30 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 65 hours. The yellow-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried and the solid was dissolved in CH 2 Cl 2 and filtered through a short plug of silica. The solvent was removed under reduced pressure to yield the product as a yellow-orange powder (0.265 g, 38%). This invention is further directed toward the use of the above-noted dopants in a host phase. This host phase may be comprised of molecules comprising a carbazole moiety. Molecules which fall within the scope of the invention are included in the following. [A line segment denotes possible substitution at any available carbon atom or atoms of the indicated ring by alkyl or aryl groups.] An additional preferred molecule with a carbazole functionality is 4,4′-N,N′-dicarbazole-biphenyl (CBP), which has the formula: The light emitting device structure that we chose to use is very similar to the standard vacuum deposited one. As an overview, a hole transporting layer (“HTL”) is first deposited onto the ITO (indium tin oxide) coated glass substrate. For the device yielding 12% quantum efficiency, the HTL consisted of 30 nm (300 Å) of NPD. Onto the NPD a thin film of the organometallic compound doped into a host matrix is deposited to form an emitter layer. In the example, the emitter layer was CBP with 12% by weight bis(2-phenylbenzothiazole)iridium acetylacetonate (termed “BTIr”), and the layer thickness was 30 nm (300 Å). A blocking layer is deposited onto the emitter layer. The blocking layer consisted of bathcuproine (“BCP”), and the thickness was 20 nm (200 Å). An electron transport layer is deposited onto the blocking layer. The electron transport layer consisted of Alq 3 of thickness 20 nm. The device is finished by depositing a Mg—Ag electrode onto the electron transporting layer. This was of thickness 100 nm. All of the depositions were carried out at a vacuum less than 5×10 −5 Torr. The devices were tested in air, without packaging. When we apply a voltage between the cathode and the anode, holes are injected from ITO to NPD and transported by the NPD layer, while electrons are injected from MgAg to Alq and transported through Alq and BCP. Then holes and electrons are injected into EML and carrier recombination occurs in CBP, the excited states were formed, energy transfer to BTIr occurs, and finally BTIr molecules are excited and decay radiatively. As illustrated in FIG. 15 , the quantum efficiency of this device is 12% at a current density of about 0.01 mA/cm 2 . Pertinent terms are as follows: ITO is a transparent conducting phase of indium tin oxide which functions as an anode; ITO is a degenerate semiconductor formed by doping a wide band semiconductor; the carrier concentration of the ITO is in excess of 10 19 /cm 3 ; BCP is an exciton blocking and electron transport layer; Alq 3 is an electron injection layer; other hole transport layer materials could be used, for example, TPD, a hole transport layer, can be used. BCP functions as an electron transport layer and as an exciton blocking layer, which layer has a thickness of about 10 nm (100 Å). BCP is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (also called bathocuproine) which has the formula: The Alq 3 , which functions as an electron injection/electron transport layer has the following formula: In general, the doping level is varied to establish the optimum doping level. As noted above, fluorescent materials have certain advantages as emitters in devices. If the L ligand that is used in making the L 2 MX (for example, M=Ir) complex has a high fluorescent quantum efficiency, it is possible to use the strong spin orbit coupling of the Ir metal to efficiently intersystem cross in and out of the triplet states of the ligands. The concept is that the Ir makes the L ligand an efficient phosphorescent center. Using this approach, it is possible to take any fluorescent dye and make an efficient phosphorescent molecule from it (that is, L fluorescent but L 2 MX (M=Ir) phosphorescent). As an example, we prepared a L 2 IrX wherein L=coumarin and X=acac. We refer to this as coumarin-6 [“C6Ir”]. The complex gives intense orange emission, whereas coumarin by itself emits green. Both coumarin and C6Ir spectra are given in the Figures. Other fluorescent dyes would be expected to show similar spectral shifts. Since the number of fluorescent dyes that have been developed for dye lasers and other applications is quite large, we expect that this approach would lead to a wide range of phosphorescent materials. One needs a fluorescent dye with suitable functionality such that it can be metallated by the metal (for example, iridium) to make a 5- or 6-membered metallocycle. All of the L ligands we have studied to date have sp 2 hybridized carbons and heterocyclic N atoms in the ligands, such that one can form a five membered ring on reacting with Ir. Potential degradation reactions, involving holes or electrons, can occur in the emitter layer. The resultant oxidation or reduction can alter the emitter, and degrade performance. In order to get the maximum efficiency for phosphor doped OLEDs, it is important to control the holes or electrons which lead to undesirable oxidation or reduction reactions. One way to do this is to trap carriers (holes or electrons) at the phosphorescent dopant. It may be beneficial to trap the carrier at a position remote from the atoms or ligands responsible for the phosphorescence. The carrier that is thus remotely trapped could readily recombine with the opposite carrier either intramolecularly or with the carrier from an adjacent molecule. An example of a phosphor designed to trap holes is shown in FIG. 16 . The diarylamine group on the salicylanlide group is expected to have a HOMO level 200–300 mV above that of the Ir complex (based on electrochemical measurements), leading to the holes being trapped exclusively at the amine groups. Holes will be readily trapped at the amine, but the emission from this molecule will come from MLCT and intraligand transitions from the Ir(phenylpyridine) system. An electron trapped on this molecule will most likely be in one of the pyridyl ligands. Intramolecular recombination will lead to the formation of an exciton, largely in the Ir(phenylpyridine) system. Since the trapping site is on the X ligand, which is typically not involved extensively in the luminescent process, the presence of the trapping site will not greatly affect the emission energy for the complex. Related molecules can be designed in which electron carriers are trapped remoted to the L 2 Ir system. As found in the IrL 3 system, the emission color is strongly affected by the L ligand. This is consistent with the emission involving either MLCT or intraligand transitions. In all of the cases that we have been able to make both the tris complex (i.e., IrL 3 ) and the L 2 IrX complex, the emission spectra are very similar. For example Ir(ppy) 3 and (ppy) 2 Ir(acac) (acronym=PPIr) give strong green emission with a λ max of 510 nm. A similar trend is seen in comparing Ir(BQ) 3 and Ir(thpy) 3 to their L 2 Ir(acac) derivatives, i.e., in some cases, no significant shift in emission between the two complexes. However, in other cases, the choice of X ligand affects both the energy of emission and efficiency. Acac and salicylanilide L 2 IrX complexes give very similar spectra. The picolinic acid derivatives that we have prepared thus far show a small blue shift (15 nm) in their emission spectra relative to the acac and salicylanilide complexes of the same ligands. This can be seen in the spectra for BTIr, BTIrsd and BTIrpic. In all three of these complexes we expect that the emission becomes principally form MLCT and Intra-L transitions and the picolinic acid ligands are changing the energies of the metal orbitals and thus affecting the MLCT bands. If an X ligand is used whose triplet levels fall lower in energy than the “L 2 Ir” framework, emission from the X ligand can be observed. This is the case for the BTIRQ complex. In this complex the emission intensity is very weak and centered at 650 nm. This was surprising since the emission for the BT ligand based systems are all near 550 nm. The emission in this case is almost completely from Q based transitions. The phosphorescence spectra for heavy metal quinolates (e.g., IrQ 3 or PtQ 2 ) are centered at 650 nm. The complexes themselves emit with very low efficiency, <0.01. Both the energy and efficiency of the L 2 IrQ material is consistent “X” based emission. If the emission from the X ligand or the “IrX” system were efficient this could have been a good red emitter. It is important to note that while all of the examples listed here are strong “L” emitters, this does not preclude a good phosphor from being formed from “X” based emission. The wrong choice of X ligand can also severely quench the emission from L 2 IrX complexes. Both hexafluoro-acac and diphenyl-acac complexes give either very weak emission of no emission at all when used as the X ligand in L 2 LrX complexes. The reasons why these ligands quench emission so strong are not at all clear, one of these ligands is more electron withdrawing than acac and the other more electron donating. We give the spectrum for BQIrFA in the Figures. The emission spectrum for this complex is slightly shifted from BQIr, as expected for the much stronger electron withdrawing nature of the hexafluoroacac ligand. The emission intensity from BQIrFA is at least 2 orders of magnitude weaker than BQIr. We have not explored the complexes of these ligands due to this severe quenching problem. CBP was used in the device described herein. The invention will work with other hole-transporting molecules known by one of ordinary skill to work in hole transporting layers of OLEDs. Specifically, the invention will work with other molecules comprising a carbazole functionality, or an analogous aryl amine functionality. The OLED of the present invention may be used in-substantially any type of device which is comprised of an OLED, for example, in OLEDs that are incorporated into a larger display, a vehicle, a computer, a television, a printer, a large area wall, theater or stadium screen, a billboard or a sign.
Organic light emitting devices are described wherein the emissive layer comprises a host material containing an emissive molecule, which molecule is adapted to luminesce when a voltage is applied across the heterostructure, and the emissive molecule is selected from the group of phosphorescent organometallic complexes, including cyclometallated platinum, iridium and osmium complexes. The organic light emitting devices optionally contain an exciton blocking layer. Furthermore, improved electroluminescent efficiency in organic light emitting devices is obtained with an emitter layer comprising organometallic complexes of transition metals of formula L 2 MX, wherein L and X are distinct bidentate ligands. Compounds of this formula can be synthesized more facilely than in previous approaches and synthetic options allow insertion of fluorescent molecules into a phosphorescent complex, ligands to fine tune the color of emission, and ligands to trap carriers.
8
CROSS REFERENCE TO RELATED APPLICATION [0001] This application is a divisional of co-pending U.S. application Ser. No. 14/479,535 filed Sep. 8, 2014, which is incorporated by reference herein. BACKGROUND [0002] The present invention relates to hydraulic valves and more particularly to valves typically utilized to control fluid flow in a toilet tank. DESCRIPTION OF THE PRIOR ART [0003] Hydraulic valves have long been employed to control flow of liquid such as in a toilet tank. These valves often rely on buoyant floats for actuation to turn the incoming water off when the water reaches a predetermined level and to turn the water back on when a flush handle has been actuated to exhaust the fluid from the tank into the toilet bowl. An example of these types of valves and arrangements is shown my U.S. Pat. No. 6,712,090. [0004] Many efforts have been made over the years to improve the construction of these valves, often referred to as ball cock valves and even to lock the valves against opening except when toilet has been flushed. [0005] As disclosed in my prior U.S. Pat. No. 6,712,090, existing ball cock valves, in some instances, incorporate a valve body which sits on an upright supply pipe to control flow from the outlet at the top of the pipe via a flexible diaphragm which may be raised and lowered to open and close such outlet. It has been common practice for such diaphragms to incorporate a central vertical pilot passage which receives a vertically elongated pilot pin or stem having longitudinally spaced apart, diametrically enlarged cross sections spaced for selective registration with respective reduced-in diameter ports spaced along the length of the pilot passage for selectively blocking flow through the annulus formed between such enlarged cross sections and ports. When the enlarged sections are out of registration with the respective ports, water may flow upwardly through the pilot passage to pressurize the topside of the diaphragm to force it down into engagement with a seat formed at the pipe outlet to thereby block flow. A lever arm is pivotally mounted at one end to engage the pilot pin medially for raising and lowering of the pilot pin in response to raising and lowering of a donut shaped float mounted concentrically about the feed pipe to selectively control flow through the pilot passage. [0006] While a significant improvement over the art at the time, this prior construction can sometimes suffer the shortcoming that stopping of flow through the pilot passage is dependent on registration of the enlarged sections with the respective ports and, over time, one or the other may be damaged or worn to the point where positive registration for control of flow is no longer effective. Further, the annuli between the pilot pin and ports in the passage provides for direct flow from the inlet pipe into the pilot passage and, with the relatively low volume of flow which can carry sediment, scum or residue, the annuli may become plugged or clogged. [0007] Another example of a pilot valve construction for a ball cock assembly is a pilot pin carried from one end of a lever arm mounted pivotally to a pivot pin and projecting through an aperture in a seal element to be formed on its lower extremity with an enlarged bulbous portion apparently intended to be, when the valve is closed, engaged with the lower surface of the seal element to block flow there-through. A device of this type, while in theory providing for some degree of control for the seal to close off the water inlet, fails to provide for positive exhausting of fluid above the seal element in a manner which will result in positively releasing pressure above the seal element for raising thereof and, further, fails to provide for diverting the water during inlet flow in a positive manner to direct any sediment in such water away from the central underside of the seal element in a manner which will serve to minimize the tendency for such sediment to be directed into the pilot passage. [0008] One commercially available ball cock valve is marketed under the mark FLUIDMASTER® and is well known in the field. Systems employing valves of this type, while popular in the marketplace, often incorporate a great number of parts, in some instances over 40, thus making them expensive to manufacture and requiring some degree of skill to assemble and install. SUMMARY OF THE INVENTION [0009] The present invention includes an upright inlet pipe terminating at its upper extremity in a housing defining a chamber sitting over an inlet port for introduction of water. A flexible valve diaphragm is received in a chamber above an inlet port and includes a central, through, pilot passage which receives a pilot pin disposed longitudinally therein and including enlarged portions to be aligned with respective ports spaced along the passage. The enlarged portions are formed with a peripheral fluted areas for escape of pilot control fluid. The pilot pin projects below the lower surface of the diaphragm and is formed with an enlarged poppet which, upon raising of the pin within the passage, serves to abut a valve seat formed on the underside of such diaphragm to close flow in the passage to thereby decrease the pressure on the top side of the diaphragm causing the water pressure on the underside to raise the diaphragm for flow of water from the inlet port outwardly into the toilet tank. BRIEF DESCRIPTION OF THE DRAWINGS [0010] FIG. 1 is a front view, partially broken away, of a toilet storage tank which incorporates the improved flow control valve of the present invention; [0011] FIG. 1 A is a partial perspective view, in enlarged scale, of the upper portion of a control tube included in the catch device shown in FIG. 1 and depicting the control valve being installed; [0012] FIG. 1 B is a perspective view similar to 1 A but showing the control valve fully installed; [0013] FIG. 2 is an exploded, vertical, sectional view, in enlarged scale, of an inlet pipe device and the control valve shown in FIG. 1 ; [0014] FIG. 3 is a vertical, sectional view similar to FIG. 2 but in enlarged scale and the components assembled; [0015] FIG. 4 is a vertical, sectional view, in enlarged scale, of the upper portion of the flow control valve shown in FIG. 3 ; [0016] FIG. 5 is a vertical, sectional view, in enlarged scale, of the lower portion of the inlet pipe device shown in FIGS. 2 & 3 ; [0017] FIG. 6 is a partial vertical sectional view, in enlarged scale and partially broken away, of the flow control valve shown in FIG. 4 and depicting the valve in its closed position; [0018] FIG. 7 is a vertical, sectional view similar to FIG. 6 but showing the flow control valve in its open position; [0019] FIG. 8 is a vertical, sectional view, in enlarged scale, of the catch device shown in FIG. 3 and depicting a catch device blocking downward travel of a float tube device controlling the control valve shown in FIG. 7 ; [0020] FIG. 9 is a vertical, sectional view, similar to FIG. 8 but showing the catch device released; [0021] FIG. 10 is a transverse, sectional view, in enlarged scale, of a locking flange incorporated in the catch mechanism shown in FIG. 9 ; and [0022] FIG. 11 is vertical, sectional view, partially broken away, of a second embodiment of the flow control device shown in FIG. 2 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0023] Referring to FIG. 4 , the control valve 13 of the present invention has utility for mounting on top of an upright inlet pipe device 15 which includes an outlet 17 surrounded by an upwardly facing valve seat 19 ( FIGS. 6 and 7 ) against which a diaphragm 20 will seat when a pilot valve 23 is opened. The diaphragm 20 is formed with a central structure defining an axial pilot stem passage 26 ( FIG. 7 ) formed with a pair of reduced-in-diameter, vertically spaced apart ports 27 and 29 with which respective enlarged portions 33 and 35 of a valve stem 37 are selectively registered. The passage terminates at its bottom end in an inlet port surrounded by a downwardly facing pilot valve seat 28 . The valve stem 37 projects downwardly below the port pilot seat 28 ( FIG. 7 ) and is formed with an enlarged poppet 41 configured in its lower portion with downwardly facing upwardly and radially outwardly angled deflecting surfaces 60 , ( FIG. 7 ) to deflect upwardly flowing, incoming water to flow radially outwardly as it passes the poppet. The stem 37 is controlled by a control lever 42 having a projecting extremity 43 controlled by a concentrically disposed cylindrical control tube 51 encircled and carried, by a donut shaped float 47 . [0024] Thus, when the float 47 is lowered, the projecting extremity 43 of the lever arm 42 will be lowered thereby raising the pilot stem 37 to raise the poppet 41 to seat against the seat 28 on the underside of the diaphragm 20 ( FIG. 7 ) to block flow of water upwardly through the passage 26 to thereby allow for pressurization of the underside of the diaphragm as shown in FIG. 7 to raise the diaphragm off its seat 19 thereby allowing flow of water up through the passage 87 defined by the upper extremity if the pipe device to flow outwardly into the toilet tank and bowl as will be described below. [0025] As will be appreciated by those of skill, lowering of the float may be selectively restricted to prevent the pilot valve 23 from opening the control valve 13 . Referring to FIG. 1 , control of the pilot valve 23 to control flow from the inlet pipe device 15 may be via the concentric control tube 51 . The inlet pipe device is typically disposed spaced laterally from a flapper flush valve 53 . [0026] Referring to FIG. 8 , a catch device, generally designated 55 , is disposed on the side of the fill pipe facing the flush valve and, in the preferred embodiment, is formed by a generally hairpin shaped somewhat stiff but resilient spring wire 57 mounted medially from a mount device 58 which may include a radially projecting hinge arm 59 constructed of elastomeric material such as flexible rubber to provide for rocking or slight rotation of such catch device about the arm. Carried at the upper extremity of the catch device is a keeper 61 to be selectively disposed in the downward path of the control tube 51 to block the downward path thereof ( FIG. 8 ). The lower extremity of the catch device 55 is connected with the flush control lever 75 by means of a link 65 such that, when the flush control lever is actuated, the catch device is rotated a few degrees counterclockwise on the hinge arm 59 , as viewed in FIGS. 1 and 9 , to move the keeper 61 to the left out from under the bottom edge of the control tube 51 thereby freeing the tube to lower as the water in the tank is lowered to thereby rotate the lever arm 42 counterclockwise as viewed in FIG. 7 to open the flow control valve 13 . Concurrently, the lever arm will lift the free side of the flapper valve 53 to flush the water from the tank into the bowl. [0027] On the other hand, should the water level in the tank 71 be lowered, by a leak, from the level shown in FIG. 1 without actuation of the flush lever, the keeper 61 will remain positioned in the path of the control tube 51 ( FIG. 8 ) to prevent lowering thereof to retain the pilot valve 23 open and the flow control valve closed ( FIG. 6 ). [0028] Referring to FIGS. 1 A and 1 B, the control tube 51 may be constructed of plastic and the upper extremity thereof formed at one diametrical side with a pair of annularly spaced apart, longitudinal slits 126 defining there-between a narrow, upwardly projecting resilient tongue 128 formed at its free extremity with the bore 129 . In this manner, when the control valve is installed, the distal extremity 43 of lever arm 42 will ride downwardly on the inner surface of the free extremity of the tongue 128 to drive the free end radially outwardly, as it is viewed in FIG. 1 A, until the bore 129 is registered with the lever arm for projection into such bore as shown in FIG. 1 B allowing the tongue to snap back into its neutral position. [0029] Toilet tanks 71 typically incorporate an upstanding inlet pipe and an upstanding overflow pipe 72 ( FIG. 1 ). The overflow pipe is formed on its top end 73 for when the water reaches a certain level, allow escape of the water thereby preventing overflow of the water from the tank. Overflow pipes of the type of the pipe 72 typically incorporate a network of water channels leading to the toilet bowl for replenishing bowl water after a flush. [0030] With continued reference to FIG. 1 , such toilet tanks also typically incorporate an actuation knob or lever which might actuate a flush lever 75 to rotate a free end 77 between a lowered fill position and a raised flush position. [0031] Referring to FIGS. 6 and 7 , the inlet pipe device 15 includes a lower pipe 131 typically connected through the bottom wall of the tank 71 and an upper pipe 141 telescoped downwardly therein. The pipe 141 is formed on its upper extremity 87 with a radially enlarged flange 81 constructed with an upwardly facing annular surface defining the control valve seat 19 . [0032] The control valve device 13 includes a tubular housing, generally designated 91 , formed on its periphery with longitudinal guide ribs spaced equidistant annularly around the housing to provide a generally annular siphon break space between the housing and the control tube 51 . The lower portion of the housing is configured in part, by an interior annular flange and an exterior connector flange 21 ( FIG. 6 ). The housing is further formed with an annular top wall 93 ( FIG. 6 ). The top wall is formed centrally with a downwardly projecting cylindrical shell defining a central, stepped, vertical bore 95 which, in the upward direction, progressively reduces in diameter to terminate at its upper extremity in an upwardly opening O-ring gland for receipt of an O-ring 97 ( FIG. 7 ). [0033] The diaphragm is then formed centrally with a upstanding, stepped tower 109 received complimentary in the stepped bore 95 and configured centrally with the pilot passage 26 . The tower is further configured at the upper extremity with an annular flange 111 receiving a reduced-in-diameter neck 113 of the stem. [0034] The tower 109 is formed with a plurality of radially, outwardly opening bleed passages 115 for selectively bleeding fluid from the pilot passage 26 when the pilot valve is open. [0035] In the preferred embodiment, the lever arm 42 is pivotally mounted on a pivot pin 121 carried from a yoke 123 standing up from the top side of the housing 93 . Referring to FIG. 6 , the right hand end of the lever arm includes a ball socket couple with a ball 125 formed at the upper extremity of the stem 37 . [0036] Referring to FIGS. 4 , 6 and 7 , a pair of posts 132 and 133 stand up from the top of the housing 93 and project through spaced apart bores 136 in a top wall 140 of a cap 143 having an annular, downwardly projecting skirt 147 sitting on an annular flange 159 formed about the periphery of the valve housing. [0037] As noted above, in one preferred embodiment, a donut shaped buoyant float 47 is telescoped over the control tube. The float is configured with an annular air chamber 154 and is formed on its interior diameter with one or more friction devices such a rib 161 ( FIG. 3 ) to form an interference fit with the exterior wall of the control tube 51 to releasably hold the float in position along the vertical length of such tube. [0038] Referring to FIGS. 1 , 3 and 4 the valve housing is conveniently formed with a downwardly depending nipple 88 which is connected on its lower extremity with a fill tube 90 leading to the top end of the overflow pipe 72 for filling the bowl. [0039] The diaphragm 20 is typically constructed of elastomeric material and includes a central body having a downwardly facing sealing surface 101 ( FIG. 7 ) to seat against the seat 19 . The diaphragm is concentrically formed about its periphery with an annular, flexible web 102 carrying the body from an anchor ring 104 trapped in an annular channel 106 formed between the top and bottom walls of the housing. The body incorporates a upwardly projecting, concentric rim 103 received in an annular clearance groove 105 formed in the underside of the top wall 93 . [0040] It will be appreciated by those skilled in the art that the poppet 41 is enlarged in diameter and is preferably formed on its bottom side with upwardly and outwardly angled deflecting surfaces 60 . This serves to, when the valve is open or closing, deflect upwardly flowing water radially outwardly to then flow back radially inwardly under the seat 28 and upwardly into the annulus formed in the passage 26 . [0041] Turning now back to FIGS. 5 and 8 , the fill pipe device 15 includes upper and lower pipes 141 and 131 respectively. The lower fill pipe 131 is configured in its upper extremity with a pair of interior annular ribs 137 formed to receive in overlapping radial relationship corresponding pairs of annular ribs 139 spaced along the exterior of the upper pipe 141 . The upper pipe is telescoped the desired distance downwardly into the lower pipe for selective registration of the ribs 137 in respective grooves formed between the ribs 139 on the upper tube 141 . [0042] Referring to FIGS. 8 and 10 , the upper extremity of the lower pipe 131 is configured with four longitudinal, upwardly opening slots 142 spaced equidistant about the periphery to form four resilient, upstanding, cantilevered fingers 144 disposed in respective quadrants. As will be appreciated, each finger is formed at its upper extremity with a respective segment of the radially, inwardly projecting ribs 137 . Consequently, I provide a snap in feature facilitated by outwardly flared flange segments defining respective lips 138 at the upper extremities of the fingers having, when the fingers are in their relaxed position, a combined maximum outside diameter larger than the inside diameter at the top of the fitting flange 149 . [0043] Formed in the lower extremity of the upper pipe 141 are a pair of O-ring grooves for receipt of O-rings 145 for sealing against the interior of the lower pipe 131 . [0044] With continued reference to FIG. 8 , a spool shaped lock fitting, generally designated 149 , is received in telescopical relationship over the upper extremity of the lower pipe 131 and is formed with upper and lower radial flanges 151 and 155 . [0045] As mentioned, in one preferred embodiment, the fitting 149 is formed with an upwardly narrowing tapered interior diameter sized to, be dropped down over the upper extremity of the lower pipe 131 during assembly to leave a concentric annulus between the pipe 131 and such inside diameter as shown in FIG. 8 for free rotation of the fitting on such pipe. In any event, as the fitting is brought into position the upper end will compress the upper ends of the fingers 144 in each quadrant radially inwardly to the point where the rib segments 137 will be diminished in their respective combined diameters to allow for relative longitudinal shifting to align with a selected groove formed between the ribs 139 to, upon release, register in the groove to lock the fill pipe device at the desired height. The fitting will thus be dropped down to the level where the lip segments will be disposed above the top of the fitting 149 to thus block the fitting from shifting upwardly, as for instance, under the force of the link 65 being drawn upwardly to the right during flush ( FIG. 5 ). [0046] The flanges 151 and 155 ( FIGS. 8 and 10 ) are configured with a plurality of through, vertical bores 156 , respectively, spaced equidistant thereabout for receipt of the tube 90 . The flanges are further formed on their respective one sides with diametrical, outwardly opening clearance slots 157 for receipt of the catch device 55 and to act as a radial guide. The closed end of the slot in the upper flange acts as a stop 158 to limit counter clockwise rotation of the catch device. [0047] With continued reference to FIG. 8 , conveniently, the fitting 149 is further formed below the flange 155 with a downwardly projecting annular skirt 167 . The mount device 58 is conveniently formed with an elastomeric ring 168 to be telescoped over the skirt 167 and is formed in its lower extremity with the radially, outwardly projecting, flexible hinge arm 59 . The hinge arm 59 is formed with a through vertical bore 174 for frictional receipt of one leg 173 of the catch device 55 . The other leg 175 of the catch device 55 is constructed of spring wire to project parallel to the leg 173 and cooperate in mounting the slider 187 . The leg 175 is formed at its lower extremity with a orthogonal tab 177 which, in the preferred embodiment, is turned radially inwardly toward the first leg 173 to terminate in an end spaced therefrom. In some embodiments, the tab 177 is turned radially outwardly so that the catch device can be mounted via that tab. As will be apparent to those skilled in the art, some embodiments do not include such a tab 177 . A U-shaped slider 187 , formed with bores and maintaining a keeper 61 , may be telescoped over the parallel legs 173 and 175 . [0048] In the preferred embodiment, the leg 173 projects below the hinge arm 59 to define a lever arm formed with an eye 181 connected with the link 65 . As will be appreciated by those skilled in the art, the link 65 may take many different forms such as a chain, rigid link, coil spring or even an elastomeric strip. [0049] The slider 187 is configured with a pair of horizontally spaced apart vertical bores into which spring wire legs 173 and 175 are friction fit for slidable adjustment of the slider 187 to the desired elevation on the catch device. As will be appreciated, such bores may merely be in the form of a single transverse, through slot, vertically receiving such legs at the opposite sides thereof. [0050] In operation, it will be appreciated that the subject device can easily be installed in a conventional toilet tank 71 and the vertical adjustment made for the vertical profile of the tank and desired water level. Hence, when the water valve under the tank is opened, the water will flow upwardly through the inlet pipe device 15 through the upper tube 87 to pressurize under the diaphragm as shown in FIG. 7 thereby raising the diaphragm off its seat 19 allowing water to flow upwardly and radially outwardly under the diaphragm as indicated by the directional arrows 201 ( FIG. 7 ) to flow downwardly through the passages 166 into the tank 71 thereby commencing filling of such tank water will also flow downwardly through the nipple 88 through the tube 90 to the overflow pipe 72 to fill the toilet bowl. As the water level in the tank rises, the float 47 will be raised causing it to raise the control tube 51 thereby raising the free end 43 of the control lever arm 42 as shown in FIG. 6 to rotate such lever arm clockwise about its pivot pin 121 to drive the stem 37 downwardly. This will then lower the poppet 41 downwardly from its seat 28 to enable flow about such poppet and upwardly through the fluted grooves in the enlarged sections 33 and 35 and upwardly in the tower to flow radially inwardly through the bleed ports 115 to flow downwardly in the tower and radially outwardly above the top of the diaphragm 20 as indicated by the directional arrows 203 ( FIG. 6 ) to pressurize the top side of such diaphragm driving it downwardly to seat on the seat 19 and block further escape of incoming water from the upper tube 87 thereby serving to maintain the water in the tank 71 at the desired level. [0051] Concurrently, as the control tube 51 is raised by elevation of the float 47 the bottom edge thereof will clear the elevation of the keeper 61 allowing the bias of the hinge arm 59 to rotate the catch device 55 clockwise about such hinge arm, as viewed in FIGS. 8 and 9 , to drive the keeper 61 radially outwardly under the wall of the tube 51 to block the downward path of such tube until such time as the toilet is flushed again. [0052] As will be appreciated by those skilled in the art, water in the tank 71 will thus remain at the desired level prepared for the next flush. In the event, however, that water should accidentally leak from the tank, as by a loose or failing connection or crack in the tank, it will be appreciated that as the water level lowers in the tank without actuation of the flush control lever (not shown), the catch 55 will remain in the catch position shown in FIG. 8 , thus blocking the control tube 51 from lowering below the position shown. This then serves to prevent such control tube from lowering the free extremity 43 of the lever arm 42 ( FIG. 6 ) thus leaving the valve poppet off its seat and the top side of the diaphragm 20 pressurized to maintain the diaphragm on its seat 19 to block inflow of water from the upper inlet tube 87 . [0053] Consequently, the total loss of water will be only that which is stored in the tank 71 and inflow of additional water from the upper inlet tube 87 will be blocked until such time as the homeowner or attendant note that the tank 71 has been evacuated without refill. This then alerts the homeowner of the leak thus allowing for repair work before the tank 71 is again filled with water. [0054] With continued reference to FIG. 7 , when the poppet is closed it will thus be appreciated that water flowing upwardly from the upper inlet tube 87 it will strike the facing conical surface of the poppet 41 to be diverted radially, outwardly, and downwardly as indicated by directional arrows 201 to the outlets 166 to be defined by annular deflectors 85 . [0055] Referring to FIG. 6 , when the poppet is open the incoming water will be directed to flow outwardly around the conical surface of the poppet to flow upwardly in the passage 26 , through the annuli formed with the respective ports 27 and 29 , via the grooves in the flutes of the enlarged sections 33 and 35 ( FIG. 6 ). Flow will continue on upwardly in the tower to flow outwardly in the bleed ports 115 ( FIG. 7 ) to maintain a positive pressure differential acting down on the top of the diaphragm 20 . The control valve will thus remain closed until such time as the float and control tube are lowered as by a toilet flush. [0056] It will be appreciated that as the float carries the control tube 51 up, the lower edge of such tube will be raised above the level of the keeper 61 to free the catch to be rotated clockwise under the influence of the elastomeric hinge arm 59 to the position shown in FIG. 8 disposed under the bottom edge of such tube. [0057] Then, when the flush handle is operated to flush the toilet, the outlet valve 53 ( FIG. 1 ) will be opened and the link 65 drawn to the right as viewed in FIG. 9 to rotate the catch device 55 counter clockwise about the point defined by the hinge arm 59 to drive the upper end of such catch device 55 to the left to strike the stop 158 as the keeper 61 is likewise shifted to the left from under the edge of the tube 51 freeing such tube to lower. This then serves to lower the free end 43 of the lever 42 ( FIG. 7 ) to raise the poppet 41 to discontinue bleed of fluid up the passage 26 and pressurize the underside of the diaphragm to raise such diaphragm off its seat. This then allows for pressurized water to flow out of the upper inlet tube 87 to flow radially outwardly and down through the ports 166 as depicted by the directional arrows ( FIG. 7 ) to again fill the tank. [0058] As will be appreciated by those of skill, for different types of water tanks 71 , such as the ever-popular low profile tanks, the vertical adjustment of the inlet pipe device 15 will be made to establish the desired level of water in the tank. Thus, for a low profile tank, the upper inlet pipe 141 may easily be telescoped downwardly into the lower pipe 131 as the ribs 139 flexibly pass the ribs 137 until the desired height of the inlet device is established thereby positioning the float 47 at the desired level for causing the control tube 51 to actuate the control lever 42 at the desired water level. [0059] In that regard, the reader will understand that when the inlet pipe device is telescoped down, it is possible to slide the slider 187 down a corresponding amount on the catch device 55 to thus coordinate actuation of and blocking in accordance with the desired height of the water in the tank 71 . [0060] The embodiment of the present invention shown in FIG. 11 is similar to that shown in FIG. 7 except that the pilot stem 37 is configured at its lower extremity with an enlarged poppet in the form of a spherical poppet 191 configured to seat upwardly on the downwardly facing pilot seat 28 . [0061] From the foregoing it will be appreciated that the valve control device of the present invention is made up of a minimal number of parts making it economical to manufacture and assemble to provide an economical and convenient and effective means for controlling flow of water from an inlet pipe and will provide for a long trouble free life with minimal or no clogging due to residue, scum or the like as might be carried by the water. [0062] Although the present invention has been described in detail with regard to the preferred embodiments and drawings thereof, it should be apparent to those of ordinary skill in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. Accordingly, it is to be understood that the detailed description and the accompanying drawings as set forth hereinabove are not intended to limit the breadth of the present invention.
In one aspect, the device includes a control apparatus including a pilot valve projecting through a passage in a control diaphragm to be formed with an enlarged poppet to seat the underside of the diaphragm and formed with a poppet head shaped to direct incoming flow away from the pilot passage to minimize entry of residue. In another aspect, the present invention includes an elongated catch device pivotally mounted intermediately to an inlet pipe device and carrying at its upper extremity a keeper selectively disposed in the path of a float device to, unless a toilet has been flushed, block lowering of the float device and consequent opening of the control valve.
4
BACKGROUND [0001] 1. Field of the Invention [0002] the present invention relates to automated speech technologies and, more particularly, to automatically providing an indication to a speaker when that speaker's rate of speech is likely to be greater than a rate that a listener is able to comprehend [0003] 2. Description of the Related Art [0004] Understanding a person speaking their native language can be difficult when that language is not a primary language of a listener since the native speaker often speaks too rapidly for the listener to digest the spoken words. For example, a person from Japan, who is moderately proficient in English, can have trouble understanding a native English speaking person, who is speaking at a pace that would be typically used when talking to another native English speaker. [0005] One simple solution to improve understanding is for a speaker to slow down their speaking rate when speaking to a non-native speaker. Unfortunately, a speaker often fails to recognize the listener's difficulty in understanding a conversation and fails to decrease their speaking rate. The non-native listener is often embarrassed or reticent to ask the speaker to slow down. This can be especially true if the listener has already asked the speaker to slow down once or twice during a conversation, which the speaker has done only to inadvertently increase his or her speaking rate as the conversation endures or as the emotional pitch of the conversation escalates. [0006] Acoustic an semantic clarity of a speaker is also a factor for determining a speaking rate, which a listener can comprehend. For example, when a speaker uses colloquialisms, which can be very difficult for a non-native speaker to process, a speaking rate should be even slower than normal. In another example, strong accents and/or dialects can increase listener difficulty, even when a listener is a native speaker of the language being spoken. This increased listener difficulty can be compensated for by a corresponding speaking rate decrease. Additionally, when a speaker mumbles or has speech idiosyncrasies, he or she can be harder than normal to understand, unless the speaking ate of the speaker is decreased to a slower than normal rate. In still another example, a clarity problem can occur for communications over a voice network connection due to the quality of the voice network being low or inconsistent. As a result, the speech received by a listener can be difficult to comprehend. Network clarity problems can be compensated for by having a speaker decrease their rate of speech. No known device or solution exists that detects situations in which a speaking rate is too rapid for a listener and that automatically informs a speaker to reduce his or her speaking rate accordingly. SUMMARY OF THE INVENTION [0007] The present invention discloses a solution that automatically informs a speaker to decrease his or her speaking rate, when that rate likely exceeds a rate that a listener can understand. This can be accomplished by determining a speaking rate for the speaker, which is compared against a speaking rate threshold. The speaking rate threshold can be based upon a listening rate, estimated or known, of the listener. The listening rate can be a variable value based in part upon a proficiency that the listener has with a language being spoken. The speaker can be informed to slow down by an activation of a sensory mechanism of a wearable computing device that is designed to vibrate, beep, blink, speak a message, display a message, and the like, whenever a speaking rate of the speaker exceeds the speaking rate threshold. [0008] The present invention can be implemented in accordance with numerous aspects consistent with the material presented herein. For example, one aspect of the present invention can include an automated method to facilitate understanding between discourse participants. The method can include a step of automatically ascertaining a speaking rate threshold for a listener. The speaking rate threshold can be a threshold over which the listener is likely to have difficulty comprehending speech. A speaking rate of a speaker can then be automatically determined. The speaker can be automatically notified that his or her speaking rate should be decreased, whenever the speaking rate exceeds the speaking rate threshold. [0009] Another aspect of the present invention can include a method for facilitating comprehension during a discourse bed in part upon a discourse language. The method can begin in a situation wherein a speaker is engaged in a discourse with a listener. A language of the discourse can be determined. A listener's proficiency with the language can be ascertained and used to establish a speaking rate threshold. A speaking rate of the speaker can then be determined. When the speaking rate exceeds the speaking rate threshold, the speaker can be automatically notified to decrease his or her speaking rate. [0010] Yet another aspect of the present invention can include a device for facilitating understanding between discourse participants that includes a microphone and a sensory mechanism. The microphone can receive speech of a speaker. The sensory mechanism can automatically inform the speaker when tat speaker's rate of speech is too rapid for a listener to easily comprehend spoken dialog. The determination that the speaking rate is too rapid can be based upon automatically comparing the speaking rate of the speaker against a previously established speaking rate threshold. [0011] In one embodiment, the device can also include a speaking rate processor and a comprehension comparator. The speaking rate processor can determine the speaking rate for speech, which is obtained via the microphone. The comprehension comparator can compare the determined speaking rate against the speaking rate threshold. In a different embodiment, the device can include a transceiver that communicatively connects the device to a network element, which performs the functions ascribed to the speaking rate processor and the comprehension comparator. [0012] It should be noted that various aspects of the invention can be implemented as a program for controlling computing equipment to implement the functions described herein, or a program for enabling computing equipment to perform processes corresponding to the steps disclosed herein. This program may be provided by sorting the program in a magnetic disk, an optical disk, a semiconductor memory, or any other recording medium. The program can also be provided as a digitally encoded signal conveyed via a carrier wave. The described program can be a single program or can be implemented as multiple subprograms, each of which interact within a single computing device or interact in a distributed fashion across a network space. [0013] The method detailed herein can also be a method performed at least in part by a service agent and/or a machine manipulated by a service agent in response to a service request. BRIEF DESCRIPTION OF THE DRAWINGS [0014] There are shown in the drawings, embodiments which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. [0015] FIG. 1 is a schematic diagram showing a solution for increasing comprehension by detecting a speaker's rate of speech, comparing the speaking rate to a listening rate, and warning the speaker to slow down when the speaking rate exceeds the listening rate. [0016] FIG. 2 is a flow chart of a method for automatically notifying a speaker to decrease their speaking rate in accordance with an embodiment of the inventive arrangements disclosed herein. DETAILED DESCRIPTION OF THE INVENTION [0017] FIG. 1 is a schematic diagram showing a solution for increasing comprehension by detecting a speaker's rate of speech, comparing the speaking rate to a listening rate, and warning the speaker to slow down when the speaking rate exceeds the listening rate. System 100 shows a speaker 102 engaged in a discourse 108 with one or more listeners 110 . A device 130 can monitor the rate of speech during the discourse 108 . When the rate of speech is too rapid for listener 110 comprehension, an indicator 106 warning the speaker 102 to slow down can be provided. [0018] In one embodiment, the discourse 108 can be in a language other than a primary language of listener 110 . The listener 110 may be able to comprehend the spoken language, but not at a rate which a native speaker could understand it. A number of techniques can be used to automatically determine that a current language is not a primary language of the listener 110 . [0019] Further, various ones of the techniques may detect that an alternative language to that the discourse 108 language exists, which both the speaker 102 and the listener 110 are proficient in. When this is the case, the indicator 106 can include an option to shift the discourse 108 to the alternative language. [0020] The discourse 108 can include any conversation involving the speaker 102 and the listener 110 . The discourse 108 can include a face-to-face conversation, a telephone conversation, a Web-based interaction having a voice modality, a speaking engagement involving a group of attendees (listeners 110 ) and the speaker 102 , and other communications. [0021] In situations where a voice communication occurs using telephony devices that are linked via a network, a quality of the voice network connection can also be an important factor in determining a listener's 110 ability to comprehend the discourse 108 . To account for network clarity, the device 130 can monitor a quality of a voice connection during a call and can prompt 106 the speaker 102 to decrease his or her speaking rate to a rate more comprehensible to listener 110 , considering an overall quality, nature, and language of received speech. [0022] The device 130 can be a wearable device, such as a smart phone, which can vibrate, blink, produce speech, and/or provide another indicator 106 that notifies speaker 102 to decease a speaking rate or to adjust a speaking language. In such an embodiment, the device 130 can be operable during mobile telephony calls where the listener 110 is a call participant as well as when no calls are being made where the listener 110 is a bystander. Thus, device 130 can add an entirely new function to a mobile telephone or other portable device, which is able to leverage computing capabilities of the portable device to provide this new speaking rate detection and notification ability. [0023] The device 130 can also be integrated into a teleprompter or other mechanism or set of mechanisms that are present in an environment in which speeches are routinely given. Additionally, the device 130 can be a portable device worn by the listener 110 that includes a sensory mechanism noticeable by the speaker 102 , which is selectively activated to notify the speaker 102 that a current rat of speech is too rapid for the listener 110 . The device 130 can be implemented as a stand-alone computing device, as a networked computing device that utilizes processing capabilities of a remotely located networked device 150 , and/or as a series of communicatively linked distributed mechanisms that together cooperatively perform the operations disclosed herein. [0024] As shown in system 120 , the computing device 130 can include a microphone 132 , a sensory mechanism 133 , a speaking rate processor 134 , a language detector 135 , a speech clarity processor 136 , a comprehension comparator 137 , a wireless transceiver 138 , and the like. The microphone 132 can be any device that converts acoustic sound waves into an electrical representation. Microphone 132 can be used to capture the speech of speaker 102 and listener 110 to determine a language being spoken, a speaking rate, and/or a language proficiency level. [0025] Sensory mechanism 133 can be any mechanism for informing speaker 102 that his/her speaking rate should be decreased. For example, a vibration, a tone, a flashing LED, a displayed message, a speech message, a haptic or tactile indicator, and the like can be indications provided by mechanism 133 . In an embodiment having multiple sensory mechanisms 133 available, an active mechanism can be user configurable. [0026] The speaking rate processor 134 can be used to process speech of the speaker 102 and to dynamically determine a speaking rate. The language detector 135 can process speech to determine a language being spoken. The comprehension comparator 137 can compare a speaking rate against a speaking rate threshold and can trigger mechanisms 133 to indicate a speaker 102 needs to slow down, when appropriate. [0027] The speech clarity processor 136 can analyze speech to determine a clarity value, which can be used to adjust a speaking rate and/or a speaking rate threshold. The clarity value can be based upon a clarity with which a communicating party 102 speaks and also based on a quality of a voice network connection, if any is present, over which speech is conveyed to a listener 110 . [0028] In one contemplated implementation, a speaker table 164 can be constructed and stored in a memory accessible by device 130 . The speaking table 164 can enumerate languages spoken by a speaker 102 and can relate a clarity value to each spoken language. The information about speaker languages contained in table 164 can be useful in embodiments that suggest an alternative language, such as Spanish, as shown in indicator 106 , which is shared by both the speaker 102 and the listener 110 . [0029] Wireless transceiver 138 can be used to exchange digital content between device 130 and one or more eternal systems communicatively linked to the network 145 . For example, wireless transceiver 138 can be used to exchange digital content between computing device 130 and network device 150 . Network device 150 can include speech processing components 152 configured to perform one or more of the operations associated with processor 134 , detector 135 , processor 136 , and/or comparator 137 . Remote speech processing by components 152 can be particularly advantageous in situations where device 130 is a resource constrained device that is unable to locally perform speech processing operations. [0030] Device 150 can also include one or more listener profiling and/or identification components 154 . In one embodiment, the listener profiling components 154 can cooperatively interact with listener identifying mechanisms 140 . For example, mechanism 140 can be a Radio Frequency Identification (RFID) tag worn by a listener, which is readable by components 154 . The tag can provide a listener identification that can be a key value of listener table 162 , which can relate to listener languages and listening rates. The listening rates can correspond to a language proficiency and can be used to establish a listener-specific speaking rate threshold. Listening rate thresholds and additional information can also be directly stored upon the RFID tag, worn by the listener 110 . [0031] In another embodiment, the listener profiling components 154 can use speech analysis, video analysis, and other technologies to identify the listener 110 , so that table 162 values can be utilized. In yet another embodiment, the listener profiling components 154 can be configured to determine characteristics of a listener 110 , as opposed to actual listener identity, which are indicative of a language proficiency. For example, components 154 can determine a speaking rate of the listener in the discourse 108 language and can base the speaking rate threshold on the listener's speaking rate. In another example, listener speech can be examined for semantic and acoustic queues that are indicative of the listener's proficiency with a particular language. In still another example, a listener's appearance can be analyzed for region specific characteristics, such as Asian characteristics, Arabic characteristics, and the like, and assumptions relating to language proficiency can be made based upon these characteristics. Preferably, imprecise indicators, such as appearance based markers, can be combined with other indicators to increase an accuracy of language proficiency estimations. [0032] As shown in system 120 , network 145 can include any hardware/software/and firmware necessary to convey digital content encoded within carrier waves. Content can be contained within analog or digital signals and conveyed through data or voice channels. The network 145 can include local components and data pathways necessary for communications to be exchanged among computing device components and between integrated device components and peripheral devices. The network 145 can also include network equipment, such as routers, data lines, hubs, and intermediary servers which together form a packet-based network, such as the Internet or an intranet. The network 145 can further include circuit-based communication components and mobile communication components, such as telephony switches, modems, cellular communication towers, and the like. The network 145 can include line based and/or wireless communication pathways. [0033] Additionally, data store 160 can be a physical or virtual storage space configured to store digital content. Data store 160 can be physically implemented within any type of hardware including, but not limited to, a magnetic disk, an optical disk, a semiconductor memory, a digitally encoded plastic memory, a holographic memory, or any other recording medium. Further, data store 160 can be a stand-alone storage unit as well as a storage unit formed from a plurality of physical devices. Additionally, content can be stored within data store 160 in a variety of manners. For example, content can be stored within a relational database structure or can be stored within one or more files of a file storage system, where each file may or may not be indexed for information searching purposes. Further, data store 160 can optionally utilize one or more encryption mechanisms to protect stored content from unauthorized access. [0034] FIG. 2 is a flow chart of a method 200 for automatically notifying a speaker to decrease their speaking rate in accordance with an embodiment of the inventive arrangements disclosed herein. The method 200 can be performed in the context of system 120 . [0035] Method 200 can begin in step 205 , where a discourse involving a speaker and one or more listeners can be identified. In step 210 , a language being spoken can be detected. In step 215 , a determination can be made regarding whether the spoken language is a primary language of the listener. If so, the method can progress from step 215 to step 220 , where a speaking threshold can be set to that of a native speaker. The method can then skip from step 220 to step 250 . [0036] When the spoken language is not a primary language of the listener, the method can progress from step 215 to step 225 , where an attempt can be made to determine the listener's identity. If the attempt of step 225 is successful, step 230 can be performed, where a listening rate associated with the listener can be determined. In step 235 , a speaking rate threshold can be set to the listener specific rate. The method can skip from step 235 to step 250 . [0037] When in step 225 , a listener identify cannot be determined, the method can progress to step 240 , where the listener can be profiled to estimate a listening rate. For example, speech processing of listener provided speech can be performed to detect whether the listener has a heavy accent, which can be indicative of the listener not being a native speaker of that language. In step 245 , the speaking rate threshold can be set to the estimated listening rate. [0038] In step 250 , a speaking rate for the speaker can be determined. In optional step 255 , a speaking clarity value can be determined for the speaker. The speaker rate can be adjusted in accordance with the speaking clarity. That is, a faster speaking rate can be comprehensible when speech clarity is high than when speech clarity is low. In one contemplated embodiment, speaking clarity can be affected by the emotional content or emotional pitch of a discourse. Thus, one actor in determining a clarity value can be ascertained by analyzing the discourse for emotional content. Generally, discourses with high emotional content have a lower clarity level than discourses with minimal emotional content. [0039] In step 260 , a determination can be made as to whether the speaking rate is less than or equal to the speaking threshold. This comparison can indicate whether the listener is able to comprehend the conversation. When the speaking rate does not exceed the threshold, the method can loop from step 260 back to step 250 , where a speaking rate for the speaker can again be determined. The loop can continue for a duration of a discourse. [0040] When the speaking rate exceeds the speaking threshold, the method can progress from step 260 to step 265 , where the speaker can be notified to reduce their speaking rate. In optional step 270 , a determination can be made as to whether the speaker and listener share a language other than the language being spoken. For example, the speaker, who was originally speaking in English, can also speak Spanish, which can be a primary language of the listener. Moreover, the speaker's proficiency with Spanish can be greater than the listener's proficiency with English, which would make changing the language of the discourse beneficial from an overall comprehension standpoint. In step 275 , the speaker can be notified of the shared alternative language, and be thereby provided an option to shift the conversation language to the alternative language. When a language change occurs, different values for the speaking rate threshold and speaker clarity can be determined (not shown). The method can loop from step 275 to step 250 , where a speaking rate of the speaker can continue to be determined. [0041] The present invention may be realized in hardware, software, or a combination of hardware and software. The present invention may be realized in a centralized fashion in one computer system or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system or other apparatus adapted for carrying out the methods described herein is suited. A typical combination of hardware and software may be a general purpose computer system with a computer program that, when being loaded and executed, controls the compute system such that it carries out the methods described herein. [0042] The present invention also may be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which when loaded in a computer system is able to carry out these methods. Computer program in the present context means any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following: a) conversion to another language, code or notation; b) reproduction in a different material form. [0043] This invention may be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope of the invention.
The present invention discloses a solution that automatically informs a speaker to decrease his or her speaking rate, when that rate likely exceeds a rate that a listener can understand. This can be accomplished by determining a speaking rate for the speaker, which is compared against a speaking rate threshold. The speaking rate threshold can be based upon a listening rate, estimated or known, of the listener. The listening rate can be a variable value based in part upon a proficiency that the listener has with a language being spoken. The speaker can be informed to slow down by an activation of a sensory mechanism of a wearable computing device designed to vibrate, beep, blink, speak a message, display a message, and the like, whenever a speaking rate of the speaker exceeds the speaking rate threshold.
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CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This nonprovisional application claims priority under 35 U.S.C. § 119(a) on European Patent Application No. 05100023.0, filed on Jan. 4, 2005, the entirety of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention is related to a printing device such as a printing or copying system employing print heads containing discharging elements, e.g. nozzles, for image-wise forming dots of a marking substance on an image-receiving member, where the marking substance is in fluid form when discharged. Examples of such printing devices are inkjet printers and toner-jet printers. Hereinafter reference will be made to inkjet printers. [0004] 2. Description of Background Art [0005] Print heads employed in inkjet printers and the like usually each contain a plurality of nozzles arranged in (an) array(s). The nozzles usually are placed substantially equidistant. The distance between two contiguous nozzles defines the nozzle pitch. In operation, the nozzles are controlled to image-wise discharge fluid droplets of a marking substance on an image-receiving member. When the printer is of the scanning type, the print heads are moveable in reciprocation across the image-receiving member, i.e. the main scanning direction. In such printers, the print heads are typically aligned in the sub scanning direction perpendicular to the main scanning direction. In a traverse of the print heads across the image-receiving member a matrix of image dots of a marking substance, corresponding to a part of an original image is formed on the image-receiving member by image-wise activating nozzles of the print heads. The printed matrix is generally referred to as a print swath, while the dimension of this matrix in the sub scanning direction is referred to as the swath width. After a first traverse, when a part of the image is completed, the image-receiving member is displaced relative to the print heads in the sub-scanning direction enabling printing of a subsequent part of the image. When this displacement step is chosen equal to a swath width, an image can be printed in multiple non-overlapping swaths. However, image quality may be improved by employing printing devices enabling the use of multiple printing stages, hence printed swaths are at least partially overlapping. In the background art, two main categories of such printing devices can be distinguished, i.e. so-called “interlace systems” and “multi-pass systems”. [0006] In an interlace system, the print head contains N nozzles, which are arranged in (a) linear array(s) such that the nozzle pitch is an integer multiple of the printing pitch. Multiple printing stages, or so-called interlacing printing steps, are required to generate a complete image or image part. The print head and the image-receiving member are controlled such that in M printing stages, M being defined here as the nozzle pitch divided by the printing pitch, a complete image part is formed on the image-receiving member. After each printing stage, the image-receiving member is displaced over a distance of M times the printing pitch. Such a system is of particular interest because it achieves a higher print resolution with a limited nozzle resolution. [0007] In a “multi-pass system”, the print head is controlled such that only the nozzles corresponding to selected pixels of the image to be reproduced are image-wise activated. As a result, an incomplete matrix of image dots is formed in a single printing stage or pass, i.e. one traverse of the print heads across the image-receiving member. Multiple passes are required to complete the matrix of image dots. The image-receiving member may be displaced in the sub scanning direction in-between two passes. [0008] In practice the majority of print jobs is executed in such multiple printing stage mode on a scanning type bidirectional printing system, i.e. a printing system capable of printing on the image-receiving member in reciprocation in the main scanning direction. [0009] Such systems, which may be “interlace systems” and “multi-pass systems” as well as combinations thereof, are known to be sensitive to gloss variations. Gloss variations can occur when at least a part of the image dots of a marking substance of the same or a different process color are deposited in multiple printing stages in superimposition or at least partially overlapping and when the drying time of the image dots printed on the image-receiving member interacts with the time period required to render all pixels of an image part, i.e. the time period required to complete a sequence of printing stages defined by the print mask. This is particularly the case when, while printing is in progress, a delay signal is generated which causes the printer to interrupt printing immediately or after completion of the printing stage in progress. In any case, printing of the subsequent printing stages is delayed until the cause of the delay is resolved and/or a resume signal is generated. This is observed to cause gloss banding on the print in progress. SUMMARY OF THE INVENTION [0010] Thus, it is an object of an embodiment of the invention to control a scanning type printing system when operating in a multiple printing stage mode such as to overcome or at least reduce gloss variations in a printed image when printing in progress is temporarily interrupted upon receipt of a delay signal. [0011] It is a further object of an embodiment of the invention to control the print heads and the image-receiving member displacement device of a scanning type printing system such that, particularly when operating in a multiple printing stage mode, at each location on the image-receiving member in the sub-scanning direction, about the same time intervals are used between the time of deposition of the respective image dots, which when deposited are in superimposition or at least partially overlapping. [0012] To meet these objects, a printing device for printing images on an image-receiving member in a sequence of printing stages includes a control that controls, in an operative state of the printer, responsive to said delay signal, the print head and the displacement device so that further printing is executed only during the stroke whereon printing is in progress until all printing stages of the sequence are completed for said stroke. Upon receipt of a delay signal, printing is continued on incompletely printed strokes until these are completed. Therefore, a huge time period between the remaining printing stages for such strokes whereon printing was in progress and the printing stages already executed during the strokes is avoided. The remaining printing stages are the printing stages not yet executed for these strokes. Hence, for these strokes, image dots deposited before receipt of the delay signal are completely dried when resuming printing and thus image dots associated with the remaining printing stages are deposited at least some of them in superimposition or at least partially overlapping with image dots already present on the image-receiving member. By completing the strokes upon which printing is in progress upon receipt of the delay signal, gloss banding caused by such delay is avoided. [0013] The printing device may be provided with a device for generating a resume signal so that responsive to such resume signal printing may be resumed on a subsequent stroke of the image-receiving member contiguous to the printed strokes. [0014] The printer may generate a delay or resume signal automatically. For instance, a delay signal may be generated because of a low ink level detection, or because a cleaning action of the print head is required, or another maintenance or service action is required. A resume signal may be generated after the requested intervention is completed. A delay signal or a resume signal may also be generated by user interaction. The image-receiving member may be an intermediate image carrying member or a print medium. The print medium can be in web or sheet form and may be composed of e.g. paper, cardboard, label stock, plastic or textile. [0015] The so-called print mask contains the information about the number and sequence of printing stages and defines for each print head which discharging elements can be image-wise activated, or in other words contains the information defining for each printing stage which pixels will be rendered by which discharging elements such that when all printing stages are completed, all the pixels of the image concerned, or at least a part of such image, are rendered. A print mask is associated with a printing mode. Selecting a printing mode enables the user to exchange image quality for productivity and vice versa dependent on his requirements. By selecting a printing mode also the discharging elements on the print heads which may be effectively used for image-wise activation are determined as well as the displacement step in the sub scanning direction after each printing stage. [0016] Gloss banding may even be further reduced by ensuring that the time intervals between the deposition of at least partially overlapping image dots, each associated with a particular printing stage, are about the same regardless of the position on the image-receiving member in the sub-scanning direction. Hence, in an embodiment of the present invention, the control means select for each said traverse of the print head in the main scanning direction an active portion of the plurality of discharging elements, each active portion of discharging elements being selected on the basis of the predetermined distance so that for substantially each position in the sub scanning direction on the part of the image-receiving member where the image is to be rendered, the traversing direction of the print head is the same for each first exposure to an active portion of the traversing print head. Each traverse of the print head in operative state results in a printed portion of an image on the image-receiving member formed by a pattern of image dots of marking substance. After each traverse the image-receiving member is displaced with respect to the print head in the sub scanning direction either by displacing the image-receiving member or by displacing the print head. When printing subsequent portions of an image, a repetitive sequence of printing stages and corresponding displacement steps is used, each displacement step being defined by the relative displacement between the print head and the image-receiving member over a predetermined distance between respective subsequent printing stages. In particular, each of the displacement steps may equal the same constant. [0017] By selecting for each traverse of the print head an active portion thereof taking account of the displacement step between subsequent traverses, the present invention accomplishes that on substantially each position of the image-receiving member the traversing direction of the print head is the same for each first exposure to an active portion of the traversing print head. The advantage thereof is that in the sub-scanning direction there are no time interval differences between the time of deposition of image dots originating from different traverses even when printing is temporarily interrupted due to a delay signal. Hence no gloss variations will occur or they will be at least severely reduced. The selected active portion for a forward traverse may be different from the selected active portion for a backward traverse. In particular each active portion may selected such that the product of the number of discharging elements available in that active portion and the discharging element pitch is a non-zero integer multiple of the displacement distance. [0018] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and 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 DRAWINGS [0019] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein: [0020] FIG. 1 depicts an example of an inkjet printer according to an embodiment of the present invention; [0021] FIG. 2 a depicts an example of a print mask defining two printing stages; [0022] FIG. 2 b depicts, according to an embodiment of the present invention, image dot patterns generated by a single print head assuming a full coverage image using all 24 nozzles of the print head and using the print mask of FIG. 2 a; [0023] FIG. 2 c depicts, according to an embodiment of the present invention, for respective traverses of the print head/printing stages used, which portion of the print head will be used and how the receipt of a delay signal is dealt with; [0024] FIG. 3 a depicts an example of a print mask defining three printing stages; [0025] FIG. 3 b depicts, according to an embodiment of the present invention, image dot patterns generated by a single print head assuming a full coverage image using in each traverse a selected active portion of the print head using the print mask of FIG. 3 a ; and [0026] FIG. 3 c depicts, according to an embodiment of the present invention, for respective traverses of the print head/printing stages used, which portion of the print head will be used and how the receipt of a delay signal is dealt with. DETAILED DESCRIPTION OF THE INVENTION [0027] In relation to the appended drawings, the present invention is described in detail in the sequel. Several embodiments are disclosed. It is apparent however that a person skilled in the art can imagine several other equivalent embodiments or other ways of executing the present invention, the scope of the present invention being limited only by the terms of the appended claims. [0028] The printing device of FIG. 1 is a scanning bi-directional inkjet printer comprising a roller ( 1 ) for supporting an image-receiving member ( 2 ) and moving it along four print heads ( 3 ), each of a different process color. The roller is rotatable about its axis as indicated by arrow A. A scanning carriage ( 4 ) carries the four print heads and can be moved in reciprocation in the main scanning direction, i.e. the direction indicated by the double arrow B, parallel to the roller ( 1 ), such as to enable scanning of the image-receiving member in the main scanning direction. The image-receiving member can be a medium in web or in sheet form and may be composed of, e.g. paper, cardboard, label stock, plastic or textile. Alternately, the image-receiving member can also be an intermediate member, endless or not. Examples of endless members, which can be moved cyclically, are a belt or a drum. The carriage ( 4 ) is guided on rods ( 5 ) ( 6 ) and is driven by suitable means (not shown). Each print head ( 3 ) comprises a number of discharging elements ( 7 ) arranged in a single linear array parallel to the sub scanning direction. Four discharging elements ( 7 ) per print head ( 3 ) are depicted in the figure, however obviously in a practical embodiment typically several hundreds of discharging elements are provided per print head. Each discharging element is connected via an ink duct to an ink reservoir of a corresponding color. Each ink duct is provided with a device for activating the ink duct and an associated electrical drive circuit. For instance the ink duct may be activated thermally and/or piezoelectrically. When the ink duct is activated, an ink drop is discharged from the discharge element in the direction of the roller ( 1 ) and forms a dot of ink on the image-receiving member ( 2 ). The printer further comprises a controller (not shown), which controls the drive of the carriage, the print heads, the image-receiving member advancement, the ink supply, etc. The printer is arranged to automatically detect a maintenance condition and to generate a delay signal, which delays printing according to an embodiment of the present invention. The printer is also arranged to automatically detect the completion of the required intervention and will generate a resume signal such that printing can be resumed. [0029] To enable printing a digital image is first formed. There are numerous ways to generate a digital image. For instance, scanning an original using a scanner can be used to create a digital image. A camera or a video camera can also be used to create digital still images. Besides digital images generated by a scanner or a camera, which are usually in a bitmap format or a compressed bitmap format also artificially created, e.g. by a computer program, digital images or documents may be sent to the printing device. The latter images can be in a vector format. The latter images can also be in a structured format including but not limited to a page description language (PDL) format and an extensible markup language (XML) format. Examples of a PDL format are PDF (Adobe), PostScript (Adobe), and PCL (Hewlett-Packard). The image processing system typically converts a digital image with known techniques into a series of bitmaps in the process colors of the printing device. Each bitmap is a raster representation of a separation image of a process color specifying for each pixel (“picture element”) an image density value for said process color. An image composed of ink dots can be formed on the image-receiving member by image-wise activating the ink ducts in relation to the pattern(s) of image pixels. EXAMPLE 1 [0030] A printing device as depicted in FIG. 1 is used to reproduce a digital image. Instead of using the print heads provided with four discharging elements each as in the figure, each print head is provided with 24 discharging elements, i.e. nozzles, arranged in a single linear array. The nozzles are positioned equidistant at a resolution of 300 npi (nozzles per inch). This means that the nozzle pitch or element pitch, being the distance between the centres of two adjacent nozzles, is about 85 μm. [0031] Suppose the user selects a particular printing mode enabling reproduction of a digital image at a printing resolution of 300 dpi (dots per inch) in both the main scanning and the sub scanning directions, or in other words, the printing pitch, i.e. the distance between centers of two contiguous dots of ink both in the main scanning direction and in the sub scanning direction, is about 85 μm. In this printing mode, the print mask as depicted in FIG. 2 a is used. In case the image is a multicolor image, the same print mask is used for each of the process colors. The print mask as depicted in FIG. 2 a defines a “multi-pass” system with two printing stages. As depicted in FIG. 2 b , in the first printing stage, a first portion of the image is printed by image-wise activating selected nozzles of the active portion of the print head. The image pattern resulting when activating all selected nozzles is indicated in FIG. 2 b with black circles. In this case the active portion includes all 24 available nozzles. This first printing stage coincides with a forward traverse of the print heads across the image-receiving member, i.e. a traverse from the left to the right. Then, the image-receiving member is advanced over a predetermined constant distance of 12 times the printing pitch to enable printing of a second portion of the image by image-wise activating a different selection of nozzles of the same active portion. The image pattern resulting when activating all selected nozzles according to the second printing stage is indicated in FIG. 2 b . This second printing stage coincides with a backward traverse of the print heads across the image-receiving member, i.e. a traverse from the right to the left. In a normal operation mode, when the image is not yet completed, the image-receiving member is again advanced over the same constant distance being 12 times the nozzle pitch. Thereafter, the above-described sequence of printing stages and image-receiving member advancing is repeated until the last portion of the image is completed. [0032] Suppose, however, that a delay signal is generated during execution of a second printing stage, i.e. during a backward traverse of the print head. As indicated in FIG. 2 b , a delay signal is generated at the time printing is in progress on a stroke ( 21 ) of the image-receiving member. It is clear from FIG. 2 b that even after finishing printing stage 2 this stroke is still printed incompletely. According to an embodiment of the present invention, upon receipt of the delay signal, printing on strokes of the image-receiving member on which printing is already started is progressed. However, printing on a subsequent stroke of the image-receiving member is not started. In this example, this means that printing on stroke ( 21 ) is progressed until all printing stages required to completely render the image portion associated with this stroke are completed. Thus, in order to complete the stroke ( 21 ), the print head is advanced over a distance of 12 times the printing pitch. Thereafter, printing stage 1 is executed using only the upper half of the nozzles. Further referring to FIG. 2 c , as stroke ( 21 ) is completed now, printing is delayed until the required intervention is completed. When resuming printing, the printing process is recovered with the strokes left blank during finishing of printing process. One option is, as depicted in FIG. 2 c , to advance the print head from the right to the left with all nozzles inactive. Thereafter, printing stage 1 is executed for the subsequent stroke using the complementary part of the print head, being the lower half of the nozzles. Thereafter, printing can proceed according to the print mask until the complete image is printed. Instead of advancing the print head from the right to the left with all nozzles inactive after the delay, another option (not shown) is immediately executing printing stage one for the subsequent stroke. In that case the print head is traversed from the right to the left using the complementary part of the print head, being the lower half of the nozzles. Thereafter printing can proceed according to the print mask until the complete image is printed EXAMPLE 2 [0033] A printing device as depicted in FIG. 1 is used to reproduce a digital image. Instead of using the print heads provided with four discharging elements each as in the figure, each print head is provided with 12 discharging elements, i.e. nozzles, arranged in a single linear array. The nozzles are positioned equidistant at a resolution of 300 npi (nozzles per inch). This means that the nozzle pitch or element pitch, being the distance between the centres of two adjacent nozzles is about 85 μm. [0034] Suppose the user selects a particular printing mode enabling reproduction of a digital image at a printing resolution of 900 dpi (dots per inch) in both directions, or in other words, the printing pitch, i.e. the distance between the centers of two contiguous dots of ink both in the main scanning direction and in the sub scanning direction, is about 31 μm. To enable rendering of an image with a resolution higher than the nozzle resolution, the print mask associated with the selected printing mode as in FIG. 3 a defines an interlacing system. The print mask defines a sequence of three printing stages required to completely render at least a part of the image. For each printing stage, i.e. for each traverse of a print head(s) in the main scanning direction, an active portion of the plurality of available discharging elements of the print head is selected. In particular, as also depicted in FIG. 3 c , when a printing stage coincides with a traverse of the print head from the left to the right, the active portion includes all 12 available nozzles. When a printing stage coincides with a traverse of the print head from the right to the left, the active portion includes the six nozzles located in the middle of the print head, while the upper three nozzles as well as the lower three nozzles are part of the inactive portion. [0035] In this example, the active portion in each forward traverse and the active portion in each backward traverse are selected such that the swath width of each portion of an image printed in the forward traverse is twice the swath width of each portion of an image printed in the backward traverse. When executing a first printing stage using the print mask as depicted in FIG. 3 a , the resulting dot pattern when activating all selected nozzles is indicated in FIG. 3 b with black circles. For instruction purposes, only the dots generated by a single print head are shown and a full coverage image is assumed. In practice, however, it is clear that images can be formed in the same way multi-color images can be formed by adequately timing both the driving of the respective print heads and the image-wise activation of the associated nozzles. Each nozzle image-wise forms a complete line of image dots of ink in the main scanning direction. In the sub scanning direction, only every third pixel is printed during the first printing stage. After the first printing stage is executed, the image-receiving member is advanced over a distance of 8 times the printing pitch. After the displacement step, the second printing stage is executed. In this second printing stage, i.e. a traverse from the right to the left, the active portion includes the 6 nozzles located in the middle of the print head, while the inactive portion includes both the lower and upper three nozzles. A dot pattern as schematically depicted in FIG. 3 b is obtained. After the second printing stage is executed, the image-receiving member is again advanced over a distance of 8 times the printing pitch. In the third printing stage, in this case a traverse from left to right, under normal operating conditions, again the full print head is employed. Under normal operating conditions, when the image is not yet completed, the image-receiving member is advanced over a distance of 11 times the printing pitch. Thereafter, the above-described sequence of printing stages, being stages 1 , 2 and 3 , and corresponding image-receiving member advancement steps of 8, 8 and 11 printing pitches, is repeated until the image is completed. [0036] As can be observed in FIG. 3 b , the selection of the active portions in the forward and backward traverses respectively takes account of the image-receiving member displacement step so that for each position in the sub scanning direction on the part of the image-receiving member where the image is to be rendered, the traversing direction of the print head is the same for each first exposure to an active portion of the traversing print head. [0037] Suppose, however, that a delay signal is generated during execution of a third printing stage, in this example during a forward traverse of the print head. As indicated in FIG. 3 b , a delay signal is generated at the time printing is in progress on a stroke ( 31 ) of the image-receiving member. It is clear from FIG. 3 b that even after finishing printing stage 3 , this stroke is still printed incompletely. According to an embodiment of the present invention, upon receipt of the delay signal, printing on strokes of the image-receiving member on which printing is already started is progressed. However, printing on a subsequent stroke of the image-receiving member is not started. In this example, this means printing on stroke ( 31 ) is progressed until all printing stages required to completely render the image portion associated with this stroke are completed. Thus, in order to complete the stroke ( 31 ), the print head is advanced over a distance of 11 times the printing pitch. Then, with reference to FIG. 3 c , printing stage 1 is executed using, in this case a traverse from the right to the left, the center half of the nozzles as an active portion of the print head. Subsequently, the print head is advanced over a distance of 8 times the printing pitch. Thereafter, printing stage 2 is executed. Normally, in this case a traverse from the left to the right, the active portion of the print head includes all nozzles. However, as printing is to be limited to stroke ( 31 ) only, only the upper half of the nozzles is image-wise activated. As stroke ( 31 ) is completed now, printing is delayed until the required intervention is completed. [0038] When resuming printing, the printing process is recovered with the strokes left blank during finishing of the printing process. In particular, the print head is advanced from the right to the left with all nozzles inactive. Thereafter, printing stage 1 is executed for the subsequent stroke using the complementary part of the print head, being the lower half of the nozzles. Thereafter printing can proceed according to the print mask until the complete image is printed. [0039] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
A scanning type printing device is capable of operating in a multiple printing stage mode. When operating in a multiple printing stage mode, this printing device is controlled such upon receipt of a delay signal, further printing is executed, but only during the stroke of the image-receiving member, whereon printing is in progress until the image portion associated with that stroke is completely printed. This is done in order to overcome or at least reduce gloss variations in a printed image when printing in progress is temporarily interrupted.
1
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit under 35 U.S.C. § 119(a) of Korean Patent Application No. 2006-66130, filed on Jul. 14, 2006, in the Korean Intellectual Property Office, the entire disclosure of which is hereby incorporated by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to an earphone. More particularly, the present invention relates to an earphone which is used by placing it inside an ear. [0004] 2. Description of the Related Art [0005] FIGS. 1 and 2 are schematic views illustrating a conventional earphone such as the one disclosed in Korean Laid-Open Patent Publication No. 10-1998-018579, which is hereby incorporated by reference in its entirety. [0006] As illustrated in FIGS. 1 and 2 , a conventional earphone 1 includes a cover connected to and combined with an earphone cord 5 at its lower part, an electroacoustic transducer 10 located inside the cover 4 , a protection plate 2 combined with a front side of the cover 4 so that the electroacoustic transducer 10 is protected, and an ear piece 3 in a predetermined shape located outside the protection plate 2 . [0007] The electroacoustic transducer 10 for converting an audio signal to sound may be, for example, a moving coil type transducer. In this type of a transducer, a voice coil is wound around a bobbin 12 , and the bobbin 12 is integrally attached to a diaphragm 11 . The voice coil or diaphragm is inserted into a gap 14 in a magnetic circuit 13 . [0008] The protection plate 2 which opposes the diaphragm 11 is provided on a sound emanating side or front side of the transducer 10 and is made of a metal plate of substantially the same size as the diaphragm 11 . The protection plate 2 has a number of holes 21 through to allow sound waves emitted from the diaphragm 11 to pass through. [0009] The ear piece 3 covers the front side of the protection plate 2 . The ear piece 3 is located within a listener's ear when the earphone 1 is worn. The ear piece 3 has a protruding portion 30 that fits into an entrance of the external auditory meatus (i.e., the ear canal). The protruding portion 30 is made of a material having an appropriate elasticity, such as rubber or plastic. The tip of the protruding portion 30 has a number of sound emanating holes 31 . [0010] The cover 4 covers a rear face of the transducer 10 . The transducer 10 is connected to the earphone cord 5 through an introducing portion 40 , which is located at a lower part of the cover 4 . An air chamber 41 inside the cover 4 is open to the outside through a passage 42 of the introducing portion 40 . The cover 4 is provided with a number of holes 43 which are closed by an acoustic resistant material 44 . [0011] An air chamber 32 is formed in front of the transducer 10 by the ear piece 3 . The air chamber 32 is open to the outside through an opening 34 and a non-woven fabric 35 which are formed on the ear piece 3 . The opening 34 is located to the side of the central portion of the ear piece 3 as shown in FIG. 2 . Thus, when the earphone 1 is put in the ear E such that the protruding portion 30 is inserted into the ear canal or the external auditory meatus, the opening 34 is located in the cavum concha F, thereby covering the skin of the cavum concha F. [0012] In the conventional earphone 1 , the whole earphone 1 including the protection plate 30 and the cover 4 is inserted into and supported by the cavum concha F, and the introducing portion 40 of the cover 4 is introduced into and supported by the intertragic notch. If a user wears the earphone for a long time, the pressure on the anti-tragus H and the tragus G, or the contact with a protruding portion of a helix K may cause discomfort. [0013] Furthermore, since the protruding portion 30 of the ear piece 3 is at the front of the transducer 10 , when the earphone 1 is inserted into the external auditory meatus, the transducer 10 is almost horizontal with respect to the cavum concha F. Accordingly, the opening 34 and the nonwoven fabric 35 contact the cavum concha F. When the opening 34 of the ear piece 3 is blocked by the cavum concha F, low frequency sounds (i.e., bass sounds) generated by the transducer 10 cannot be transmitted. Furthermore, the opening 34 of the ear piece 3 is adjacent to the protection plate 2 . Thus, there is only a small space created in the ear piece 3 where the opening 34 is provided, and bass sounds may be muted. [0014] Accordingly, there is a need for an improved earphone for insertion into the ear canal that provides increased comfort and better sound quality. SUMMARY OF THE INVENTION [0015] An aspect of the present invention is to address at least the above problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide an earphone which has an improved structure to improve the comport when wearing the earphone and the sound quality. [0016] In accordance with an aspect of an exemplary embodiment of the present invention, an earphone includes an electroacoustic transducer for converting an audio signal into sound and a housing for holding the electroacoustic transducer. The housing includes a sound output unit for introducing the sound produced by the electroacoustic transducer into the ear canal of an ear when the housing is placed in the ear. The electroacoustic transducer emits sound in a direction transverse to the ear canal of the ear. [0017] The sound emission direction of the electroacoustic transducer may be substantially parallel to a side of a cavum concha of the ear. [0018] The housing may includes a front housing that surrounds the front of the electroacoustic transducer and a rear housing, that is combined with the front housing and surrounds the rear of the electroacoustic transducer. [0019] The rear housing may include a rear wall that surrounds the rear of the electroacoustic transducer and a base wall that extends from the rear wall to the front of the electroacoustic transducer and forms the sound output unit, together with the front housing. [0020] The base wall may be adapted to contact the side of the cavum concha of the ear. [0021] The front housing may include a front wall located at an angle with respect to the front of the electroacoustic transducer and a protruding extension wall extending from the front wall and forming the sound output unit, together with the base wall. [0022] The housing may include a first space located in the rear of the electroacoustic transducer and a second space located in the front of the electroacoustic transducer. The second space is larger than the first space and is operatively connected to the sound output unit. [0023] The housing includes may include a rear opening operatively connecting the first space to the outside and a front opening adjacent to the front of the electroacoustic transducer and operatively connecting the second space to the outside. [0024] The rear opening may include a cover including a nonwoven fabric. [0025] A cover may cover a portion of the housing and contact the ear. The cover may include an exit corresponding to the sound output unit. [0026] The cover may be made of a flexible material, and the exit may be spaced apart from the sound output unit by a distance. The distance is controllable when the shaped of the cover is changed. [0027] A supporting protrusion may be located at a lower part of the outside of the housing, and the supporting protrusion may protrude outwardly with a shape that corresponds to the anti-tragus notch of the ear when the housing is placed in the ear. [0028] In accordance with another aspect of an exemplary embodiment of the present invention, an earphone includes an electroacoustic transducer for converting an audio signal into sound and a housing for holding the electroacoustic transducer. The housing includes a sound output unit for introducing the sound produced by the electroacoustic transducer into the ear canal of an ear when the housing is placed in the ear, and wherein the electroacoustic transducer is at an angle of 90°±10° with respect to a side of the cavum concha when the housing is placed in the ear. [0029] The housing may include a substantially circular first body for holding the electroacoustic transducer, a second body that protrudes from the first body and extends from the front of the electroacoustic transducer to the ear canal of the ear, a third body that extends from the first body and extends substantially parallel to the electroacoustic transducer in parallel, and a cord connected to the electroacoustic transducer disposed in the third body. [0030] The sound output unit may be located at a protruding tip of the second body. [0031] The second body may include a base side which faces the side of the cavum concha so that it can be placed against the cavum concha. [0032] A supporting protrusion may be disposed on the second body so that it protrudes outwardly in a shape corresponding to the shape of the anti-tragus notch of the ear when the housing is placed in the ear. [0033] The housing may include a first space located in the rear of the electroacoustic transducer and a second space located in the front of the electroacoustic transducer. The second space is larger than the first space and is operatively connected to the sound output unit. [0034] The housing may include a rear opening operatively connecting the first space to the outside and a front opening adjacent to the front of the electroacoustic transducer and operatively connecting the second space to the outside. [0035] A bushing member may be combined with the housing. The bushing member supports a cord which is connected to the electroacoustic transducer to enter from the outside of the housing. [0036] The first space may be operatively connected to a cord hole of the bushing member. [0037] A cover may cover a portion of the housing that contacts the ear, and may include an exit corresponding to the sound output unit. [0038] In accordance with another aspect of an exemplary embodiment of the present invention, an earphone includes a housing adapted to hold an electroacoustic transducer. The housing includes a sound output unit for introducing sound emitted by the electroacoustic transducer into an ear canal of an ear. The housing holds the electroacoustic transducer so that it emits sound in a direction transverse to the ear canal. [0039] The electroacoustic transducer may emit sound in a direction substantially parallel to the cavum concha. [0040] The housing may include a front housing disposed at the front of the electroacoustic transducer and a rear housing disposed at the rear of the electroacoustic transducer. [0041] The rear housing may form a first space located in the rear of the electroacoustic transducer and the front housing may form a second space located in the front of the electroacoustic transducer. [0042] The second space may be larger than the first space and may be operatively connected to the sound output unit. [0043] At least one opening may be provided to connect the first space to an exterior of the housing. The at least one opening controls the treble response of the sound emitted from the electroacoustic transducer. [0044] At least one opening may be provided to connect the second space to an exterior of the housing. The at least one opening controls the bass response of the sound emitted from the electroacoustic transducer. [0045] In accordance with another aspect of an exemplary embodiment of the present invention, an earphone includes a front housing and a rear housing connected to the first housing to form an interior space. An electroacoustic transducer for emitting sound is disposed in the interior space formed by the front and rear housings. The electroacoustic transducer emits sound in a first direction. A sound output unit disposed on the front housing transmits sound emitted by the electroacoustic transducer into an ear canal of an ear in a second direction. The first and second directions are transverse to one another. [0046] The first and second directions may be at an angle in the range of approximately 80° to 100° with respect to one another. The first and second directions may be at an angle of approximately 90° with respect to one another. [0047] The interior space may include a first space between the electroacoustic transducer and the rear housing and a second space between the electroacoustic transducer and the front housing. [0048] At least one opening may be provided to connect the first space to an exterior of the housing. The at least one opening controls the treble response of the sound emitted from the electroacoustic transducer. [0049] At least one opening may be provided to connect the second space to an exterior of the housing. The at least one opening controls the bass response of the sound emitted from the electroacoustic transducer. BRIEF DESCRIPTION OF THE DRAWINGS [0050] The above and other objects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which: [0051] FIG. 1 is a schematic view of a conventional earphone; [0052] FIG. 2 is a plan view of the earphone of FIG. 1 in an ear; [0053] FIG. 3 is a view of an external ear; [0054] FIG. 4A is a left side view of an earphone in accordance with an exemplary embodiment of the present invention; [0055] FIG. 4B is a sectional view taken along line 4 B- 4 B of FIG. 4A ; [0056] FIG. 4C is a sectional view taken along line 4 C- 4 C of FIG. 4A ; [0057] FIG. 5 is a front view of the earphone of FIGS. 4A-4C ; [0058] FIG. 6 is a right side view of the earphone of FIGS. 4A-4C ; [0059] FIG. 7 is a view of the earphone of FIGS. 4A-4C while being worn in an ear; and [0060] FIG. 8 is a graph of sound pressure showing a comparison of the earphone of FIGS. 4A-4C in and a conventional earphone. [0061] Throughout the drawings, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS [0062] The matters defined in the description such as a detailed construction and elements are provided to assist in a comprehensive understanding of the exemplary embodiments of the invention and are merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the exemplary embodiments described herein can be made without departing from the scope and spirit of the invention. Also, descriptions of well-known functions and constructions are omitted for clarity and conciseness. [0063] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. [0064] FIG. 3 illustrates a structure of an ear E. The ear has a cavum concha F, a tragus G, an anti-tragus H, an intertragic notch I between the tragus and the anti-tragus, a helix K, and the external auditory L. The entrance of the external auditory meatus L is located at a side of the cavum concha F and partially covered by the tragus G. [0065] The earphone in accordance with an exemplary embodiment of the present invention is worn in the ear E. The earphone extends over the tragus G, the anti-tragus H and the intertragic notch I. When the earphone is placed adjacent and the side of the earphone is basically aligned with the cavum concha F, the earphone introduces sound into the external auditory meatus L. [0066] As shown in FIGS. 4A , 4 B and 4 C, the earphone 100 in accordance with an exemplary embodiment of the present invention comprises an electroacoustic transducer 110 , a housing 120 , and a cover 130 . The electroacoustic transducer 110 converts an audio signal into sound. The housing 120 receives the electroacoustic transducer 110 and is worn in a user's ear. The cover 130 is combined with the housing 120 and covers part of the housing 120 . [0067] The electroacoustic transducer 110 converts an audio signal transferred through a cord into a sound signal to be output. The structure of the electroacoustic transducer 110 may be same as that used for a typical, conventional earphone. That is, the electroacoustic transducer 110 may have the same structure as the conventional electroacoustic transducer 10 described with respect to FIGS. 1 and 2 . The electroacoustic transducer may also be any type of sound element known to those of skill in the relevant art. [0068] The housing 120 is divided into a first body 120 a , a second body 120 b , and a third body 120 c . The first body 120 a covers the electroacoustic transducer 110 and has a shape corresponding to the electroacoustic transducer 110 . The second body 120 b extends outwardly from the first body 120 a . The third body 120 c extends downwardly from the first body 120 a. [0069] As illustrated in FIGS. 4B and 5 , the housing 120 includes a sound output unit 120 d that outputs the sound from the electroacoustic transducer 110 into the external auditory meatus L. The sound output unit 120 d is located at a protruding tip of the second body 120 b . The second body 120 b extends forward from the electroacoustic transducer 110 to form an internal space 122 . Sound is output into the external auditory meatus L through the sound output unit 120 d , as indicated by arrows in FIG. 4B . When wearing the earphone in an ear, a base side S 1 of the second body 120 b faces a side of the cavum concha F so that they contact each other. For this purpose, as illustrated in FIGS. 4B and 5 , the sound output unit 120 d is located at one side of the base side S 1 . With this construction, the electroacoustic transducer 110 is almost vertical, i.e., at an angle of 90±10°, with respect to the side of the cavum concha F. The direction that the sound is output from the electroacoustic transducer 110 is at an angle of about 90° with respect to the external auditory meatus L. As illustrated in FIG. 4B , the direction of the sound output from the electroacoustic transducer 110 is changed, as indicated by the arrows, so that it transmitted to the entrance of the external auditory meatus L. [0070] As illustrated in FIG. 4C , the third body 120 c extends downwardly from the first body 120 a . A cord 140 is connected to the electroacoustic transducer 110 and passes through the inside of the third body 120 c . A bushing member 141 made of, for example, a rubber material, is disposed on the outside of the third body 120 c. [0071] As illustrated in FIGS. 4B and 4C , a first space 121 and a second space 122 are provided within the housing 120 . The first space 121 is provided in the rear of the electroacoustic transducer 110 , and the second space 122 is provided in the front of electroacoustic transducer 110 . The second space 122 is larger than the first space 121 and transmits the sound output from the electroacoustic transducer 110 to the sound output unit 120 d. [0072] As illustrated in FIGS. 4B and 6 , a rear opening 124 a is located at the rear of the housing 120 . The rear opening 124 a operatively connects the first space 121 to the outside. The rear opening 124 a controls the treble response (i.e., higher frequencies) of the sound that is output from the electroacoustic transducer 110 . The treble characteristics may be changed by varying the number and size of the rear opening 124 a. [0073] As illustrated in FIGS. 4A and 4B , a front opening 123 a is formed in the front of the housing 120 . The front opening 123 a operatively connects the second space 122 to the outside. The front opening 123 a controls the bass response (i.e., lower frequencies). The bass characteristics may be changed by varying the number and size of the front opening 123 a. [0074] A covering 151 , such as a nonwoven fabric, is provided at a portion corresponding to the rear opening 124 a inside the first space 121 of the housing 120 . [0075] As illustrated in FIGS. 4A and 4B , a decorative plate 153 may be combined with a front outer side of the housing 120 . The decorative plate 153 includes holes 153 a corresponding to the front opening 123 a. [0076] As illustrated in FIG. 4C , the first space 121 of the housing 120 is formed to be operatively connected to a cord hole 141 a of the bushing member 141 . Thus, the treble frequencies generated in the rear of the electroacoustic transducer 110 may be controlled by both the hole 141 a of the bushing member 141 connected by the cord 140 and the rear opening 124 a , as discussed above. [0077] The cover 130 covers a part of the housing 120 , i.e., the protruding portion of the second body 120 b . The cover 130 may be made of a flexible material, for example, rubber, so that it is easily placed on or removed from the housing 130 . Accordingly, even though the cover 130 contacts a user's ear for a long time, it does not cause discomfort and prevents the earphone from sliding down. The cover 130 includes an exit 131 corresponding to the sound output unit 120 d . The exit 131 is spaced apart from the sound output unit 120 d , by a predetermined distance. The shape of the exit 131 for introducing the sound from the sound input unit 120 d to the external auditory meatus L corresponds to the shape of the entrance of the external auditory meatus L. Since the cover 130 is made of the flexible material, the exit 131 will conform to the different shapes user's ears. As a result, even though the earphone is worn for a long time, a user experiences no discomfort. As illustrated in FIG. 7 , when the earphone 100 is worn in the ear E, the cover 130 is supported by the tragus G, the anti-tragus H and the intertragic notch I and also contacts the side of the cavum concha F. [0078] The housing 120 further includes a supporting protrusion 120 e formed on the outside of the second body 120 b . The supporting protrusion 120 e has a protruding shape that corresponds to the shape of the intertragic notch I. When the earphone 100 is worn in the ear E, the supporting protrusion 120 e contacts the intertragic notch I so that the protrusion 120 e is stably supported. [0079] In the above description, the housing 100 in accordance with the exemplary embodiment of the present invention is described with respect to the outer shape. The housing 100 may also be described with respect to other aspects, such as its construction. That is, as illustrated in FIG. 4C , the housing 120 may be divided into a front housing 123 and a rear housing 124 between which the electroacoustic transducer 110 is located. When the housings 123 and 124 are connected together, they form the housing 120 having the previously described first, second and third bodies 120 a , 120 b and 120 c. [0080] As illustrated in FIG. 4B , the front housing 123 includes a front wall 123 b and a protruding extension wall 123 c . The front wall 123 b is at a predetermined angle with respect to the front of the electroacoustic transducer 110 . The protruding extension wall 123 c extends from the front wall 123 b to the sound output unit 120 d . The protruding extension wall 123 c forms the sound output unit 120 d and the second body 120 b , together with a base wall 124 c of the rear housing 124 , which will be described below. The front opening 123 a is located on the front wall 123 b. [0081] The rear housing 124 includes a rear wall 124 b and a base wall 124 c . The rear wall 124 b surrounds the rear of the electroacoustic transducer 110 . The base wall 124 c extends, in a predetermined shape, from the rear wall 124 b and is combined with the protruding extension wall 123 c of the front housing 123 . The base wall 124 c is almost parallel to the side of the cavum concha F. The base wall 124 c is at an angle of about 90±10° with the electroacoustic transducer 110 . Thus, the electroacoustic transducer 110 is placed at an angle of about 90±10°, preferably, at an angle of 90° with the side of the cavum concha F. The base wall 124 c is secured against the side of the cavum concha F. [0082] When the earphone 100 in accordance with the exemplary embodiment of the present invention, which has the above-described constitution, is worn in the ear E, the electroacoustic transducer 110 is almost perpendicular to the side of the cavum concha F, as illustrated in FIGS. 4B and 7 . Due to such a structure, the front opening 123 a and the rear opening 124 a are neither covered by nor contacted by the ear E even though the earphone 100 is worn in the ear E. Thus, it is possible to control excessive increases in bass tones generated by the electroacoustic transducer 110 . [0083] Further, the second space 122 may be designed to be larger than a corresponding space in conventional earphones, according to the position of the electroacoustic transducer 110 . Thus, since a sufficient resonance space is secured in the space from the electroacoustic transducer 110 to the sound output unit 120 d , the bass response is increased and improved. As illustrated in FIG. 8 , the results of experimental testing using the earphone 100 in accordance with the exemplary embodiments of the present invention show that the bass response of the earphone 100 is improved in comparison to a conventional earphone. [0084] Further, since the electroacoustic transducer 110 is substantially perpendicular to the side of the cavum concha F, the second space 122 is less restricted in space. Thus, it is possible to form the shape of the second space 122 , i.e., the second body 120 b , to correspond to the shape of the ear E, thereby improving the comfort when wearing the earphone. [0085] As described above, in accordance with the earphone of the present invention, when the earphone is worn in the ear, the electroacoustic transducer is substantially perpendicular to the side of the cavum concha. Consequently, the openings located at the front and rear of the earphone are not blocked by an ear, thereby effectively controlling the treble and bass frequency responses. [0086] Furthermore, the space between the electroacoustic transducer to the sound output unit which reaches the external auditory meatus is larger, compared to a conventional earphone. Consequently, the resonance space is improved, thereby improving the bass response and improving the sound quality. [0087] Furthermore, when the earphone is worn in the ear, a predetermined portion of the earphone, which reaches the external auditory meatus, is freely designed and formed in a shape corresponding to the shape of the ear, thereby improving comfort when wearing the earphone and minimizing discomfort caused by wearing the earphone for a long time. [0088] While the invention has been shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.
An earphone which fits into an ear is disclosed. The earphone includes an electroacoustic transducer for converting an audio signal into sound and a housing for holding the electroacoustic transducer. The housing includes a sound output unit for introducing the sound produced by the electroacoustic transducer into the ear canal of an ear when the housing is placed in the ear. The electroacoustic transducer is oriented so that it the sound in a direction which is transverse to the ear canal of the ear.
7
FIELD OF THE INVENTION [0001] The present invention relates to improvements in devices and process for producing salt from brine and more easily and efficiently collecting the salt crystals, and more particularly to a process which enables salt from a brine to be extracted through a soil zone known as a capillary zone which will enable salt to be extracted with much less energy and much less land area for a given amount of salt to be produced. BACKGROUND OF THE INVENTION [0002] Salt annual world production of 250 million tons is used primarily by the chemical industry (70%), the food industry (10%), road deicing (10%) and (10%) for other uses. The Salt Institute has listed the ways salt is produced as including underground mining of salt deposits, solar evaporation of salt containing water from seas and lakes. In another method known as solution mining, brine is produced underground by pumping water to dissolve salt deposits and then pumping the dissolved brine to the surface or mechanical evaporation where salt is concentrated by any of a number of methods including heating, vacuum, precipitation. Other process steps for all of the above recovery methods may include removal of impurities with recycling of heat for higher efficiency. [0003] In all of the above production methods energy is needed to heat, vacuum, pump, mix, and transport the product, and extensive coastal land is required. Removal of impurities requires either extensive foot print for solar Salinas, which rely on precipitation of undesirable salt constituents and zoological/biological process to reduce organic contaminations. Chemical processing under controlled conditions is required to precipitate and remove undesirable components. These processes require extensive investments, space, and energy and, save properly designed Salinas, tend to be polluting. Coastal areas now being used to evaporate sea water in salt ponds or Salinas are being encroached upon by tourism and urban development making the land too expensive for salt production. [0004] The high cost of energy could be lowered by using renewable energy salt production is still expensive and requires unduly large land areas. Production methods that can achieve high product quality with maximum renewable energy and a smaller footprint, will have a more competitive edge and are more environmentally acceptable. [0005] Where a pond or other holding body is used the sealing of the bottom of the pond is expensive, and the harvesting operation always produces some form of wear and tear on the pond bottom, ranging from gravity effects of equipment wear to inadvertent loss of integrity of sealing of the pond bottom. Filling the pond with brine and waiting for sun and wind to remove the water is a process requiring significant time which allows undesirable organic matter to grow and requires costly cleanup. [0006] Production of salt by spraying through enhanced heat exchange has been described in U.S. Pat. No. 6,027,607 which is dependent on the availability and proximity of heat from an industrial plant, a significant limitation. This process may be more properly characterized as a method for spending waste heat than an economic process for the production of salt. Production of salt in a pond, as described by the patent, will also require dredging of the salt deposited in the bottom of the pond, an expensive process. Dredging can also produce colloidal clay particles ingrained into the salt crystals which requires expensive treatment. [0007] Other processes, such as the Grainer process described in U.S. Pat. No. 2,660,236, rely on evaporation of water to concentrate and deposit the salt but the expense of fuel and complexity of exchanging heat and maintenance of piping and pumps end up with an expensive salt and potential failure due to mechanical maintenance problems. [0008] In another process, U.S. Pat. No. 4,334,886 describes concentration of salt based on natural evaporation through recycling of the brine to cascade down a tower and adding salt to assist in crystallization. Even though the process uses natural heat source, it requires erection of a tower and sacrificing part of the salt to concentrate the brine which makes the process inefficient and difficult to automate for collecting. [0009] It is therefore desirable to produce crystalline salt on the surface from efficiently evaporating brine by heat from the sun and wind on soils that may be porus without sealing the underlying surface and building retaining walls to contain the brine while it evaporates. It is also desirable that the crystallization of brine into salt is fast such that biological products are not allowed to form. If undesirable biological products form, they must be removed through expensive, time consuming and extensive land environmentally sensitive processes. SUMMARY OF THE INVENTION [0010] It is possible to use the combination of natural energy sources of the sun and wind to evaporate water from brine, in combination with the capillary forces of the soil and crystalline salt to “grow” a salt layer by capillary action. The method, equipment and instrumentation preferably involves spraying the brine into the atmosphere over a brine field in such a way as to cause the formation of a capillary layer. As will be shown, the capillary layer is maintained in different ways in different soil conditions. [0011] By spraying, the operator can minimize the droplet size and can also increase the residence time so that the brine droplet is suspended in the air for a longer period of time such that evaporation is increased significantly. In some cases, the brine crystallizes while it is in the air and falls to the ground as white crystalline salt. This is mainly expected to happen significantly during the hottest and windiest part of the day and for concentrated brine. [0012] When spraying of brine ceases, any brine which has seeped below the surface and is no longer in contact with the sun or wind may be brought up to the surface by capillary action. It is therefore advantageous to take advantage of this natural process, which arises from the surface tension of a capillary of liquid within the soil or crystalline salt vertical pore column. In order for the capillary rise to take place most effectively, it is important to stop the spraying when the brine horizontal boundary within the soil is not substantially lower than the lower boundary of the capillary zone. This method uses minimal energy to lift the brine up to the soil surface for it to crystallize into solid salt and allows the mechanical harvesting of the salt to be carried away in a dump truck. Spraying devices are described to achieve additional benefits such as piling of salt and curing it. [0013] It has been observed in hot and dry climates and in many commonly encountered desert soils that the conditions for high quality and lower cost salt production may be achieved through natural processes that create sabkhas which, according to Warren, John K. in his book entitled Evaporites: Sediments, Resources and Hydrocarbons, Springer 2006) are salt flats with crystalline salt on the surface. Saturated underground brine within the capillary zones of sabkhas is the source of this deposited salt which has been lifted by capillary action to the surface to crystallize upon exposure to sun and wind. [0014] A combination of elements in which the underground brine may be pumped and sprayed on the soil surface and the excess liquid brine is retained within the capillary zone using the appropriate instrumentation will produce crystalline salt economically and make it available to traditional collection and washing process eliminating much of the additional processing, costs and large land area that current methods employ. [0015] Most desert countries are scarcely populated and, where countries have substantial coastlines with nearby salt flats or sabkhas, substantial high quality salt could be produced at substantially lower cost than by current systems if the current process that naturally produce salt on the surface are used to grow the salt on the surface for harvesting. Salts on the surface of a sabkha has been lately shown to result not from marine or continental flooding but from deeply circulated resurging continental underground saline water through capillary action (Warren). [0016] As will be shown in more detail, the control of the level of a capillary zone which can be placed in communication with an upper surface can provide a method whereby a salt layer can be “grown” at the surface as an upper layer which can be much more easily scraped or sliced off than in having to form an impermeable pit. Further, the surface harvesting can be performed without disrupting the salt production operations in adjacent areas. [0017] It is because the salt collects at ground surface that it can be more easily collected and at a higher purity and with greater ease than a pit operation. Further, whereas pit operations are somewhat batch operated, the system and method of the invention enables a more continuous operation which promotes constant, generally uninterrupted growth and harvesting. The top layer of a unit area can be scraped off and as soon as the scraping device is completed, possibly in less than an hour, the growth process can continue. [0018] It is typical in deep salt mining for brine to be pumped from a well commonly used to inject water into a salt layer hundreds or thousands of feet below ground to produce brine which is then pumped to the surface and crystallized by the process of the invention herein). The key to operations, of producing salt is spraying the brine on the surface of any soil and what is not crystallized in the air is held in the capillary zone upon termination of spraying and can migrate upward to further crystallize more salt. [0019] The invention contemplates the creation and maintenance of a brine “capillary zone” between the ground surface and the underground strata. The creation of this zone is performed by insuring that the crystalline salt loading of soil material extending between the surface and the brine layer presents a sufficiently small porosity to enable brine to be continuously wicked upward toward the surface to be evaporated and deposited as crystalline salt it. [0020] The creation of the brine capillary zone is begun by starting a concentrated salt layer at the top surface by spraying brine into smaller droplets which will form a crystalline cap. The higher salt gradient at the top will help wick the brine through an established brine capillary layer by both capillary action and tendency of the brine to travel into the most concentrated crystalline salt layer which will exist at the surface. [0021] At the very beginning of the process, any excess brine which is sprayed onto the top surface will seep into the ground through the uppermost concentrated crystalline layer. As it seeps through the ground (regardless of the ground material) it will set up a gradient which ranges from a crystalline concentrated level at the surface to a brine level at the point it reaches the lowermost brine layer. Once this is established, the brine will begin to be wicked toward the surface. On its way to the very top most surface it becomes more and more concentrated while it carries dissolved salt upward to the surface crystallizing as the solubility of the salt is exceeded. [0022] Salt transported into and through the surface layer will be deposited at the surface in the form of sun and wind dried crystalline salt. As the upper crust continues to dry through the action of wind and sun, more and more salt will be transported to the surface. In the end, the salt at the surface will have some combination of origin, either originating by being sprayed on, or originating by being drawn through the surface. [0023] At the beginning of the operation, when the capillary zone is being established, nearly all of the salt at the surface will come from spraying. At the surface, some of the spraying will result in a thin layer of salt at the surface, while some brine will soak through the upper salt layer and into the ground. The initial brine from the surface begins to set up a salt gradient extending into the soil media. A gradient of more salt near the top of the soil media to less salt in the deeper media is created. As more and more highly concentrated brine begins to move past the top crystalline salt layer a capillary structure begins to be formed. The capillary structure forms due to the salt concentration forming, in combination with the soil media, a path through which brine could be wicked upward. [0024] Where this zone simply ends due to concentrated brine no longer having the ability to build an appropriate capillary passage, no wicking occurs. However, as more and more brine passes through the concentrated crystalline salt at the surface layer and passes through what are effective diameter or void space capillary areas, more and more salt is deposited within the soil media to further and further extend the effective depth of a zone having an effective void space which is capable of capillary action were it to come into contact with a liquid which would be incapable of dissolving the layer, such as brine. [0025] So, as may be seen, the process of forming this “capillary layer” continues so long as brine is continued to be introduced. The result is a layer which has very salt laden deposits near the top and possibly lesser salt laden deposits and possibly a slightly larger effective capillary cross sectional layer farther into the soil media as you proceed farther into the soil media. As more concentrated brine seeps through from the top, more salt is deposited which reduces the effective cross sectional capillary cross section further down in the layers of soil media. [0026] Another way of looking at the process is that a wetted salt and soil media bridge is established which has the ability to draw brine upwardly. Where the upper surface is no longer sprayed with brine, water evaporation of the upper crystals will draw bring upward through the salt and soil capillary zone to the surface. At the surface, the water evaporates and leaves crystalline salt. This upper layer will continue to “grow” as it brings more and more brine through the capillary zone of the soil media. [0027] Without the controlling process of the invention, the surface brine might typically flow through the soil and into the pool of brine existing at the sub surface level. It is the control of the invention which promotes the building of a continuous gradient capillary zone which is capable of bringing salt upwardly through the soil from a brine level which is close enough to be wicked to the surface, depending upon the type of soil and other factors. An impermeable base is not a requirement and as has been stated, in non-sabkha applications any underground soil matrix can be used as a capillary zone for storing and then retrieving brine in the production of crystalline salt. [0028] The invention can be set up in a wide variety of soil types which have different brine levels. The ability to create and maintain the capillary zones will depend upon both the above factors (soil and brine level) as well the ability to react to those factors using sensors and the like. For example, where the brine level is near the upper surface, the depth of a working capillary zone will necessarily be thin. As another example, where the soil is of a clay consistency, very little salt accumulation will be needed to maintain a capillary zone as the soil interspacing. In a sandy soil, significant salt loading is needed to reduce the effective cross sectional area to create a capillary zone. [0029] For example, spraying can be done, either continuously or intermittently, until the capillary zone is set up. Once the capillary zone is set up, spraying can be reduced (so long as the capillary zone is maintained) to force quite a bit more of the brine to come to the surface through the ground matrix. The rate of spraying is done in accord with a number of factors, including how much sunlight is present, whether the season is winter or summer, whether rain has occurred, the depth and vertical thickness of the capillary zone. [0030] In addition, the inventive method is subject to the ability to change operation depending upon any immediate production needs. For example, where production is needed to be quickly increased, the spraying rate can be increased, along with controlling other factors such as aerosol size control through piezoelectric actuation of the end of the sprayer, as well as gross pressure input to produce a finer spray, as well as the night and day spraying rate. The mode of operation can be adjusted this way increase production at a smaller droplet size to insure that salt crystals fall onto the top layer and that minimal or no brine soaks through the surface layer. This mode of operation will likely represent an increase in input energy. Even where production is to slightly increase, the continued sun and wind drying of the upper layer can will still contribute to the wicking of salt laden brine through the ground layer so long at there is no net brine soaking through the upper crystalline layer. [0031] The sun and wind change the brine from liquid to solid and indirectly contribute to the capillary action created by the crystallization of salt. The upward movement of the brine is a capillary natural process resulting from the force between the brine in the pore space column of the soil and the solid phase, the smaller the effective diameter of the column, the higher the brine will travel upward. [0032] The capillary zone can be controlled by how much spraying is done in conjunction with the type of soil matrix present. Oven though desert soils tend to be sandy with apparent limited vertical gradient capillary zone, it has been shown that high content of calcium carbonates, a common occurrence in desert soils, increases the water holding capacity considerably which contributes to a more significant moisture content in the capillary zone. The result is a naturally wetted increased vertical expanse of capillary zone. The increased water holding capacity in the top (or any level) soil horizon acts to replenish evaporation from the surface with fresh brine from the underground water table. Any brine pulled through the soil horizon is replaced by brine from adjacent areas in a slow manner. In essence, the presence of high content of calcium carbonates vertically expands the vertical height of the capillary zone over what such vertical height would have been with simply sand and brine (forming a concentration gradient) alone. Thus, the calcium carbonates act with soil layers to produce a more finely divided soil and thus present a lesser cross sectional area to increased capillary action with less crystalline salt loading within the layer. [0033] Many salt flat locations in deserts have brine near the surface which could be pumped; sprayed and excess brine is stored by wetting the capillary zone, except for occasional leaching to remove bitterns. Brine in the capillary zone migrates upward after spraying stops, causing more salt to be pulled up and crystallize at or near the top soil layer. [0034] Scarcity of rainfall and low porous flat land where the underground water table is very close to the surface and is in communication with sea water during high and low tide cycles produces brine that is concentrated to the level close to sodium chloride crystallization. The problem is that the soil is often sandy with high infiltration rate. Traditionally such high infiltration rate is minimized by sealing the surface and boundaries with clay, lining, rock and concrete barriers to contain the brine and minimize downward and lateral seepage when flooding the soil. Sea water is pumped and is allowed to cascade in series of evaporation ponds, retained on the surface by the artificial impervious layer and walls, ending up in crystallizer ponds where it is collected. Extensive land, leveling, pumping and operation and maintenance are required to establish and operate such a system. [0035] The configuration of the above mechanisms do not exist in a vacuum. One of the main purposes of this invention is to produce high quality salt for the lowest competitive cost by utilizing brine that is concentrated by renewable energy of sun and wind and the capillary action of the soil and crystallized salt. Brine which is sprayed in natural sun and wind and at a rate to assist in evaporating its water and cause it to crystallize on the surface of the ground and that which seeps to the ground is brought up to the surface by capillary action for crystallization provides a competitive alternative to current high energy, large footprint and expensive methods. [0036] A second purpose is to use brine capillary rise within the soil or salt capillary zone to enhance crystallization and reduce dilution of already crystallized salt. A third purpose is using the brine capillary rise phenomena instead of sealing the surface and boundaries to reduce costs and expand the type of soils that can be used for brine evaporation. A fourth purpose is to crystallize the salt on the soil surface in order to harvest it with traditional salt harvesting and transport equipment, at high ease and low cost. A fifth objective is to produce very high quality salt by filtering the brine before it is sprayed to remove organic and crystallizing it quickly to arrest growth of organic contaminants. A sixth objective is to crystallize the salt on the soil surface so that it is possible to periodically wash it with excess brine to remove magnesium and potassium salts that are in solution after the salt has crystallized. A seventh purpose is to produce salt of different crystal size where small crystals can be obtained by harvesting early after crystallization and larger crystals through delayed harvesting. An eighth objective is to save on energy, manpower, production management, and heavy equipment use to make the operation much easier on labor. A ninth purpose is to minimize capital investment to further impact the market availability for and price of salt. A tenth objective is to substantially reduce the footprint of the production area to save on initial land costs and on subsequent reclamation costs. An eleventh purpose is to use sprayers on towers in order to pile the crystallizing salt around the tower and save on stacking. A twelfths objective is to use wind machines to evaporate the brine while being sprayed in ambient air during calm days. A thirteenth purpose is to enable a salt production system which will facilitate the use of renewable energy for pumping, evaporation and crystallization. A further purpose is to provide means of matching the quantity of sprayed brine with the heat input of the environment and the capillary zone brine holding capacity to minimize seepage and dilution. BRIEF DESCRIPTION OF THE DRAWINGS [0037] The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: [0038] FIG. 1 is a schematic view of one embodiment in which the inventive system and components may be employed, and emphasizing a pop up sprinkler system shown in operation; [0039] FIG. 2 is a schematic view as seen in FIG. 1 , but with the sprinkler not in operation and emphasizing the layers underneath the ground level and the formation of the capillary zone along with the initial growth of the upper salt layer; [0040] FIG. 3 is a schematic view as seen in FIG. 2 , and emphasizing the continued growth of the upper salt layer along with a showing that the surface crystalline salt layer becomes part of the capillary zone; and [0041] FIG. 4 is a schematic view as seen in FIG. 3 , and emphasizing the continued growth of the upper salt layer along with a showing that the surface crystalline salt layer becomes an increasing part of the capillary zone. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0042] A description with the aid of schematics will be of assistance in fleshing out the further possibilities and illustrating the advantages of the inventive components and steps herein. Referring to FIG. 1 , a sectional schematic looking into a sectional view of the ground of a potential configuration in which the system and process of the invention may be used. In this particular example, a central spray configuration will be shown, although any number of land and spray configurations can be used. [0043] It is known to have circular fields and rectangular fields with a wide variety of watering and spraying mechanisms. In a round field, a spraying mechanism may be centrally located or it may be made of a linear rotational spraying mechanism which circles a round field like the second hand on a clock. A rectangular field can have a similarly moving line of sprinklers along its length. Any number of configurations are possible. [0044] Ideally a salt brine production system 19 on a sabkha will be located on a salt flat with a brine water table located one, two or three feet from a ground surface 21 . A soil matrix 23 extends downward beneath the ground surface 21 to an effective lower level 25 . Soil matrix 23 can be any type of water permeable soil through which water may pass and may include soil with fine particulate matter as well as non-homogeneous components. A brine level 27 will ideally exist underneath the ground surface and overlies the effective lower level 25 . [0045] The effective lower level 25 can be due to an impermeable layer or in the case of a very deep strata, can extend downwardly for a long distance. This effective lower level is shown to emphasize that any brine which is removed will be expected to be replaced laterally, and that there should be no significant areas where the lower level 25 is above the top of the brine level 27 . In Such a case, a capillary zone would either be extremely difficult to create and maintain, or it would have to be effectively lateral or slanted and thus effectively longer and difficult or impossible to maintain. [0046] In normal circumstances, and before the components of the invention are installed and before the process of the invention is practiced, any rain reaching ground surface 21 , simply washes through the soil matrix 23 before reaching the brine level 27 . Over time, mixing in the brine level 27 will maintain the salt strength of the brine in the brine level 27 . The soil matrix 27 can range in particulate size from clay to sand. Crystalline salt loading in a soil matrix 23 necessary to form a capillary effective cross section will be higher for sand than for clay. In some instances, such as clay, the soil matrix 23 may already be in a condition to begin wicking brine to the ground surface 21 . [0047] In order to have a supply of brine to begin to spray on top of the ground surface 21 , it may be preferable to form a well 31 or to draw from an open pond or trench. The important aspect is to have a source of free liquid brine from which pumping can freely occur. The liquid capacitance of the source of free liquid bring should ideally be able to provide a significant volume of brine throughout a sustained pumping operation. [0048] A pump 35 is in liquid contact with the brine, and as shown here extends slightly below the brine level 27 so that it has access to a brine pool or other free liquid brine volume 37 . The pump 35 is in fluid communication with a sprinkler 39 which can be a pop-up sprinkler which has the ability to achieve a high level during operation, but drop back below the ground surface 21 when not in use. Sprinkler 39 can be quite high to increase the residence time in the sun and wind before droplets of brine strike the ground surface 21 . This mechanism will insure that the ground surface 21 will be accessible by scraping machinery once a layer of crystalline salt is built up. A pop-up mechanism reduces the probability that any harvesting equipment might damage the sprinkler 39 if it were left in the up position. [0049] The sprinkler 39 has an atomizing sprinkler head 41 which can preferably produce droplets of any size and can project droplets over any portion of the ground surface 21 within an effective portion of the salt brine production system 19 . Much of the effectiveness of the sprinkler head 41 can be achieved with a piezo electric element which can add atomizing energy to any brine pumped from the brine pool or volume 37 by the pump 35 . This system need not depend solely upon gross liquid pressure in order to operate. Further, the atomizing sprinkler head 41 can be directional and need not have to produce an effective stream 45 in all directions at once. Further, with piezo electric control the atomized droplets of brine can be directed near or far, depending upon the even-ness of coverage in a line to be produced from the sprinkler head 41 . In much more advanced control systems, the wind direction, represented by the arrow 49 can be fed into a control system so that the effective streams 45 will not be unevenly distributed. [0050] With the wind directions shown in FIG. 1 , the sprinkler head 41 would fire an effective stream 45 to the left with more velocity than one to the right, in order to achieve even coverage. A good system would also take to account other aspects of the environment, including the presence of direct sun 51 , temperature of the surrounding air, as well as humidity. In addition, reaction to the wind can not only be had through sprinkler head 41 and its directional and adjustable force firing mechanism, but air movement devices such as fan 55 can be used to help dry either streams 45 of falling brine droplets, or to combat the wind movement in any direction or to produce a more even coverage of the brine droplets. [0051] Shown at the left is a sensor/controller 57 which may operate a series of moisture sensors 59 which will be able to sense moisture, perhaps even to the extent of determining the brine level 27 as well as the moisture in the soil matrix 23 between the brine level 27 and the surface 21 . Thus, the sensor/controller 57 and series of moisture sensors 59 can be used to indicate the rising water content and location of that content in the soil matrix 23 . This signal can be used to control the spray, and can indicate whether the operation is one of buildup or of growing salt at the surface 21 . The sensor/controller 57 and series of moisture sensors 59 can enable fully automatic operation. The sensor/controller 57 is shown as being operatively connected to the pump 35 . The sensors are shown to the side for convenience of illustration, but it is expected that a sensor set might be completely buried with perhaps only a controller box located above ground surface 21 in a safe location. Temperature and humidity sensors may preferably be co-located within the sensor/controller 57 , and it may also control the fans 55 (only one of which is shown). Again, the provision of a flat clear ground surface 21 will contribute to harvesting. [0052] The method to produce salt by the salt brine production system 19 herein may benefit from further instrumentation to control the flow of brine to within the boundaries of heat of evaporation and the holding capacity of the capillary zone of the soil and or crystalline salt. As the seasons change the amount of heat from the sun and wind also change. Other sensors imbedded in the capillary zone measure its brine holding capacity and measurements of evaporation from an evaporation pan through well known formulae and available software, provide the necessary information to activate the pump and spray system in order to optimize evaporation and capillary rise without excess brine discharge. [0053] To start operations, the sprinkler head sensor/controller 57 starts the sprinkler 39 to begin producing a spray which is calculated to begin to deposit crystalline salt, as well as some droplets of very concentrated brine which are intended to begin to only slightly seep through the top crystalline layer initially set down upon the ground surface 21 . Where the controls and atomization enable it, and where the conditions support it, it would be preferable to first deposit a very thin layer of crystalline salt for subsequent small droplets of brine to filter through. Proceeding in this way sets up the initial gradient and expands the gradient. If only liquid brine is sprayed directly into the soil matrix 23 , without the possibility of crystalline salt being formed atop the ground surface 21 , and depending on the porosity of the soil matrix 23 , a salt pore gradient might not be able to be set up, or might not be as rapidly set up. If complete controllability is possible, a thin layer of crystalline salt should be applied by high atomization before larger droplets of brine are provided for soaking through it. Depending upon the conditions the spray may have to be so intermittent as to allow each micro-layer applied to the ground surface 21 to completely dry before each subsequent layer is applied and prior to generating particles of brine of sufficient size to begin to soak through a layer atop the ground surface 21 . [0054] Referring to FIG. 2 , a view is seen similar to FIG. 1 , but eliminating a view of the sensor/controller 57 and series of moisture sensors 59 , the sun 51 and wind 49 , as well as deployment of the sprinkler 39 for space saving and clarity of the other features. The remainder of the showing is based upon illustrating how a capillary zone is set up and exploited. FIG. 2 represents an accurate view of what may be observed most of the time, as sprinkling is expected to be intermittent. FIG. 2 illustrates the buildup of a thin layer of crystalline salt 61 atop the ground surface 21 . Additional droplets of brine are introduced which filter through the thin layer of crystalline salt 61 and begin to seep into the soil matrix 23 . The brine which has seeped through the thin layer of crystalline salt 61 has only reached a point slightly below the ground surface 21 to form a capillary zone 63 . The bottom of the capillary zone 63 can represent salt which came out of solution due to dryer layers of soil below the capillary zone 63 , for example. The bottom of the capillary zone 63 is not in contact with any wet layer or brine and thus no capillary action is taking place. However, since the capillary zone 63 was formed slowly, it is a gradient with the uppermost layers being most heavily laden with salt and the bottom layers possibly less so. The bottom of the capillary zone 63 has not yet reached the brine level 27 . [0055] Referring to FIG. 3 , a view is seen similar to FIG. 2 , illustrates an expanded capillary zone 63 which has continued to build. The layer of crystalline salt 61 is not so thin, but has been allowed to build up. This need not be the case. The layer of crystalline salt 61 can be maintained at a thin level until the capillary zone 63 can expand sufficiently to make wetted contact with the brine level 27 . As soon as wetting contact is had (or as much as the even contact can be either sensed or approximated based upon a knowledge of soil permeability and size), the mode of operation is changed from a mode where the capillary zone 63 is being “set up” to a mode of operation where the spraying is severely reduced. [0056] Once wetted contact of the capillary zone 63 is made with the brine level 27 , reduced spraying enables a “dryness” gradient to be set up in which the sun 51 and wind 49 are allowed to continue to enable the layer of crystalline salt 61 to dry as much as possible consistent with the production objectives. The dryness at the top of the layer of crystalline salt 61 will create a moisture gradient vertically throughout the capillary zone 63 which will pull brine from the brine level 27 upward and through the capillary zone 63 and to the ground surface 21 . [0057] At the point before the capillary zone 63 can expand sufficiently to make wetted contact with the brine level 27 , all of the layer of crystalline salt 61 will have come from spraying. Once the capillary zone 63 is enabled to bring brine through the soil matrix 23 , additional growth of the layer of crystalline salt 61 will come from brine which has been drawn through the capillary zone 63 and into the layer of crystalline salt 61 . Without further spraying, increases in the crystalline salt 61 will come from below. Brine which is drawn through the soil matrix and into the layer of crystalline salt 61 will be deposited into the layer of crystalline salt 61 . The layer of crystalline salt 61 may grow from the bottom, through the top or by vertical expansion. Much may depend upon whether the layer of crystalline salt 61 is compacted, and how rapidly it is formed. Rapid formation very likely encourages a light fluffy consistency which can produce greater drying by the wind and sun due to the expanded surface area presented at the top layer. [0058] Further operations can be controlled by either spraying or not spraying. Where no further spraying is performed, the layer of crystalline salt 61 simply grows in thickness over time to the extent its moisture content is replenished from brine spraying and evaporation is allowed to continue. For harvesting, small bulldozers or other mechanical scrapers are able to skim the surface of the layer of crystalline salt 61 . In some cases scraping may be by a suspended blade mechanism to help prevent overall random compaction of the layer of crystalline salt 61 . Where the layer of crystalline salt 61 is compacted, it will not function as efficiently as a low density growth layer. Blades, scrapers and other devices can be suspended as by a scraper bucket and drag line to eliminate compaction from supporting the equipment. In other cases, defined areas can be designated for compaction, such as designated tire or tread areas, to free the other areas for low density layer of crystalline salt 61 growth. Where a circular field is used, a harvester can be periodically run about the center point much like the second hand on a clock. This type of fixed operation harvesting can slice or vacuum the top of the layer of crystalline salt 61 to keep it fluffy and of low density. [0059] As mentioned earlier, further spraying can be limited to that which will not impact the moisture at the top of the layer of crystalline salt 61 , such as spraying to create droplets so small that they dry in the wind to crystalline form before they reach the top of the layer of crystalline salt 61 . It is clear that further spraying will be energy intensive, whereas growth of the layer of crystalline salt 61 solely from brine drawn through the capillary zone 63 will be passive and drawn through the action of wind 49 and sun 51 alone. As a result, the production can be optimized for slow inexpensive production, high cost high production, or a mixture of the two. [0060] The process can work well in open areas. In the event of rain, especially during set up of the capillary zone 63 , the spraying operation is simply suspended for a sufficient time to allow the rain which soaked through the layer of crystalline salt 61 to “back dry”. In the alternative, if there is enough layer of crystalline salt 61 present to not have a break through dissolution, spraying could be accomplished in the same manner as the initial establishment of the layer of crystalline salt 61 , with the assumption that any rain which was filtered through the layer of crystalline salt 61 was completely saturated and laden with salt to the same extent as would be the case had penetrating brine been sprayed. The boundaries of the production field may be protected from flooding by levies. [0061] FIG. 3 illustrates a case where the brine layer is deeper and where the capillary zone 63 was vertically more deep. A deeper capillary zone 63 will translate to a slower salt production through the ground surface 21 . Referring to FIG. 3 , a view of a soil matrix 23 with a brine level which is higher and closer to the ground surface 21 is shown. This is the optimum configuration for a higher rate of salt production through the ground surface 21 . The system of the invention performs best in areas with a brine level which is nearer the ground surface 21 . However, more finely divided soil, such as fine clay could result in a slower production rate. [0062] There are other considerations in locating a production facility of the salt brine production system 19 . Desirable brines should have salt concentration close to that at which sodium chloride crystallizes. Salts that are more soluble than sodium chloride are already precipitated and crystallized. A simple filter can be used in the spraying system to removes organic matter and insure that the layer of crystalline salt 61 is not contaminated and has no impediment to being low density, fluffy and moisture transmissive. Pumps 35 specially made to pump brine are used. The spray system could be selected from a number of spraying system including center pivot, lateral, spray gun and fixed systems made from plastic, polypropylene and PVC or similar low cost salt resistant materials. The design of the salt brine production system 19 is topologically analogous in area and material movement to an irrigation system except that the intent is to vaporize water. The water holding capacity is that determined by the capillary zone and the degree to which moisture is restricted on the wetted surface of the layer of crystalline salt 61 and the wetted distance from the ground surface 21 to the lower limit of capillary zone. [0063] As the surface of the layer of crystalline salt 61 the heat impacting the surface creates suction and the capillary action lifts the brine in the capillary zone 63 to the surface where it is evaporated and its salt is deposited and crystallized. The same capillary process takes place in the soil matrix 23 . The combination of spraying the brine, wetting the capillary zone 63 of the soil and or the salt of the layer of crystalline salt 61 on the surface coupled with heat from the sun 51 and wind 49 results in the growth of a salt layer which could be collected by salt harvesting equipment. It may be preferable to allow harvesting of only the uppermost portion of the layer of crystalline salt 61 to insure that the collected product is dryer. This may involve more frequent harvesting of lesser amounts of the layer of crystalline salt 61 to insure an immediately dryer product. [0064] Salt collection may also be limited to a schedule where the layer of crystalline salt 61 has grown to a depth of 50 or more centimeters such that the harvester scrapes the top 20 or more centimeters leaving a salt pad of from about 10 to 30 cm to insure that the soil from the ground surface 21 is not scraped with the salt collected in the harvesting process. Much may therefore depend upon product needs and harvesting equipment capability. Different industries require different crystal size salt. Finer crystals are produced if harvesting takes place in a short time after salt crystallization. Larger crystal size is produced from leaving the salt for a longer period of time as this will allow the crystals to grow and infuse into each other. [0065] Depending on the size and shape of the fields, there are many ways of spraying the brine. The primary ways are either stationary or mobile. A stationary sparing system includes fixed structures such as a network of pipes, valves and sprayers. The sprayers could be pop-up type which is recessed below surface level when not spraying so as not to interfere with harvesting equipment. Sprayers attached to risers will require the risers removed temporarily for harvesting. Other types of stationary spray systems are towers that may be as high as 10 meters, with sprayers radially attached at the top, to a pressurized main brine feed line. Such towers may include wind machines as used in the fruit trees frost protection industry. The tower will need a shield around it inclosing the service ladder with enough space for a service person to go up the ladder to maintain the sprayers, fans and gears. A canopy that protects the entrance to the shielded ladder provides access to the tower. Such stationery tower systems will deposit the salt in a conical shape if no fans are used. Such a shape may be advantageous as a piling method. A loader loads the salt from the pile or stack to a dump truck for transport. Mobile spraying systems include center pivot irrigation systems where a large pipe that may be half a mile long, supported by a truss and gear driven tires, pivots around its center where the brine is feed. The same system may be used but move laterally rather than in a circle, where the brine is feed from an underground pipe with risers or more simply from a canal on either the side or the middle of the lateral spray system. Other moving spray systems are lateral move and spray gun systems to mention a few. These spray systems may be modified for salt applications by replacing standard steel pipes with corrosion resistant materials, coating or adding a plastic pipe, supported by the structure of the system, with much less diameter since spray systems are designed for irrigation purposes which carry much more flow than brine intended to be sprayed to produce salt. [0066] The salt brine production system 19 uses a fraction of the land area foot print of currently used open salt production systems. Production of one million tons of crystalline salt using the brine capillary salt crystallization system requires less than ten percent of systems that pump sea water into evaporation and crystallization ponds. The method and apparatus described in this invention uses no heavy equipment, other than the harvester and dumb truck, to transport salt to the wash plant compared to conventional mining of solid salt using dredging equipment, excavators, loaders, crushers and screens to prepare the salt for the wash plant. The salt brine production system 19 and process thus described uses limited manpower compared to evaporation and crystallization ground spreading methods or solid salt mining. [0067] While the present invention has been described in terms of a salt brine production system and components used to affect the process of setting up and maintaining a capillary zone in a soil or ground matrix and which may be used with or without a spraying system once the capillary zone is set up, a wide variety of alternate land areas, sprayers, sensors and controllers within the teaching above can be used to make a wide variety of alternate variations thereof. [0068] Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.
This invention relates to a method of crystallization of salt from brine on top of any soil surface through airborne brine droplet crystallization, controlled moisture depth, capillary action and enhanced renewable energy to grow a layer of salt which can be collected. The brine is pumped from an underground source, sprayed in ambient air over a solid surface and, if water is not completely evaporated, allowed to seep through the surface to saturate the capillary zone. Water is evaporated while the sprayed brine is in the air or on the surface where capillary action brings it up to the surface for the water component to be evaporated by net heat gained from the environment resulting in salt crystallization. The evaporation of sprayed brine is enhanced by smaller droplet size, residence time due the spray height and wind machines to reduce humidity and increase natural thermal input. The salt layer thus formed further grows by capillary action of the soil and the crystalline salt to a depth suitable for conventional mechanical harvesting. Instrumentation is included to optimize the method through the measurement of evaporation and moisture content of the lower boundary of the capillary zone of the soil and or crystalline salt.
2
CROSS REFERENCE TO RELATED APPLICATIONS This application claims priority of U.S. Provisional Patent Application Ser. No. 60/238,297, filed on Oct. 6, 2000. TECHNICAL FIELD This invention relates to optical communications, and in particular to a method of optical domain clock signal recovery from high-speed data, which is independent of the data format or the optical signal rate. BACKGROUND OF THE INVENTION Optical fiber networks are in widespread use due to their ability to support high bandwidth connections. The bandwidth of optical fibers runs into gigabits and even terabits. Optical links can thus carry hundreds of thousands of communications channels multiplexed together. One of the fundamental requirements of nodal network elements in optical networks is the capability to extract the line rate clock from the incoming signal. Presently, this is achieved by converting the incoming optical signal into an electrical signal followed by clock extraction using an application specific electronic circuit. As optical networks become increasingly transparent, there is a need to recover the line rate clock from the signal without resorting to Optical-to-Electrical, or O-E-O, conversion of the signal. Future optical networking line systems will incorporate service signals at both 10 Gb/s, 40 Gb/s and much higher data rates, along with the associated Forward Error Corrected (FEC) line rate at each nominal bit rate. The FEC rates associated with, for example, 10 Gb/s optical signal transport include the 64/63 coding for 10 Gb/s Ethernet, the 15/14 encoding of SONET-OC192 FEC, and the strong-FEC rate of 12.25 Gb/s. As these networks tend towards optical transparency, the nodal devices in the optical network must work with any commercially desired line rate, independent of format, whatever that is or may be. Thus, one of the fundamental functions these devices must provide is the capability to extract the clock from an arbitrary optical signal. Moreover, to maintain the high speeds of modern and future data networks, as well as increase efficiency, this clock recovery must be done completely in the optical domain. In future All Optical Networks (AON) the same network element will need to handle both 10 Gb/s and 40 Gb/s. Consequently, the clock recovery in these network elements must be tunable over a wide range of frequencies. Previous embodiments of clock recovery systems are experimental in nature, and relegated to research laboratories. They do not include the possibility of recovering the line rate clock from the various ubiquitous NRZ data formats. Additionally, any tuning of the clock signal is done using a linear phase section. What is therefore needed is an all optical clock recovery system that can operate upon any given optical signal, regardless of its format or bit rate. What is further required is a system that exploits non-linear optical elements to reshape the clock output for optimal retiming of the various data formats. SUMMARY OF THE INVENTION A method and circuit are disclosed for the recovery of the clock signal from an arbitrary optical data signal. The method involves two stages. The first stage consists of a Semiconductor Optical Amplifier—Asymmetric Mach-Zehnder Interferometer, or SOA-AMZI, preprocessor, which is responsible for transforming an incoming NRZ type signal into a pseudo return to zero (“PRZ”) type signal, which has a significant spectral component at the inherent clock rate. This preprocessing stage is followed by a second stage clock recovery circuit. In a preferred embodiment the second stage is implemented via an SOA-MZI circuit (symmetric in structure, i.e., no phase delay introduction in one of the arms) terminated by two Distributed Feedback (DFB) lasers that go into mutual oscillations triggered by the dominant frequency of the first stage's output signal. The SOA-MZI is tuned to adjust the input phase of the oscillatory signal into the DFBs. This provides the tuning and control of the oscillation frequency of the output clock signal. The SOA gain currents can be adjusted to reshape the clock signal, which is the output of the second stage. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 depicts a circuit implementing the method of the present invention; FIG. 2 depicts just the second stage of the circuit of FIG. 1; and FIG. 3 depicts an exemplary semiconductor optical amplifier device used according to the method of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The above described and other problems in the prior art are solved in accordance with the method, apparatus, circuit and devices of the present invention, as will now be described. Most, if not all, optical networks currently operating transmit some or all data as NRZ signals. In the case of the NRZ signal format, the RF spectrum reveals no spectral component at the line rate. This is a simple consequence of the format. The RF spectrum of an ideal NRZ signal looks like the mathematical sinc function with the first zero at the line rate. On the other hand, the RF spectrum of an RZ signal reveals a strong spectral component at the line rate. Consequently, an incoming RZ signal can be operated upon directly to extract the clock signal. The fundamental problem of all-optical clock recovery from an arbitrary incoming optical signal is thus the passing of an RZ signal without attenuation, and the generation of a RF spectral component at the line rate for a NRZ signal. For an NRZ signal of unknown bit rate and format, an NRZ/PRZ converter is used to generate this latter spectral component by converting the incoming NRZ into a pseudo return to zero, or PRZ signal. Once the incoming signal has a significant spectral component at the line rate, optical oscillations can be triggered to obtain a pure line rate optical clock signal. FIG. 1 depicts a preferred embodiment of the two circuit stages needed for all optical clock recovery of an arbitrary NRZ signal. For various design considerations, most data in optical data networks is currently sent in the NRZ format. The first stage 150 , converts an input signal 100 to PRZ format, where PRZ denotes a “pseudo return to zero” or PRZ data format. The PRZ signal is generated from a standard NRZ format input signal 100 by generating an RZ like pulse each time the NRZ signal transitions, whether from high to low or from low to high, i.e. PRZ has a pulse at each rising edge and at each falling edge of the original signal. As above, the key property of a PRZ signal is that its RF frequency spectrum has a significant frequency component at the original NRZ signal's clock rate. It is this very property that the method of the invention exploits to recover the clock signal. The actual conversion of an NRZ signal to the PRZ format is the result of the operation of a PRZ generator 150 on an NRZ input. A related patent application, under common assignment with the present one, describes in detail a method and circuit for implementing the preprocessor of the first stage 150 . That patent application is entitled “FORMAT INSENSITIVE AND BIT RATE INDEPENDENT OPTICAL PREPROCESSOR” by Bharat Dave, et al., filed on May 4, 2001. That disclosure is hereby fully incorporated herein by this reference. The method and circuit described therein will thus be summarily described here for purposes of reference. The PRZ generator forms the first stage 150 of the All Optical Clock Recovery (“AOCR”) scheme. This stage consists of a path-delayed Asymmetric Mach-Zehnder Interferometer (AMZI). The AMZI incorporates semiconductor optical amplifiers (SOAs) in each of its arms 105 and 106 , respectively, and a phase delay element 107 in one, but not both, of the two arms; hence the asymmetry. The AMZI is set for destructive interference of the signals in the two paths. Thus, the interference of a high bit with its path delayed inverse, i.e. a low bit, generates an RZ-like bit at both the leading and falling edges of the original high bit. This latter signal, with a bit rate effectively double that of the original NRZ bit rate, is the PRZ signal 110 . This effective doubling of the bit rate leads to the generation of a large component of the line rate frequency in the RF spectrum of the output signal 110 of the AMZI 150 . Generally, unless the input signal is exceptionally aberrant, this line rate frequency will be the far and away dominant frequency in the spectrum. Since the preprocessor does not need to know the actual bit rate or format of the input data, it is data rate and format insensitive. Thus the preprocessor has the ability to reshape the PRZ signal as well as adjust its duty cycle. The output 110 of the first stage 150 becomes the input to the second stage 160 . In a preferred embodiment, the second stage 160 comprises a symmetric Mach-Zehnder Interferometer, where each arm contains a semiconductor optical amplifier 111 and 112 , respectively. The principle of clock recovery is based on inducing oscillations between the two lasers DFB 1 113 and DFB 2 114 . The oscillations are triggered by the output of the first stage 110 . As described above, this output can be either RZ or PRZ. The current to DFB 2 114 is tuned close to its lasing threshold, with DFB 1 113 energized so as to be in lasing mode. Thus the trigger pulse 110 induces lasing in DFB 2 114 . The feedback from DFB 2 114 turns off the lasing in DFB 1 113 resulting in DFB 2 114 itself turning off. The reduced feedback from DFB 2 114 now returns DFB 1 113 to lasing. In this manner the two lasers mutually stimulate one another in oscillation. Recalling that the dominant frequency in the input signal 110 is the original signal's 100 clock rate, pulses from the input 110 are sufficient to lock the oscillation of the DFB lasers at that rate, and, in general, to hold for quite a number of low bits (such as would appear where the original signal 100 had a long run of high bits). Thus, the forced triggering by the PRZ/RZ input 110 locks the phase of the oscillations at the original signal's 100 clock rate. The interferometer improves the control of the phase input to DFB 2 114 . The use of the SOA-MZI facilitates the tuning of the oscillation rate by adjusting the input signal phase into DFB 2 114 . As the phase of the MZI output is tuned, the gain recovery time of DFB 2 114 is adjusted. This results in the oscillation rate being altered. In this manner the clock frequency can be tuned to the desired line rate. Using non-linear SOA elements also allows shaping of the output clock with a lesser energy expenditure. Moreover, by adjusting the currents in each of the two SOAs in the second stage interferometer, the refractive index of each SOA's waveguide can be manipulated, thus altering the phase of the pulse entering DFB 2 114 . Thus, the oscillation rate of the circuit can be altered, and the identical circuit can be tuned to the various bit rates available in the network, thus rendering the system bit rate independent. The use of the SOA-AMZI in the first stage 150 of the clock recovery system allows the input power required by the device to be quite nominal, in the embodiment depicted approximately −10 dBm; thus signal pre-amplification concerns are diminished or avoided. The output power of the clock signal in this embodiment is on the order of 0 dBm. The laser wavelength of the all-optical clock signal is a function of the wavelength amplification spectrum of the second stage SOAs. With suitably designed SOAs, the standard carrier frequencies used in optical networks all fall within the SOA amplification spectrum. This wavelength can be anywhere in the amplification window of the SOAs in the second stage 160 SOA-MZI circuit. Thus, as examples, for the C-band of optical transmission a wavelength such as 1550 nm may be chosen, and for the L-band of optical transmission a wavelength such as 1585 nm may be chosen. In a preferred embodiment, Multimode Interference (MMI) couplers with a 50:50 splitting ratio (commonly known as 3 dB couplers) make up the couplers of the first stage 102 and 103 , respectively, as well as the couplers of the second stage 120 and 125 , respectively. FIGS. 2 and 2A show the second stage clock recovery circuit in isolation. The input 200 to this stage, at the top left of the figure, is the amplified RZ or PRZ signal output from the first stage. The stage comprises a symmetric interferometer, with an SOA 210 and 215 , respectively, in each arm. The interferometer has two DFB lasers as termini, DFB 1 205 , in lasing mode, and DFB 2 220 near the lasing threshold. This state of affairs results in an optical cavity that is sensitive to the incoming input signal such that self-pulsating behavior will be triggered by any incoming data pulse. The input signal 200 , which has a large, usually far and away dominant, frequency component at the original optical signal's clock rate, thus triggers the DFB lasers 205 and 220 into self pulsating behavior at that frequency, and the feedback between the two lasers results in a pendulum like behavior that maintains the two lasers in a conservative self oscillatory state. This self oscillation is thus maintained for some time, due to the mutual interaction of the lasers, even if the incoming data has numerous “zero” bits in a row (and thus no pulses at all for that interval). Thus the output signal of the second stage 225 is an optical clock signal at the original line rate of the optical input signal 100 in FIG. 1 . In general the clock signal can be “locked” on to after the second stage MZI has been fed ten (10) or more “one” bits from the input signal. As well, due to the conservative mutual feedback and self oscillation of the lasers (which preserve their oscillation rate even in the absence of continually added energy from the RZ/PRZ input signal 110 ), the output clock signal 225 can be maintained even during significant periods of no second stage input signal 200 , such as in the event of 100 “zero” bits, a statistically very rare occurrence, and under some data formats, (where scrambling is done prior to transmission over a link, and descrambling at the receiving end), quite impossible. Thus the mutual feedback and self oscillation of the two lasers presents a robust structure for extracting a clean optical clock signal as its output 225 . The method of the invention can be implemented using either discrete components, or in a preferred embodiment, as an integrated device in InP-based semiconductors. The latter embodiment will next be described with reference to FIG. 3 FIG. 3 depicts a cross section of an exemplary integrated circuit SOA. With reference to FIG. 1, FIG. 3 depicts a cross section of any of the depicted SOAs taken perpendicular to the direction of optical signal flow in the interferometer arms. Numerous devices of the type depicted in FIG. 3 can easily be integrated with the interferometers of the preprocessor, so that the entire circuit can be fabricated on one IC. The device consists of a buried sandwich structure 350 with an active Strained Multiple Quantum Well region 311 sandwiched between two waveguide layers 310 and 312 made of InGaAsP. In an exemplary embodiment, the λ g of the InGaAsP in layers 310 and 312 is 1.17 μm. The sandwich structure does not extend laterally along the width of the device, but rather is also surrounded on each side by the InP region 304 in which it is buried. The active Strained MQW layer is used to insure a constant gain and phase characteristic for the SOA, independent of the polarization of the input signal polarization. The SMQW layer is made up of pairs of InGaAsP and InGaAs layers, one disposed on top of the other such that there is strain between layer interfaces, as is known in the art. In a preferred embodiment, there are three such pairs, for a total of six layers. The active region/waveguide sandwich structure 350 is buried in an undoped InP layer 404 , and is laterally disposed above an undoped InP layer 303 . This latter layer 303 is laterally disposed above an n-type InP layer 302 which is grown on top of a substantially doped n-type InP substrate. The substrate layer 301 has, in a preferred embodiment, a doping of 4-6×10 18 /cm −3 . The doping of the grown layer 302 is precisely controlled, and in a preferred embodiment is on the order of 5×10 18 /cm −3 . On top of the buried active region/waveguide sandwich structure 350 and the undoped InP layer covering it 304 is a laterally disposed p-type InP region 321 . In a preferred embodiment this region will have a doping of 5×10 17 /cm −3 . On top of the p-type InP region 321 is a highly doped p+-type InGaAs layer. In a preferred embodiment this latter region will have a doping of 1×10 19 /cm −3 . The p-type layers 320 and 321 , respectively, have a width equal to that of the active region/waveguide sandwich structure, as shown in FIG. 3 . As described above, the optical signal path is perpendicular to and heading into the plane of FIG. 3 . Utilizing the SOA described above, the entire all-optical clock recovery device can be integrated in one circuit. An exemplary method of effecting this integration is next described. After an epiwafer is grown with the waveguide and the SOA active regions, the wafer is patterned to delineate the SOAs, the AMZI and the MZI. In a preferred embodiment the path length difference between the two arms of the AMZI is approximately 1 mm. Next, the DFB regions of the second stage of the device are created using either a holographic or a non-contact interference lithographic technique. The periodicity of the grating in a preferred embodiment is approximately 2850A. The grating is of Order 1 and provides optical feedback through second-order diffraction. The undoped InP top cladding layer, the p-type InP layers, and the contact layer are then regrown on the patterned substrate. This step is then followed by photolithography for top-contact metallization. The device is then cleaved and packaged. While the above describes the preferred embodiments of the invention, various modifications or additions will be apparent to those of skill in the art. Such modifications and additions are intended to be covered by the following claims.
A method and circuit are presented for the all optical recovery of the clock signal from an arbitrary optical data signal. The method involves two stages. A first stage preprocesses the optical signal by converting a NRZ signal to a PRZ signal, or if the input optical signal is RZ, by merely amplifying it. In a preferred embodiment this stage is implemented via an integrated SOA in each arm of an asymmetric interferometric device. The output of the preprocessing stage is fed to a clock recovery stage, which consists of a symmetric interferometer that locks on to the inherent clock signal by using the second stage input signal to trigger two optical sources to self oscillate at the clock rate. In a preferred embodiment the second stage is implemented via SOAs integrated in the arms of an interferometer, with two DFB lasers as terminuses. The output of the interferometer is an optical clock signal at the clock rate of the original input.
7
This application is a Divisional of application Ser. No. 08/802,408 now U.S. Pat. No. 5,942,768, filed Feb. 18, 1997; which itself is a Continuation of Ser. No. 08/539,558, filed Oct. 5, 1995 now abandoned. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a semiconductor circuit having a plurality of thin-film transistors (TFTs) and a manufacturing method thereof. The semiconductor circuit that is manufactured according to the invention is formed on either an insulating substrate such as glass or a semiconductor substrate such as single crystal silicon. In particular, the present invention is effectively applied to a semiconductor circuit, such as a monolithic active matrix circuit (used in, for instance, a liquid crystal display), having a matrix circuit that is required to have a small off-current with a small variation and peripheral circuits for driving it which are required to operate at high speed and to have a small-variation on-current. 2. Description of the Prior Art In recent years, various studies have been made of insulated-gate semiconductor devices having a thin-film active layer (also called an active region) on an insulating substrate. In particular, thin-film insulated gate transistors, i.e., thin-film transistors (TFTs), have been studied eagerly. The TFTs, which are formed on a transparent, insulating substrate, are intended to be used for controlling individual pixels in a display device having a matrix structure such as a liquid crystal display. The TFTs are classified into an amorphous silicon TFT, a crystalline silicon TFT, etc. depending on a semiconductor material used and its crystal state. In general, having a small field-effect mobility, amorphous semiconductors cannot be used for a TFT that is required to operate at high speed. Therefore, to manufacture circuits having higher performance, crystalline silicon TFTs have been studied and developed recently. As methods for obtaining a crystalline silicon film, there are known a method in which amorphous silicon is thermally annealed for a long time at a temperature of about 600° C. or higher, and an optical annealing method in which amorphous silicon is illuminated with strong light such as laser light. Having a larger field-effect mobility than amorphous semiconductors, crystalline semiconductors can operate at higher speed. Since crystalline silicon can provide not only an NMOS TFT but also a PMOS TFT in a similar manner, a CMOS circuit can be formed by using crystalline silicon. For example, among active matrix type liquid crystal display devices, there is known one having a monolithic structure (i.e., a monolithic active matrix circuit) in which peripheral circuits (drivers, etc.) are also constituted of CMOS crystalline TFTs. FIG. 1 is a block diagram showing a monolithic active matrix that is used in a general liquid crystal display. A source driver (column driver) and a gate driver (row driver) are provided as peripheral driver circuits. A large number of pixel circuits each constituted of a switching transistor and a capacitor are formed in an active matrix circuit area (pixel area). The pixel transistors of the matrix circuit are connected to each of the peripheral driver circuits via source lines or gate lines having the same number of columns or rows. TFTs used in the peripheral circuits, particularly peripheral logic circuits such as a shift register, are required to operate at high speed. Therefore, those TFTs are required to allow passage of a large current with a small variation in a selected state (on-current). On the other hand, to assure a long-term holding of charge in the capacitor, TFTs used in the pixel circuit are required to have a sufficiently small leak current (off-current) with a small variation in a non-selected state, i.e., while a reverse-bias voltage is applied to the gate electrode. Specifically, the off-current should be smaller than 1 pA, and the variation should be less than 10%. On the other hand, the on-current need not be so large. Although the above characteristics are physically contradictory, it is required that TFTs having such characteristics be formed on the same substrate at the same time, which means that all the TFTs should have a large on-current and a small off-current both with a small variation. It is easily understood that it is technically very difficult to satisfy such requirements. For example, it is known that crystallizing an amorphous silicon film by optical annealing such as laser annealing is effective for obtaining a TFT having a large on-current (i.e., a large field-effect mobility). However, it is empirically known that it is impossible to attain both of a large field-effect mobility and a small off-current variation at the same time. Also known is a method of crystallizing an amorphous silicon film by thermal annealing. Although this method can reduce an offcurrent variation, it cannot provide a large field-effect mobility. The present invention is to solve such a difficult problem. SUMMARY OF THE INVENTION The present inventors have found that it becomes possible to proceed crystallization more easily and provide better crystallinity than in the conventional methods of using thermal annealing or optical annealing by bringing a very small amount of an element of Ni, Pt, Pd, Cu, Ag, Fe, or the like, or its compound substantially in close contact with the surface of an amorphous silicon film and then performing thermal annealing or optical annealing (laser annealing, rapid thermal annealing (RTA), or the like). For example, when the thermal annealing is employed, the crystallization time can be shortened and the crystallization temperature can be lowered from the conventional cases. It has been confirmed that the above advantages are obtained because Ni, Pt, Pd, Cu, Ag, Fe, or the like serves as a catalyst element for accelerating crystallization of an amorphous silicon film. More specifically, the above catalyst elements form a crystalline silicide with amorphous silicon at a crystallization energy lower than that of amorphous silicon. Then, after the catalyst element in the silicide moves to the location of amorphous silicon ahead, silicon enters the site of the silicide which was occupied by the catalyst element, thus forming crystalline silicon. As the catalyst element moves through amorphous silicon, a crystallized region is formed. Thus, it has been confirmed that the crystallization of an amorphous silicon film utilizing a catalyst element proceeds in two steps that respectively correspond to the following modes: (1) The mode in which crystallization that occurs at a region where a catalyst element is introduced. Although it is not appropriate to strictly define the crystallization direction, it may be said that crystal growth proceeds perpendicularly to a substrate. (2) The mode in which a crystal-grown region expands as catalyst element moves from the region where it was introduced to a region where it was not, so that crystal growth proceeds parallel with the substrate. In particular, as for the crystal growth mode (2), growth of columnar crystals parallel to a substrate has been confirmed by observations using a TEM (transmission electron microscope). In the following description, the crystal growth mode (1) and a resulting crystallized region are called vertical growth and a vertical growth region, and the crystal growth mode (2) and a resulting crystallized region are called lateral growth and a lateral growth region. For example, if a thin coating of a catalyst element, or its compound or the like is formed on an amorphous silicon film by a certain means so as to be substantially in close contact with the latter and then thermal annealing is performed, the coated portion is initially crystallized mainly by the vertical growth and thereafter a region surrounding that portion is crystallized by the horizontal growth. The crystallinity can be improved by performing proper optical annealing after the above crystal growth by thermal annealing. The main effects of the optical annealing are to increase the field-effect mobility and reduce the threshold voltage. The vertical growth and the lateral growth have a difference in the degree of crystal orientation. In general, the vertical growth does not provide so high a degree of crystal orientation in which orientation in the (111) plane with respect to the substrate surface is dominant to a small extent. In contrast, remarkable orientation is found in the lateral growth. For example, where a silicon film is coated with a silicon dioxide film or a silicon nitride film and then crystallized by thermal annealing, orientation in the (111) plane mainly occurs. Specifically; in an X-ray diffraction measurement, the ratio of a reflection intensity of the (111) plane to the sum of reflection intensities of the (111), (220) and (311) planes amounts to more than 80%. The above tendency becomes more remarkable if optical annealing is performed after the crystallization by thermal annealing; the above ratio increases to more than 90%. Where a silicon film surface is crystallized by thermal annealing without coating it, orientation in the (220) plane is also enhanced, so that reflection intensities of both (111) and (220) planes become larger than 90%. To effect the lateral growth, a catalyst element needs to be introduced selectively. This is usually done such that a hole for introduction is opened by photolithography in a coating of a material whose main component is silicon dioxide, silicon nitride or silicon oxynitride which coating is formed on an amorphous silicon film and then a thin film, a cluster, or the like of a catalyst element or its compound is formed by sputtering, CVD, spin coating, or some other method. The studies of the present inventors have revealed that if the hole diameter is less than 7 μm, a crystal growth defect occurs at a very high probability. This is disadvantageous for use in a high-integration area such as peripheral logic circuits. In particular, such a manufacturing method is not applicable to the cases of design rules of 5 μm or less. On the other hand, the lateral growth does not cause any problem in an active matrix circuit where a sufficient distance is secured between adjacent TFTs. However, it has become apparent that the lateral growth need not be employed for peripheral logic circuits. The investigations of the present inventors have revealed that while the lateral growth and the vertical growth do not cause a large difference in field-effect mobility, however, it can be increased by up to about two times by an optical annealing subsequent to thermal annealing. A typical field-effect mobility is 50 to 80 cm 2 /Vs when only thermal annealing is performed. By additionally performing, for instance, laser annealing, an increased value of 100 to 200 cm 2 /Vs was obtained. Either value is sufficiently large for TFTs in peripheral logic circuits. It is not necessary to change the conditions of the above optical annealing for a vertical growth region and a lateral growth region. This is advantageous in terms of mass productivity because optical annealing for a single substrate can be performed under substantially the same conditions (except unintentional variations of conditions). On the other hand, the vertical growth and the lateral growth cause large differences in the magnitude of the off-current and its variation. That is, while both of the off-current and its variation are small with the lateral growth, both of them tend to be large with the vertical growth. The present invention is characterized in that by utilizing the above features of the vertical growth and the lateral growth, crystallization is effected by the lateral growth for TFTs of an active matrix circuit and by the vertical growth for TFTs of peripheral logic circuits. The peripheral logic circuits mean those included in a source driver and a gate driver. In such circuits as analog switches, either the vertical growth or the lateral growth may be employed. The present invention is characterized in that a region crystallized by the lateral growth is used for TFTs of an active matrix circuit. In this case, there are several variations for the arrangement of TFTs as shown in FIG. 4 . In FIG. 4, reference numeral 401 denotes a region where a catalyst element has been introduced, i.e., a region that has been crystallized by the vertical growth. A region 402 that has been crystallized by the lateral growth develops around the region 401 . As shown in FIG. 4, if the catalyst-added region 401 has a rectangular shape, the lateral growth region 402 assumes an elliptical shape. In one case (in the case of TFT1), a gate electrode 404 is formed generally parallel with the region 401 and crystal growth is effected in the direction from a drain 405 to a source 403 , or the direction opposite thereto. In another case (in the case of TFT2 in FIG. 4 ), a gate electrode 407 is formed generally perpendicularly to the region 401 and portions of a source 406 and a drain 408 are crystallized approximately at the same time. It has been confirmed that the above two cases do not cause much difference. In an active matrix circuit, a catalyst element may be added linearly so as to be generally parallel with source lines or gate lines. FIGS. 5 (A) and 5 (B) show examples where catalyst-added regions 501 and 506 are parallel with gate lines 502 and 507 , respectively. FIG. 5 (A) shows a case corresponding to TFT2 in FIG. 4 in which case a catalyst is added generally perpendicularly to gate electrodes of TFTs 503 to 505 . FIG. 5 (B) shows a case corresponding to TFT1 in FIG. 4 in which case a catalyst element is added generally parallel with gate electrodes of TFTs 508 to 510 . Catalyst-added regions may be provided generally parallel with source lines in a similar manner. As described above, orientation in the (111) plane and the (220) plane is remarkable in a lateral growth region, and is not so remarkable in a vertical growth region. Therefore, in the present invention, a crystalline silicon semiconductor (lateral growth regions) for such elements as TFTs of an active matrix circuit, resistors and capacitors is given orientation in the (111) or (220) plane, and a crystalline silicon semiconductor for peripheral circuits is given a lower degree of orientation than that for the active matrix circuit. If the thermal annealing for crystallization is performed at a temperature higher than the crystallization temperature of an amorphous silicon thin film, there can be obtained crystallinity equivalent to that obtained when laser annealing is also performed. The crystallization temperature of an amorphous silicon thin film is approximately in the range of 580 to 620° C. although it depends on the film deposition method and conditions. By performing a heat treatment at a temperature higher than this temperature (as high a temperature as possible is preferred as long as it is allowable), a crystalline silicon film having superior crystallinity can be obtained. It is preferred that the upper limit of the temperature of this heat treatment be set at about 1,100° C. To employ a heat treatment at such a high temperature, it is necessary to use a quartz substrate or a glass substrate capable of withstanding such a high temperature. In the present invention, the vertical crystal growth utilizing a catalyst element is performed to obtain a crystalline silicon semiconductor for peripheral logic circuits having a high integration degree. As a result, TFTs having a large field-effect mobility can be obtained irrespective of the integration degree. On the other hand, the lateral crystal growth utilizing a catalyst element is performed for an active matrix circuit. As a result, TFTs having a small off-current with a small variation can be obtained. In particular, if the heat treatment for crystallization is performed at a temperature higher than the crystallization temperature of an amorphous silicon thin film, superior crystallinity can be obtained. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a general configuration of a monolithic active matrix circuit; FIGS. 2 (A) to 2 (F) show manufacturing steps of TFTs according to Embodiment 1; FIGS. 3 (A) to 3 (G) show manufacturing steps of TFTs according to Embodiment 2; FIG. 4 shows an example of an arrangement of TFTs of an active matrix circuit and a lateral growth region; and FIGS. 5 (A) and 5 (B) show examples of arrangements of TFTs of an active matrix circuit and catalyst-added regions. DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 This embodiment relates to a process for manufacturing an active matrix circuit (pixel circuit) and peripheral logic circuits to be used in a liquid crystal display device on a single glass substrate at the same time. A crystalline silicon film for constituting TFTs of the active matrix circuit is obtained such that a catalyst element for accelerating crystallization is introduced into a region in the vicinity of a region to be crystallized and crystal growth is effected parallel with a substrate from the catalyst-added region by performing a heat treatment. A crystalline silicon film for constituting TFTs of the peripheral logic circuits is obtained such that a catalyst element for accelerating crystallization is introduced into a region including a region where the TFT is to be formed and the entire area of the latter region is crystallized by performing a heat treatment. FIGS. 2 (A) to 2 (F) are conceptual sectional views showing manufacturing steps of TFTs of a peripheral logic circuit and an active matrix circuit. In those figures, a region where a peripheral logic circuit is to be formed (peripheral circuit region) is shown on the left side and a region where pixels are to be formed (pixel region) is shown on the right side. Although the peripheral circuit region and the pixel region are shown adjacent to each other in those figures, actually they are not arranged in such a manner. Although in those figures the TFT of the pixel region is shown such that a catalyst-added region and a gate electrode are arranged generally parallel with each other like TFT1 in FIG. 4, they may be arranged generally perpendicularly to each other like TFT2 in FIG. 4 . Manufacturing steps will be described below. First, a substrate 201 (Corning 7059 or some other borosilicate glasses) was cleaned, and a 2,000-Å-thick silicon oxide undercoat film 202 was formed by plasma CVD with TEOS (tetra ethoxy silane) and oxygen used as material gases. Then, an amorphous silicon film 203 added with almost no conductivity-imparting impurities (phosphorus, boron, etc.) was deposited by plasma CVD or LPCVD at a thickness of 300 to 1,500 Å, for instance, 500 Å. Immediately thereafter, a silicon oxide film 204 was deposited by plasma CVD at a thickness of 100 to 2,000 Å, for instance, 200 Å. Portions of the amorphous silicon film 203 were exposed by selectively etching the silicon oxide film 204 . After this step, the silicon oxide film 204 was completely removed in the peripheral circuit region that is shown on the left side of the figures, so that the surface of the amorphous silicon film 203 was exposed. The silicon oxide film 204 was selectively removed in the pixel region that is shown in the right side of the figures. A very thin (several tens of angstroms) oxide film was formed on the surface of the amorphous silicon film 203 which were exposed in the above step, to prevent a solution from being repelled by the surface of the amorphous silicon film 203 in an ensuing solution applying step. This oxide film may be formed by thermal oxidation, illumination with ultraviolet light, or a treatment with a solution having a strong oxidizing ability such as an aqueous solution of hydrogen peroxide. Then, a very thin film 205 of nickel acetate was formed on the surface of the amorphous silicon film 203 by applying thereto a nickel acetate solution containing nickel, which is a catalyst element for accelerating crystallization. Since this film is extremely thin, there is a possibility that it does not constitute a complete film. This step was performed by spin coating or spin drying. An appropriate range of the density (in terms of weight) of nickel in the acetate solution was 1 to 100 ppm. It was 10 ppm in this embodiment. (FIG. 2 (A)) Thereafter, crystallization was effected by performing thermal annealing at 400 to 580° C., at 550° C. in this embodiment, for 4 hours. As a result, the almost entire amorphous silicon film 203 of the peripheral circuit region changed to a crystalline silicon film 206 . In the pixel region, a crystalline silicon film 208 was obtained in a lateral growth region 208 . An amorphous silicon film 207 was left in a region that is away from the nickel-added region. (FIG. 2 (B)) After the silicon oxide film 204 was removed, to improve the crystallinity, KrF excimer laser light (wavelength: 248 nm) was applied to the entire surface by 2 to 20 shots per one location. The optimum energy density was 250 to 300 mJ/cm 2 . However, since the optimum energy density depends on each silicon film, it was determined by preliminarily setting the conditions. The laser light illumination conditions were set in the same manner for the entire substrate surface. Although the energy density of the laser light illumination naturally has a temporal variation (fluctuation) and a microscopic observation will reveal variations of the number of shots of the laser light illumination and the accumulated illumination energy from one location to another, such variations are not intended ones. In this embodiment, the laser light illumination was performed under such conditions as limit the variation of the accumulated illumination energy within 10% in an arbitrary 1-cm 2 area. Other excimer lasers such as a XeCl excimer laser (wavelength: 308 nm), an ArF excimer laser (193 nm) and a XeF excimer laser (353 nm), and other pulsed oscillation lasers were successfully used. This step may be performed by a rapid thermal annealing (RTA). A measurement by a secondary ion mass spectrometry (SIMS) showed that the nickel concentration in the resulting crystallized silicon film was typically 1×10 18 to 1×10 19 atoms/cm 3 in the vertical growth region 206 and 1×10 17 to 5×10 18 atoms/cm 3 in the lateral growth region 208 . After completion of the above steps, island-like active regions 209 to 211 were formed by dry-etching the silicon film. Although the active layers 210 and 211 partially include the amorphous silicon region 207 , this causes no problem because the amorphous silicon region 207 does not constitutes the channel forming regions of the TFTs. In the active layer 211 , the region where nickel was directly introduced (i.e., the region that was not covered with the silicon oxide film 204 when nickel acetate was applied) was positioned so as not to overlap with the channel forming region of the TFT, for the following reason. It has been confirmed that in a region where nickel is directly introduced (i.e., a vertical growth region), nickel comes to exist at a higher concentration than in a lateral growth region. In TFTs of the pixel area which are required to have a small off-current with a small variation, a vertical growth region should not occupy at least part of the channel forming region. (FIG. 2 (C)) Then, a 1,500-Å-thick silicon oxide film 212 to serve as a gate insulating film was formed by plasma CVD using monosilane (SiH 4 ) and dinitrogen monoxide (N 2 O) as materials. In this embodiment, monosilane of 10 SCCM and dinitrogen monoxide of 100 SCCM were introduced into a reaction chamber, and the following conditions were employed. Substrate temperature: 430° C.; reaction pressure: 0.3 Torr; and applied power: 250 W (13.56 MHz). These conditions depend on the reaction apparatus used. The deposition rate of the silicon oxide film under the above conditions was about 1,000 Å/min, and its etching rate with a mixed solution (20° C.) of hydrofluoric acid, acetic acid, and ammonium fluoride (at a ratio of 1:50:50) was about 1,000 Å/min. Subsequently, a polycrystalline silicon film (containing phosphorus at 1 to 2% to improve conductivity) was deposited by low-pressure CVD at a thickness of 2,000-8,000 Å, for instance, 4,000 Å, and etched to form gate electrodes 213 to 215 . Then, the active layers 209 to 211 were doped with impurities for imparting N-type and P-type conductivity by ion doping (also called plasma doping) in a self-alignment manner with the gate electrodes 213 to 215 used as a mask. In this embodiment, the TFT of the pixel region was of a P-channel type. That is, the active layers 210 and 211 were doped with a P-type impurity and the active layer 209 was doped with an N-type impurity. The known CMOS technology may be used for the doping of impurities of different conductivity types. In this embodiment, phosphine (PH 3 ) was used as an N-type doping gas and diborane (B 2 H 6 ) was used as a P-type doping gas. The acceleration voltage was 60 to 100 kV, for instance, 90 kV, for the former case and was 40 to 80 kV, for instance, 70 kV, for the latter case. The dose was 1×10 14 to 8×10 15 atoms/cm 2 , for instance, 4×10 14 atoms/cm 2 for the N-type impurity and 1×10 15 atoms/cm 2 for the P-type impurity. In this manner, an N-type impurity region 216 and P-type impurity regions 217 and 218 were formed. Then, to activate the doped impurities, thermal annealing was performed at 400 to 550° C. for 1-12 hours, for instance, at 450° C. for 2 hours. Since the catalyst element for accelerating crystallization of amorphous silicon was included in the active layers, the thermal annealing of such a low temperature and short period was sufficient for the activation and the resistivity of the impurity regions was reduced to about 1 kΩ/square or less, which feature is common to the invention. (FIG. 2 (D)) Thereafter, an insulating film 219 , which was composed of two layers of a 500-Å-thick silicon nitride film (having a passivation effect of preventing water and movable ions from being entering into the TFT) and a 4,000-Å-thick silicon oxide film, was formed as a first interlayer insulating film by plasma etching. After contact holes were formed in the insulating film 219 , electrodes and wiring lines 220 to 223 of the TFTs were formed by using a metal material such as a multilayered film of titanium and aluminum (in this embodiment, a 500-Å-thick titanium film and a 4,000-Å-thick aluminum film). (FIG. 2 (E)) Further, a 2,000-Å-thick silicon oxide film 224 was formed as a second interlayer insulating film by plasma CVD. After a contact hole was formed for the impurity region of the TFT of the pixel region for which impurity region a pixel electrode was to be formed, a pixel electrode 225 was formed by depositing a 800-Å-thick ITO (indium tin oxide) film by sputtering and etching it. (FIG. 2 (F)) In the above manner, the pixel area and the peripheral circuit area of the active matrix liquid crystal display device were formed on the same glass substrate at the same time. Embodiment 2 FIGS. 3 (A) to 3 (G) are sectional views showing manufacturing steps of this embodiment. The left side and the right side of the figures show a logic circuit region and a pixel region, respectively. Although in an actual circuit the logic circuit is a CMOS circuit including N-channel TFTs and P-channel TFTs, for simplicity the figures show only an N-channel TFT in the logic circuit region. An N-channel TFT was used also in the pixel region. In this embodiment, the TFTs have a structure in which lightly doped impurity regions are provided adjacent to the source and drain. The differences between the N-channel TFT and the P-channel TFT are only in the kind and concentrations of a doping impurity of the source/drain and the low-concentration impurity regions. First, a 2,000-Å-thick silicon oxide undercoat film 302 was formed on a substrate (Corning 7059) 301 by sputtering. An intrinsic (I-type) amorphous silicon film was deposited by plasma CVD at a thickness of 300 to 1,000 Å, for instance, 500 Å. Further, a 200-Å-thick silicon oxide film 303 was formed by sputtering, and etched in the same manner as in Embodiment 1 to form regions for introduction of a catalyst element (nickel). A nickel acetate film was then formed by spin coating. Then, the amorphous silicon film was crystallized by performing thermal annealing at 550° C. for 4 hours in a nitrogen atmosphere, to form a vertical growth region 304 and a lateral growth region 306 . A region 305 was left amorphous. Thereafter, the crystallinity was improved by laser light illumination. In this embodiment, a KrF excimer laser was used and its appropriate energy density range was from 250 to 350 mJ/cm 2 . After the laser light illumination, thermal annealing was again performed at 550° C. for 1 hour to reduce strain due to the laser annealing. (FIG. 3 (A)) By etching the silicon film thus crystallized, an island-like active layer 307 (for the logical circuit TFT) and an island-like active layer 308 (for the pixel TFT) were formed. After a 1,200-Å-thick silicon oxide film 309 was deposited by thermal CVD with monosilane (SiH 4 ) and oxygen (O 2 ) used as materials, thermal annealing was performed at 1 atm and 400 to 500° C. for 1 to 12 hours in a dinitrogen monoxide (N 2 O) atmosphere. Subsequently, an aluminum film was deposited by sputtering at a thickness of from 2,000 to 8,000 Å, for instance, 4,000 Å. To improve adhesiveness with a photoresist, a very thin (50 to 200 Å) anodic oxide film (not shown) was formed on the aluminum film. After photoresist masks 310 and 311 were formed by a known photographic method with application of a photoresist, the aluminum film was etched to form gate electrodes 312 and 313 . To prevent abnormal crystal growth (hillock) in heat treatment or the subsequent anodic oxidation step, aluminum was mixed with scandium (Sc) or yttrium (Y) at 0.1 to 0.5 wt %. The photoresist mask that was used as the mask of the above etching was left as it was on the gate electrodes 312 and 313 . (FIG. 3 (B)) Then, anodic oxide films 314 and 315 were formed at a thickness of 1 to 5 μm, for instance, 2 μm, by anodic oxidation in which a current was caused to flow through the above structure in an electrolyte. The anodic oxidation may be performed by using an acid aqueous solution of citric acid of 3 to 20%, nitric acid, phosphoric acid, chromic acid, sulfuric acid, or the like and applying a constant voltage of 10 to 30 V to the gate electrodes 312 and 313 . In this embodiment, the anodic oxidation was performed by using an oxalic acid solution (pH=0.9 to 1.0; 30° C.) and applying 10 V. The thickness of the anodic oxide films 314 and 315 were controlled by the anodic oxidation time. The thus-obtained anodic oxide films 314 and 315 were porous ones. In the above anodic oxidation step, the thin anodic oxide film between the gate electrodes 312 and 313 and the photoresist masks 310 and 311 suppressed current leakage from the photoresist, and anodic oxidation was allowed to proceed on the side faces of the gate electrodes 312 and 313 . (FIG. 3 (C)) After the photoresist masks 310 and 311 were removed, a voltage was applied to the gate electrodes 313 and 314 in an electrolyte. This time, an ethylene glycol ammonia solution (pH=6.9 to 7.1) containing at least one of tartaric acid of 3-10%, boric acid and nitric acid. Better oxide films were obtained when the temperature of the solution was about 10° C., i.e., lower than the room temperature. Thus, anodic oxide films 316 and 317 were formed on the top and side faces of the gate electrodes 312 and 313 . The thickness of the anodic oxide films 316 and 317 was approximately proportional to the application voltage, and 2,000-Å-thick anodic oxide films were formed with an application voltage of 150 V. Being dense and hard, the anodic oxide films 316 and 317 were effective in protecting the gate electrodes 312 and 313 in subsequent heating steps. (FIG. 3 (D)) Subsequently, the silicon oxide film 309 was etched by dry etching. Since the porous anodic oxide films 314 and 315 were not etched in this etching step, silicon oxide films 318 and 319 under those films 314 and 315 were also not etched and were left as they were. (FIG. 3 (E)) Then, the anodic oxide films 314 and 315 were etched with a mixed acid of phosphoric acid, acetic acid, and nitric acid. In this etching step, only the anodic oxide films 314 and 315 were etched at an etching rate of about 600 Å/min. The gate insulating films 318 and 319 under those films 314 and 315 were left as they were. Thereafter, the active layers 307 and 308 were doped with an impurity (phosphorus) by ion doping with the gate electrodes 312 and 313 and the gate insulating films 318 and 319 used as a mask. Two-step doping was performed by using phosphine (PH 3 ) as a doping gas. In the first step, the acceleration voltage and the dose were set at 80 kV and 5×10 12 atoms/cm 2 . In this doping step, ions penetrated through the gate insulating films 318 and 319 and reached the regions thereunder. Because of a low dose, lightly doped impurity regions 322 and 323 were formed. In the second doping step, the acceleration voltage and the dose were set at 30 kV and 5×10 14 atoms/cm 2 . In this doping step, ions could not penetrate through the gate insulating films 318 and 319 , and were mainly implanted into the silicon-exposed regions of the active layers. Because of a high dose, heavily doped impurity regions (source and drain) 320 and 321 were formed. In forming actual circuits, doping of a P-type impurity was also conducted. After the doping, impurities were activated by laser annealing. In this embodiment, a KrF excimer laser (wavelength: 248 nm) was used and its appropriate energy density range was 200 to 300 mJ/cm 2 . Instead of the laser annealing, thermal annealing as in Embodiment 1 was successfully used for the impurity activation. Further, a successful result was obtained when thermal annealing was performed after the laser annealing. (FIG. 3 (F)) Subsequently, an interlayer insulating film 324 composed two layers of a 500-Å-thick silicon nitride film and a 4,000-Å-thick silicon oxide film was formed by plasma CVD. After contact holes were formed in the insulating film 324 , source electrodes and wiring lines were formed by using a multilayered film of titanium and aluminum. (FIG. 3 (G)) Then, a 2,000-Å-thick silicon oxide film (second interlayer insulating film) 325 was formed by plasma CVD. After a contact hole was formed in the pixel TFT, a pixel electrode 326 made of a transparent conductive film was connected to the TFT through the hole. With the above steps, a monolithic active matrix circuit was completed. (FIG. 3 (G)) Embodiment 3 In this embodiment, a Corning 1737 glass substrate is used in the configuration of Embodiment 1 or 2. Since the Corning 1737 glass substrate has a strain point of 667° C., it can withstand a heat treatment that is conducted at a temperature lower than that point. According to experiments, the crystallization temperature of amorphous silicon films deposited by plasma CVD is about 590° C. This embodiment is characterized in that a crystalline silicon film is obtained by a heat treatment of 650° C. and 4 hours. Where the heat treatment is performed at a temperature higher than the crystallization temperature of an amorphous silicon film, a crystalline silicon film having superior crystallinity can be obtained with action of an element of nickel introduced. As described above, according to the present invention, peripheral logic circuits and an active matrix circuit can be constructed effectively. In particular, by utilizing a metal element that accelerates crystallization of silicon, superior crystallinity can be obtained, to thereby enable construction of peripheral logic circuits and an active matrix circuit having necessary characteristics.
Thin-film transistors (TFTs) of peripheral logic circuits and TFTs of an active matrix circuit (pixel circuit) are formed on a single substrate by using a crystalline silicon film. The crystalline silicon film is obtained by introducing a catalyst element, such as nickel, for accelerating crystallization into an amorphous silicon film and heating it. In doing so, the catalyst element is introduced into regions for the peripheral logic circuits in a nonselective manner, and is selectively introduced into regions for the active matrix circuit. As a result, vertical crystal growth and lateral crystal growth are effected in the former regions and the latter regions, respectively. Particularly in the latter regions, the off-current and its variation can be reduced. The vertical growth and the lateral growth have a difference in the degree of crystal orientation. In general, the vertical growth does not provide so high of a degree of crystal orientation in which orientation in the (111) plane with respect to the substrate surface is dominate to a small extent. In contrast, remarkable orientation is found in the lateral growth. For example, the ratio of a reflection intensity of the (111) plane to the sum of reflection intensities of the (111), (220) and (311) planes can amount to more than 80 or 90%.
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PRIORITY APPLICATION [0001] Priority is claimed from U.S. Provisional Patent Application Ser. No. 61/335,711, filed Jan. 11, 2010, and said U.S. Provisional Patent Application is incorporated herein by reference. FIELD OF THE INVENTION [0002] This invention relates to the field of mobile communications and, more particularly, to promoting safety in use of mobile communication devices, such as cellular phones, by implementing safety-promoting action. BACKGROUND OF THE INVENTION [0003] Mobile communication devices, such as cellular telephones, are in widespread use throughout the world, and have many obvious benefits. However, certain uses of a cell phone by the operator of a moving vehicle can result in substantial distraction and concomitant safety hazard that risks injury or death to the user and the user's passengers, as well as occupants of other vehicles and pedestrians put in harm's way by a distracted operator. One example that has already become notorious, is cell phone “texting” by the operator of a motor vehicle. [0004] The U.S. Patent Application Publication US2009/0224931 discloses a mobile device configured to have at least one function disabled when the speed of the mobile device exceeds a threshold. In an embodiment of the '931 Publication, when a determination is made that a mobile device is in motion above a threshold speed, a user interface on the device can notify the user of the device that a safety feature disabling the device or one or more functions of the device is about to be activated. The user can then be given an opportunity to prevent the safety feature from being activated and allow the mobile device to continue normal operation. The interface that notifies the user of the impending disablement of the mobile device might be a text-based message that appears on the display screen of the device, an automated voice message spoken by the device, an audible, visible, and/or tactile alarm signal, or some other type of output. As also described in the '936 Publication, upon receiving this notification, the user can provide an input into the mobile device to prevent the activation of the safety feature. For example, a driver who is willing to accept the safety risk of sending and receiving messages while driving may provide an input to override the safety feature. Alternatively, a passenger in an automobile being driven by another person or in a public transportation vehicle may not be an appropriate target for the safety feature and may choose to prevent the activation of the safety feature of the '931 technique. [0005] The U.S. Patent Application Publication US200910240464 discloses a technique generally similar to that of the '931 Published Application. In an embodiment of the '464 Publication, frequency error distributions for Doppler shift measurements are used in determining the speed at which a mobile communication device is moving. Then, as in the '931 Publication, a determination is made as to whether a threshold speed has been exceeded, whereupon action can be taken. [0006] While existing techniques, such as those described, are a step in the right direction, improvement is needed. For example, depending on various operational factors and safety assessments for individual situations, it may not be appropriate to provide an option to the operator of the mobile device. Further, the option itself, or implementation of a response thereto, may involve a degree of safety risk. Another shortcoming of existing approaches is the reliance on device speed alone in making a decision as to whether corrective action is necessary. It is among the objects of the invention to overcome these and other shortcomings or limitations of existing techniques. SUMMARY OF THE INVENTION [0007] It has been recognized in the prior art that the user of a mobile communication device may be a passenger in a moving vehicle. To date, the solution as been to give a passenger the option of overriding disabling controls or warnings resulting from detected speed of the mobile communication device. In accordance with a feature hereof, determination of driver/passenger status of the device user can, in many instances, be made with a relatively high probability, thereby providing greater flexibility of action. [0008] In accordance with a first form of the invention, a method is set forth for controlling operation of an active mobile communication device, including the following steps: performing a first determination of whether said device is in a moving vehicle; performing a second determination of whether the user of said device is the vehicle operator; and producing a risk indication signal as a function of said first and second determinations. In an embodiment of this form of the invention, the of performing said second determination includes determining the relative position of said device in the vehicle. In this embodiment, the step of performing said second determination includes determining the presence of a proximity group of communication devices, and determining the relative position of said active mobile device in the proximity group. The determining of the relative position of said active mobile device can be performed at a plurality of successive times, and the relative positions obtained at a plurality of times can be interpolated to obtain a refined relative position. Also in this embodiment, the determining of the relative position of said active mobile device in said proximity group is performed with respect to the direction of motion of the proximity group. [0009] In an embodiment of this first form of the invention the risk indication signal comprises a conditional disabling signal, and at least one function of said device is disabled in response to said risk indication signal when a predetermined condition has been met. In this embodiment, the predetermined condition includes at least one factor selected from the group consisting of geographical features at the location of the vehicle, traffic, weather conditions, and time of day. Also in this embodiment, the step of performing said first determination includes determining the speed of said moving vehicle, and the risk indication signal is also a function of said determined speed. In one embodiment, said first determination and/or said second determination are determined using probabilities, and the detecting of whether said probabilities exceed predetermined thresholds. [0010] In an embodiment of this form of the invention, at least one function of said device is disabled in response to a risk indication signal. The at least one function can be a tactile input function, such as manual texting, which is dangerously distracting for a vehicle operator. [0011] In an embodiment of a further form of the invention, a method is set forth for controlling operation of an active mobile communication device, comprising the steps of: performing a determination of whether said device is in a moving vehicle at a relevant location; and producing a risk indication signal as a function of said determination. A warning can be issued and/or at least one function of the device can be disabled in response to said risk indication signal. In an embodiment of this form of the invention, the risk indication signal comprises a conditional disabling signal, and at least one function of said device can be disabled in response to said risk indication signal when a predetermined condition has been met. The predetermined condition can include at least one factor selected from the group consisting of geographical location of the vehicle, weather conditions, and time of day. [0012] Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a bock diagram of a mobile communication device used as an example of a type of device that will be subject to receiving risk indication signals or control signals in accordance with embodiments of the invention. [0014] FIG. 2 is a simplified block diagram, partially in schematic form, of part of an existing type of GSM in conjunction with which embodiments of the invention can be implemented, and which includes a processor that can be programmed to implement techniques in accordance with embodiments of the invention. [0015] FIG. 3 shows an example of a moving vehicle containing plural mobile communication devices, which is useful in understanding operation of an embodiment of the invention. [0016] FIG. 4 , which includes FIGS. 4A and 4B placed one below another, is a flow diagram of a routine for controlling a machine processor for implementing embodiments of the invention. DETAILED DESCRIPTION [0017] Referring to FIG. 1 , there is shown a block diagram of a typical cell phone, it being understood that the features hereof are not dependent on use of any particular type of cell phone or other mobile communications device. The main computational subsystem is represented at 110 , and includes, inter alia, signal processing unit 102 and central processing unit (CPU) 104 . As is well known, specialized digital signal processing (DSP) chips are typically used for implementation of part of these functions. The device key pad and display are represented at 120 , and can typically include any suitable kind of input media and display media. A display controller circuit, for example including an LCD module controller, backlit driver, etc., is represented at 125 . An antenna 130 is coupled with transmitter circuitry 133 and receiver circuitry 135 , which are respectively coupled with the processor 110 via an IF stage 137 . A voltage-controlled oscillator 139 conventionally provides appropriate frequency signals to the IF stage. Microphone and speaker circuitry are represented at 141 and 143 , respectively. Power supply module 160 includes a charging circuit for the battery (not separately shown) and an appropriate voltage conversion circuit. Storage is represented at 170 , and will typically include, at least, a flash memory module. [0018] Referring to FIG. 2 , there is shown a simplified diagram of part of an existing type of “GSM” or “global system for mobile communication” in conjunction with which embodiments of the invention can be implemented. As is well known, the GSM uses digital radio transmission to provide voice, data, and multimedia communication services. (It will be understood that the invention can operate in the content of any other suitable type of communication system.) Among other functions, the GSM of this example operates to coordinate and control the communication between mobile telephones (such as examples shown at 211 and 212 , with 211 being in vehicle 215 ), base stations/towers (such as examples shown at 225 and 226 ), and a mobile switching center represented at 240 . Servers and one or more central processors, represented at 260 , communicate with the mobile switching center 240 and with the internet, represented at 270 . Data bases, represented generally at 280 , are available to the central processor, directly and/or via internet. In an example hereof the central processor can be programmed to implement an embodiment of the technique of the invention. [0019] Mobile device systems can detect location of active mobile devices (e.g., cell phones). Sometimes mobile devices can detect their own locations. This knowledge is acquired in substantially “real time” using information that can be obtained, for example, from satellites (GPS systems), relative locations of cell towers (triangulation), beacon systems, etc. Collecting this information over time (for at least two time instants) allows for the estimation of the velocity vector of mobile devices. [0020] FIG. 3 shows an example of a moving vehicle 310 at times t 1 , t 2 , and t 3 . Three determined positions in the vehicle are represented by 311 , 312 , and 313 , respectively. In this example, the position 311 turns out to be the vehicle operator (driver) position, the position 312 turns out to be a passenger position, and position 313 turns out to be a “chip” (fixed in vehicle) position. (It will be understood, throughout, that references to a mobile communication device can also include an integrated circuit or chip that may, for example, be fixed in a vehicle, and which performs an essential function of the mobile communications device.) The crossed axes at each position represent uncertainly in position location of the mobile devices in this proximity group. The solid curved line 371 , the dashed curved line 372 , and the dotted curved line 373 , respectively represent the tracking of the three mobile devices (or “chip” in the case of 313 ), as a function of time, as the vehicle proceeds in a general direction of motion indicated by arrow 350 . The curves are constructed based on multiple measurement points to improve accuracy of the location (and relative location) of the respective mobile devices in the proximity group. (It will be understood that the timing associated with different mobile devices, which can be on different provider systems, may differ with respect to each other of with respect, for example, to a given universal clock, and that appropriate correction for such differences, including corrections for fundamental clock differences, delays, or the like, can be appropriately made.) The more separated the curves, the better distinction between location of mobile devices (or fixed points in the proximity group) can be achieved. [0021] With no a priori knowledge, operator (e.g. driver) position may be obtainable by identifying a group of moving mobile devices (e.g. cell phones) that are moving at approximately the same speed at a relevant location, and maintaining approximately the same relative positions with respect to each other. The mobile devices (in this proximity group) are then likely to be located in the same vehicle, and the “left front” mobile device (e.g., cell phone) is likely to be the one used by the driver. (In some other countries or cases, e.g., mailman, it would be “right front”.) A way of detecting “front” is by finding the direction of motion. The system can detect that particular mobile device (e.g. cell phone) and apply desired action or restriction. In the case of a driver with no passengers, the mobile device (e.g. cell phone) in use is the mobile device used by the driver. [0022] Identification of a vehicle operator in a proximity group can be aided by overlaying locations of mobile devices (e.g. cell phones) with available maps (satellite-based, or others, e.g. on-line maps): For example, if the mobile device appears to be moving on a railroad track, then it is probably used by a passenger and not by the vehicle operator. If the mobile device appears to be moving in an amusement park where the holder does not operate a vehicle but still moves, then there is no reason to implement safety promoting action. [0023] Mapping can also be used to increase the probability of identifying the vehicle operator by determining the location of the mobile device relative to the center of a highway lane. If, for example, the mobile device is identified to be on the left of the center of the lane on which the vehicle is moving, then it means that it is more likely to be the mobile device used by the driver or a passenger behind the driver, and not by other people in the vehicle. This increases the probability of identifying the driver. Within the grouping, the “front” mobile device is likely to be used by the driver. Also, if there is no mobile device activity to the near right of the driver, then the mobile device activity is more probably coming from the driver himself/herself, since normally if there is more than one person in the car, that person is likely to sit next to the driver. [0024] Mapping that includes a third dimension, namely altitude, can also be utilized to advantage. For example, based on geographical input and altitude, the presence of the active mobile communication device in an aircraft can be discerned, with appropriate restriction or limitation of use being applied. [0025] FIG. 4 is a flow diagram of a routine for controlling the processor of FIG. 2 (and/or additional or alternative processors) to implement a technique in accordance with an embodiment of the invention for determining the use of an active mobile communication device by a vehicle operator in a situation where plural mobile communication devices, such cell phones, are present in a moving proximity group. The block 402 represents monitoring the location of an active mobile device, and the decision block 405 represents determination of whether the location is considered relevant. When this condition is met, the block 408 represents the monitoring of the speed of the active mobile device, it being understood that inquiry is continuously made (decision block 410 ) as to whether the monitored speed exceeds a predetermined threshold. If not, monitoring is continued. If so, however as represented by the block 415 , locations of mobile communications devices in a defined proximity group are determined. These operations will typically be performed in parallel for a multiplicity of devices at relevant locations (dashed arrows 420 ). The devices may be in use (active) or passive, but in a mode where positional determination can be implemented. The size of the proximity group, including uncertainties, can be modified, depending on positional map determination, which can indicate whether vehicular motion is more likely to be a private vehicle or public transportation such as may be indicated by a mapped railroad track region, a mapped bus lane, etc. [0026] Next, inquiry is made (decision block 420 ) as to whether more than one device is involved. If not, the device is considered as having a substantial likelihood of being the vehicle operator (block 422 ). If so, the block 430 represents determination of velocity vectors for the mobile communication devices in the proximity group at reference times t 1 , t 2 , . . . (see the example of FIG. 3 ). Then, as described, initial values for the relative locations of the mobile devices in the proximity group (vehicle) can be determined at the referenced times (block 435 ). The block 445 represents an optional interpolation of measurements at the referenced times, t 1 , t 2 , . . . to minimize positional uncertainty and obtain refined locations of mobile communication devices in the proximity group (see, again, FIG. 3 and its accompanying description). Then, the block 455 represent the determination of the probability that the active device is being used by the person at the position of the vehicle operator. [0027] Referring back to block 435 , the output thereof is also input to block 460 , which represents the retrieving of information from the data bases 280 (see FIG. 2 ) that is relevant to the latest location, for example, geography of the location, weather at the location, traffic, time of day, etc. These factors, together with the determined speed and the probability of use by a vehicle operator, are used, in the example of this embodiment, to determine the probability of a safety hazard (block 470 ). Then, as represented by the block 480 , determination is made based on the hazard probability and predetermined thresholds, of action to be taken. In the example of the present embodiment, these actions include sending a warning indication signal, issuing a conditional disabling signal, and, at the higher levels of probability of safety hazards, issuing a “hard” disabling signal. [0028] The invention has been described with reference to particular preferred embodiments, but variations within the spirit and scope of the invention will occur to those skilled in the art. For example, it will be understood that other techniques, consistent with the principles hereof, can be used to detect a probability or certainty that the active mobile communication device is being utilized by the vehicle operator.
A method for controlling operation of an active mobile communication device, including the following steps: performing a first determination of whether the device is in a moving vehicle at a relevant location; performing a second determination of whether the user of the device is the vehicle operator; and producing a risk indication signal as a function of the first and second determinations
7
This is a continuation, of application Ser. No. 457,795, filed Apr. 4, 1974, now abandoned. BACKGROUND OF THE INVENTION In the technology of founding the need has arisen for a source of sand having accurately determined proportions of solid and liquid additives, the source to deliver sand at a variable rate according to the momentary need of the foundrymen. While the art of mixing per se as a mechanical process is well advanced, the expedients known to me all require means for individually varying the feed rate of each component, when a total supply rate is to be changed, in order to maintain the proportions of a mixture unchanged. SUMMARY OF THE INVENTION My invention comprises the new concept of simultaneously varying the feeds of the various components while maintaining them in the same proportion, and the new mechanical arrangement described below for realizing this concept. Briefly, a conveyor supplies sand to my mixer, the arrangement being such that the quantity of sand delivered is determined by the speed of the conveyor: an auger supplies iron oxide to the conveyor at a rate determined by the speed of the auger. The conveyor and auger are both driven by fixed gearing from a variable speed drive, so that no matter how the drive varies, the speeds of auger and conveyor remain in the same proportion. The same variable speed drive is also coupled by fixed gearing to one or more variable speed pumps, which supply liquid ingredients directly to the mixer: the proportion of liquid accordingly remains constant also, as the drive speed varies. The mixer itself is separately powered to operate at a substantially constant speed, its output rate being in fact a throughput determined by the rate of supply of input ingredients. It is accordingly an object of my invention to provide a new and improved process and method for supplying a foundry sand mixture of constant proportion at a varying rate. More specifically my invention includes a conveyor, an auger, and at least one variable speed pump all powered by a single variable speed drive to supply properly proportioned solid and liquid ingredients to a mixer at any desired rate. Various other objects, advantages, and features of novelty which characterize my invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, FIG. 1 is a view of my invention in elevation; FIG. 2 is a view taken along the line 2--2 of FIG. 1; FIG. 3 is a fragmentary view taken along the line 3--3 of FIG. 1; FIG. 4 is a fragmentary plan view of the apparatus of FIG. 1, parts being broken away along line 4--4 of FIG. 1; and FIG. 5 is a system diagram illustrative of my new process. DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in FIG. 1, my foundry sand mixing apparatus is mounted on a base 11 for pivotal movement about a vertical axis, to facilitate delivery of sand at a number of locations, for example, to any of several molding areas surrounding the apparatus. The frame 12 of my apparatus includes a cantilever arm 13 at one end of which is mounted a mixer 14 including a housing 15 and a shaft 16 carrying paddles 17 and mounted in bearings 20 and 21 in the ends of the housing. Also mounted on arm 13 is a motor 22 for driving the mixer shaft at a substantially uniform speed. The paddles are canted on shaft 16 so that they not only agitate any solid material in the housing but gradually propel it toward an output spout 23 at one end of the housing. The material is fed to the mixer through a hopper 24 at the other end of the housing from spout 23. Supported on hopper 24 and a bracket 25 at the other end of arm 13 is a belt conveyor 26 shown to comprise a housing 27 in which are rotatably mounted a drive roller 30 and a plurality of idler rollers 31, 32 and 33 carrying a conveyor belt 34. The cover 35 of the conveyor is pierced by a sand hopper 36 connected to a supply of foundry sand, and terminating inside the conveyor, at a short distance above belt 34, in a spreader 37. The axis of rotation of base 11 passes through the center of sand hopper 36, so that sand can continuously be supplied to the hopper regardless of how the apparatus is pivoted. Roller 31 is almost directly under hopper 36 to support the weight of the incoming sand. As the belt moves in the direction shown sand is delivered as a layer, of fixed thickness under the spreader, tapering to zero thickness toward the sides of the belt. The supply of sand is sufficient to always keep hopper 36 full, so that the sand layer on the belt is of uniform cross section and is delivered to hopper 24 as the belt moves around roller 33. A variable speed drive 40 including a motor 41 is mounted on a casing 42 and includes a speed varying lever 43. The output shaft of drive 40 carries a first sprocket wheel 44, connected by a sprocket chain 45 to a second sprocket wheel 46 on the shaft of roller 30, to drive the conveyor belt. It is obvious that the quantity of material delivered by the belt to hopper 24 varies only with the speed of the belt, that is, with the setting of lever 43. One of the desired additives for foundry sand is iron oxide, also a solid material. This additive is used in comparatively small quantity, and accordingly is supplied from a refillable hopper 47 mounted on rails 50, 51 on the top of conveyor 26. The hopper tapers at the bottom to supply an auger 52 which projects laterally from hopper 47 in a horizontal tube 53, to discharge material through an aperture 54 in the top of the conveyor directly on the belt, before it reaches sand hopper 36. It will be apparent that the amount of iron oxide fed to the belt in any given time is determined by the speed of the auger, and that if the belt moves at a given speed beneath aperture 54 the amount of iron oxide delivered to the mixer is determined by the speed of the belt as well as that of the auger. The auger carries a sprocket wheel 55 which is connected by a sprocket chain 56 to a further sprocket wheel 57 carried by the shaft of roller 30. This arrangement insures that regardless of the rate at which sprocket chain 45 is driven, roller 30 and auger 52 always operate in fixed ratio to one another, so that the proportion of iron oxide to sand remains constant. Casing 42 contains a pair of variable speed pumps, driven by a shaft which carries a sprocket wheel 60. This wheel is connected by a sprocket chain 61 to a sprocket wheel 62 mounted, like sprocket wheel 44, on the output shaft of variable speed drive 40. Each pump is of the conventional nature to give a fluid output which varies with the speed of the pump. The first pump is connected by an input hose 63 to a source of a first liquid ingredient, which is supplied at an output hose 64. The second pump is connected by an input hose 65 to a source of a second liquid ingredient, which is supplied at an output hose 66. As long as the sprocket wheels are not changed, the fluid supplied by the pumps varies solely with the speed setting of lever 43, and hence remains proportional in quantity to the solid ingredients. Hoses 64 and 66 are carried along the underside of conveyor 26 and empty into housing 15 of mixer 14 at 67 and 70 respectively. The sources of the liquid may conveniently be fifty-five gallon drums, not shown, contained within the frame of the apparatus for rotation therewith on the base 11. It will now be clear that there is only one variable available to the foundryman, namely the setting of lever 43 to adjust the mixture output volume. The relative outputs of the conveyor, the auger, and the pumps are all fixed by the designer when he selects the sprocket wheels, and if some other ratio is desired substitution of sprocket wheels must be accomplished. I conceive that it may be desirable to insert a two-speed change gear in casing 42, for example, if it should appear that two different proportions of liquids to solids may frequently be desired, or that a clutch may be provided between sprocket wheel 55 and auger 52 so that the supply of iron oxide may be cut off if desired, and I conceive both of these modifications to be within the spririt of my invention. Numerous objects and advantages of my invention have been set forth in the foregoing description, together with details of the structure and function of the invention, and the novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
Means for delivering a foundry sand mixture at a variable rate, the proportions of the ingredients in the mixture being constant as the total quantity varies. A single variable speed motor comprises the sole drive for separate components supplying different solid and liquid ingredients to the mixer itself, which has an independent drive. The machine components include a conveyor, an auger, and at least one variable speed pump.
1
BACKGROUND OF THE INVENTION The invention relates to a method of controlling a warp beam drive of a weaving machine in which the warp beam drive speed is proportional to a value governed by the number of rotations of the warp beam and the tension of the warp thread, and to a device for carrying out the method which includes a control for influencing the warp beam drive, and a device for measuring the tension of the warp threads and generating a signal to the control. Such a method, as well as a suitable device for carrying out the method, is disclosed in German Pat. No. 29 39 607. There, the tension of the warp threads is measured by the position of a dancer, and the number of revolutions of the warp beam is recorded by means of a driving pinion. Both measurements are supplied to a controller or regulator, which controls a driving unit that drives the warp beam at a predetermined speed. The aforementioned device does not deliver satisfactory weaving results, particularly when the warp beam is started up from a stationary condition. In such instances, so-called "stop marks" or "start marks" are formed in the woven fabric. This flaw originates from the fact that the dancer is inclined to overswing or over-shoot on starting up and therefore no longer delivers any usable or rated or ideal value for the controller. Also, the starting-up setting means proposed in the aforementioned patent, which supplies a specific starting curve for starting up the warp beam drive and thereby replaces the position of the dancer as a nominal or rated value signal, can only to a limited extent eliminate the occurrence of stop marks in the woven fabric. SUMMARY OF THE INVENTION The object of the invention is to improve the known method in such a manner that no flaws or errors occur even when the warp beam drive is started up from a stationary condition, and therefore no stop marks or start marks are formed in the woven fabric. The method of the invention is a modification of the known method in that, before the warp beam drive is started up again from a stationary state, the tension of the warp threads is raised to a predetermined value by rotating the warp beam backward or in reverse and, during the starting-up is taken back to a likewise-predetermined value through action on the warp beam drive. In this manner, for one thing, the tension of the warp threads normally used as the rated or nominal value is replaced by predeterminable values or functions, and for another thing, the tension of the warp thread is adjusted to these values or functions by rotation of the warp beam. In that way, it is possible to influence the starting-up process of the warp beam drive so precisely that no stop marks or start marks can be detected in the woven fabric. In one embodiment of the invention, the predeterminable normal value corresponds to the value of the tension of the warp threads before the warp beam is first started up, while the predeterminable heightened value forms a constant difference with the normal value, which for its part is dependent on the starting-up behavior of the main drive. In a further embodiment of the invention, the type and manner of taking into consideration the tension of the warp threads when the warp drive is started up are attained by the fact that the setting-back of the tension of the warp threads from the predeterminable heightened value to the normal value is performed in the form of a pre-supposed time-dependent function. In that way, it is possible to adapt the lowering of the tension of the warp threads precisely to the starting-up behavior of the main drive and thereby to avoid any flaws or errors in starting up. In a particularly advantageous embodiment of the invention, the regulating or control device is designed in digital form, particularly in the form of a suitably-programmed digital computing apparatus. The device for measuring the number of rotations of the warp beam is realized with the aid of an impulse emitter coupled to the warp beam, which generates a specific number of digital impulses per whole rotation of the warp beam. The device for measuring the tension of the warp threads is put into effect by means of a potentiometer, which detects the position of a tension roller which determines the tensile stress or strain of the warp threads, and to which an analog-digital converter is coupled at the outlet side. With this arrangement, it is possible that the regulating or controlling device can at every moment detect and process, exactly, the tension of the warp threads and the number of revolutions of the warp beam. Therewith it is also possible, in a case where the warp beam drive is standing still, to raise the tension of the warp threads to the predetermined value and to reset it again to the normal value during the starting-up of the warp beam drive. Of particular advantage in connection with the invention is the use of the impulse transmitter, since with the latter not only the number of revolutions of the warp beam drive, but also the number of impulses which result through turning the warp beam backward in order to increase the tension of the warp threads, can be measured. This number can be further used to particular advantage in forming the starting-up function. With the apparatus of the present invention, the forward movement of the interwoven warp threads--that is, the woven fabric--is measured with the aid of a second impulse transmitter which is coupled to a shaft that is operatively connected to the woven warp threads by means of friction. The velocity of the forward movement of the interwoven warp thread serves to further act upon the regulating of controlling device and therewith to influence the warp beam drive. The warp drive itself is provided as a drive which is regulatable in its number of rotations by means of alternate actuation of a coupling and a brake. Optionally, however, any other regulatable drive may be employed. Further features and advantages of the invention will be apparent from the claims as well as from the following description with reference to the drawing, in which is shown a preferred embodiment. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 shows a schematic block circuit diagram of a regulator or control in accordance with the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT In FIG. 1, warp threads 11 are unwound from a warp beam 10 and guided by means of a first deflector roll 12, a dancer 13, and a second deflector roll 15 to a weaving machine, which is indicated schematically by the reference numeral 16. There, the warp threads 11 are subjected to the shedding process, whereby the warp threads designated 17 form the upper warp and those designated 18 form the lower warp, through which the woof or filling threads are guided in a conventional manner. Leaving the weaving machine 16, the now-interwoven warp threads 11--that is, the woven fabric 19--run between two driving rollers 20 and thereafter are wound upon roll 21. The warp beam 10 is driven by a warp beam drive 25, while the two driving rollers 20 are set into motion by means of a roller drive 26. The roller drive 26 is the main drive and is therefore labelled with an M, because it is a "Master Drive"--that is, an independent drive--while the warp beam drive 25 is characterized by an S, because it is a "Slave Drive"--that is, the drive is dependent on the roller drive 26. To the warp beam 10 and to one of the two drive rollers 20 are connected impulse transmitters 27 and 28, respectively, each of which generates a specific number of digital impulses at every rotation of the warp beam 10 or the drive rollers 20. As an example, this may be accomplished by fastening a disk, which has teeth on its outer edge, to the shaft of the warp beam 10 or to one of the two drive rollers 20. The number of rotations of the shaft is then detected by a device--a light barrier, for example--which detects the individual teeth as they pass by and emits a signal for each tooth which has moved past. An impulse-former stage connected to this device can then upgrade this signal to a corresponding digital impulse. The number of such digital impulses per specific unit of time then yields the number of rotations of the shaft. At the same time, with such an impulse transmitter, it is possible, to certain extent, also to perform angular or odometrical measurements in one rotation of the shaft, by counting the number of impulses generated by this rotation and combining them with the spacing of the teeth of the impulse transmitter. The dancer 13 serves to equalize the variations of velocity of the warp threads 11 which originate through the shedding process. For this reason, the dancer 13 moves up and down synchronously with the shedding process. The dancer 13 is held by a spring 14, so that the warp threads 11 are always under tension. The position of the dancer 13 is detected by a motion pickup 29 and a zero-point pickup 31. An analog-digital converter 30 is connected to the motion pickup 29 and an impulse former 32 is connected to the zero-point pickup 31. The motion pickup 29 may, for example, be designed in the form of a potentiometer whose pickup is coupled to the dancer. On the other hand, the zero-point pickup 31 may be a switch which is closed at a specific, predetermined position of the dancer 13 but otherwise is always open. The output signals from the impulse transmitter 27, the impulse former 32, the converter 30, and the impulse former 28, designated IS, NP, TS, AND IM respectively, are suplied to a computing apparatus 35, which as a further input signal is acted upon by a value U and which generates an output signal which is put through to a digital-analog converter 45. The computing apparatus includes a conversion computation 36, a nominal value computation 37, a theoretical-actual comparator 38, an actual-value correction 39, and a linkage 40. The signal TS and the signal U are supplied to the conversion computation 36, while the signal NP and the signal IS are conducted to the actual-value correction 39. Depending on its two input signals, the conversion computation 36 generates an output signal TK, which acts upon the nominal value computation 37 together with the signal IM. The output signal from the nominal value computation 37 is designated ISS and is connected to the theoretical-actual comparator 38. From its two input signals NP and IS, as well as from a signal t, which represents time, the actual-value correction 39 forms an output signal NK, which together with the signal IS is connected to the linkage 40 and there is combined to form signal ISI. Finally, this signal ISI is guided as a second input signal to the theoretical-actual comparator 38, whose output signal controls the converter 45. The number of rotations of the roller drive 26 is given by a signal LWM, which on one hand is supplied to the roller drive 26 and on the other hand is supplied to a converter 47. With the aid of the converter 47, and in dependence on the aforementioned signal U, the signal LWF, which is connected to a linkage 46, to which likewise the output signal LWK from the converter 45 is suplied, is generated from the signal LWM. Finally, the output signal from the linkage 46 is designated LWS, and, for the purpose of controlling the warp beam drive 25, is connected to the latter. The signal LWM is constant and causes the roller drive 26 to drive the driving rollers 20 at a likewise contant number of revolutions. Therefore, the woven fabric 19 is pulled off out of the area of the weaving machine 16 at a uniform velocity. Since the roller drive 26 is the independent drive (Master Drive), the dependent warp beam drive 25 (Slave Drive) must be adjusted to this constant pull-off velocity of the woven fabric 19. This is accomplished by means of the linkage of the signals LWF and LWK to the signal LWS. If the warp beam 10 should have a constant diameter during the entire period of operation of the regulation or control, a constant relationship would result therefrom between the number of rotations of the warp beam 10 and the number of rotations of the drive rollers 20. In such a case, it would suffice to link the signal LWM, which controls the roller drive 26, with the aid of the converter 47 at the same relationship, in order then to directly control the warp beam drive 25 with the output signal LWF. In that case, the signal LWK would be permanently zero because of the constant conversion relationship. However, since the warp threads 11 unwind from the warp beam 10, its diameter gradually becomes smaller with each layer of thread unwound from it. For this reason, it is not sufficient to operate with a fixed relationship of the numbers of rotations of the drive rollers 20 and the warp beam 10; rather, the number of rotations of the warp beam 10 must be corrected because of the constant reduction of its diameter--put more precisely, must be heightened or increased. This is accomplished with the aid of the signal LWK generated by the computing apparatus 35, which influences the warp beam drive 25 by means of the linkage 46. In order that compensation for the diminution of the diameter of the warp beam 10 may be possible, the actual diameter of the warp beam must be measured before the first start-up of the entire regulation or control, and the conversion relationship of the number of revolutions of the warp beam 10 and the driving rollers 20 must be computed therefrom. This conversion relationship must be conveyed, as signal U, to the computing apparatus 35 and the converter 47. Furthermore, before the first start-up of the regulation or control, the actual position of the dancer 13 must be adjusted so that it corresponds to the position detectable by the zero-point pickup. Thus the zero-point pickup 31 must then precisely emit a signal when the dancer 13 is situated in this actual position. If the weaving machine has been started up, the regulation or control is in operation, and the dancer 13 moves regularly up and down, as already mentioned. If the diameter of the warp beam 10 does not vary, the mean value of this movement also remains constant. However, if one thread layer is unwound from the warp beam 10, the diameter of the same diminishes, the result of which is that, because of the number of rotations of the warp beam remaining constant in the first moment, too little warp-thread length is supplied to the weaving machine, and thereby the mean value of the up-and-down movement of the dancer 13 is altered slowly in the form of a long-term upward movement of the dancer 13. This process is established by the motion pickup 29 from the conversion computation 36, so that now the conversion relationship U initially given by the conversion computation 36 can be altered in such a manner that the diminished diameter of the warp beam 10 is taken into account. Detection, particularly of the alteration of the mean value of the dancer 13, can be accomplished though integration of the movements of the dancer, for example. The output signal from the conversion computation 36, which represents the actual conversion relationship--that is, the conversion relationship at any given moment--is linked by the nominal value computation 37 to the signal IM, which, for example, corresponds to the number of impulses in a predetermined unit of time, and in such a manner that, at the end of the nominal value computation 37, there originates a signal (which corresponds to the desired number of impulses in the same unit of time of the impulse transmitter 27 correlated with the warp beam 10. Thus the number of impulses IM is converted to the theoretical number of impulses with the aid of the actual conversion relationship TK. The theoretical-actual comparator 38 compares the number of theoretical impulses ISS with the number of actual impulses ISI, which normally corresponds to the output signal IS of the impulse transmitter 27 when the signal NK is equal to zero. When the number of actual impulses differs from the number of theoretical impulses, the comparator 38 generates an output signal which by means of the linkage 46 influences the warp beam drive 25 in such a manner that diminution of the diameter of the warp beam 10 is compensated by an increase in the number of revolutions of the same. Since the input signals of the theoretical-actual comparator 38 become equal in magnitude because of the increase of the number of rotations of the warp beam 10, the comparator 38 must possess storage--that is, integrating--properties in order to maintain the increased number of revolutions of the warp beam 10. Up to this point, it has been assumed that the signal NK is equal to zero. However, this is the case only when the entire weaving machine is operating at its normal velocity of operation. If, on the contrary, an error occurs during operation, so that the weaving machine comes to a standstill, the entire weaving machine must be re-started after the error has been corrected. The signal NK is not equal to zero during this re-start and has the task of assuring precise, accurate operation of the entire weaving machine when it is started up from a stationary condition, thereby eliminating the stop marks or start marks which would normally occur. If the weaving machine is at a standstill after the occurrence and eliminiation of an error, the warp beam 10 is rotated backward or in reverse for such a time that the zero-point pickup 31 indicates that the dancer 13 is situated in its normal position. In order that this condition may always be able to be attained, the warp beam drive 25 is so designed that the warp beam 10 comes to a standstill after the drive rollers 20, so that the dancer 13 is below its normal position and can attain the normal position through backward rotation of the warp beam 10. Specifically, the warp beam drive 25 continues to run after the drive rollers 20 stop until a selected number of pulses are generated by the impulse transmitter 27. If the signal NP has enabled the actual-value correction 39 to recognize that the dancer 13 has attained this normal position, then, if the warp beam 10 is rotated backward even further, it counts the signals IS generated by the impulse transmitter 27. The actual-value correction 39 is allowed a specific number of impulses X with reference to the signal IM, which is converted by the actual-value correction 39, with the aid of the actual conversion relationship delivered by the conversion computation 36, into a number of impulses Y with reference to the signal IS. If the number of impulses of the signal IS delivered by the impulse transmitter 27 reaches the value of the pre-assumed number of impulses Y, the warp beam 10 is stopped. The dancer 13 is now situated in a position above its normal position, this position being clearly defined by the value of the number of impulses X. In this process, it is important that the value X be converted to the value Y with the aid of the actual conversion relationship, as otherwise the position of the dancer 13 would be dependent on the diameter of the warp beam 10 after the warp beam 10 had been rotated backward, and therewith no definite position of the dancer 13 could be attained. After the dancer 13 has reached the predetermined defined position through backward rotation of the warp beam 10, starting-up of the weaving machine can begin. For this purpose, first of all, the influence of the signal TS on the conversion computation 36 is eliminated, as otherwise an erroneous actual conversion would be computed by the conversion computation 36 resulting from the elevated position of the dancer 13 resulting from the backward rotation of the beam 10. In order that, during the starting-up of the weaving machine--that is, during a period of time T 0 necessary therefore in which the signal TS is not permitted to act upon the conversion computation 36--the signal TK, which represents the last actual conversion relationship, may remain preserved, the conversion computation 36 must have storage--fo example, integrating--properties. The period of time T 0 , during which the signal TK is stored, is imparted to the conversion computation 36 by the actual-value correction 39, which is indicated in FIG. 1 by the broken-line arrow connection. This period of time T 0 , is dependent on the starting-up behavior of the roller drive 26, for example. The displacement of the dancer 13 out of its normal position before the two driving units 25 and 26 are started up presents overshooting of the dancer 13 during the re-starting process. However, the displacement of the dancer 13 must be corrected again at the end of the starting-up process--that is, after the period of time T 0 --in order that the dancer 13 may again move up and down about its normal position in normal operation. This correction is accomplished during starting-up of the two drive units 25 and 26 with the aid of the signal NK/generated by the actual-value correction 39. For this purpose, the actual-value correction 39 stores the value Y, about which the warp beam 10 has been rotated backward over the normal position of the dancer 13, and passes this number of impulses along, as signal NK, to the theoretical-actual-value comparator 38 during the starting-up procedure. Thus, the signal NK manipulates the number of impulses IS in such a manner that, through control of the warp beam drive 25, the mean value of the position of the dancer 13 slowly approaches its normal position again during the starting-up process. At the end of the starting-up process--that is, after the time interval T 0 --the signal NK is zero again, and the mean value of the position of the dancer 13 again corresponds to the normal position. At the same time now, the influence of the signal TS on the conversion computation 36 is again released, so that, after the two driving units 25 and 26 have been started up, the normal control circuit is intact again, and diminutions of the diameter of the warp beam 10 can be taken care of with the aid of the conversion computation 36. The course of the signal NK during starting-up of the drives 25 and 26--that is, during the period of time T 0 --is particularly dependent on the starting-up behavior of the roller drive 26. The course of the signal NK is a function which varies with the time t. It is particularly advantageous to reduce the signal NK from larger to smaller values during the starting-up process--in a linear manner, for example. Likewise, it is conceivable that the course of the signal NK is dependent of the actual conversion relationship at any given moment. For this purpose, the actual-value correction is coupled to the conversion computation 36 by means of the arrow connection represented in broken lines in FIG. 1. The computing apparatus 35, with which the regulation of the warp beam drive 25, and especially the control of the same during starting-up, is accomplished, is built up in digital form. Thereby it is especially advantageous to employ a suitably-programmed digital computer, particularly a micro-processor. Through the use of a digital computing apparatus, it is possible, in a particularly simple and advantageous manner, not only to relate the output signal IS from the impulse transmitter 27--that is, the individual impulses of this signal--to time and therewith to compute a number of revolutions, but also to use it for odometrical measurements or angle measurements, particularly when the warp beam 10 is rotated backward. For this purpose, the individual impulses are counted and multiplied with a factor dependent on the transmitter wheel which generates the impulse, for conversion to the distance or angle covered. Also, it is possible to carry out the function of the zero-point pickup 31 with the aid of the motion pickup 29. For this purpose, only the value measured by the motion pickup 29, which corresponds to the normal position of the dancer 13, which normally is detected by the zeropoint pickup 31, need be stored by the computing apparatus 35. Should the normal position of the dancer 13 be detected, especially during the backward rotation of the warp beam 10, then in such case the value corresponding to the dancer 13 and measured by the motion pickup 29 must be continually compared with the stored value, so that the normal position of the dancer 13 can be recognized when the two values are the same. It is also possible not to undertake the conversion outside of the computing apparatus 35, but rather to perform it with the aid of the same. Then for this purpose it is necessary to digitalize the signal LWM and finally to convert the signal LWS into an analog value again according to the combination undertaken in the computing apparatus. It is particularly advantageous to provide the warp beam drive 25 with a coupling and a brake, which are alternately actuated by the signal LWS, so that, all together, a drive which is variable in its number of revolutions is available. The higher the frequency of the alternate actuation of the coupling and the brake, the more precisely controllable is the number of revolutions of the warp beam drive 25. Finally, the aforementioned dancer arrangement can be used for measuring the tension of the warp threads, and also this warp-thread tension can be measured directly by means of suitable devices, or can be measured indirectly by deflection rollers from the position of tension elements or the stress on the bearing. However, such changes in the embodiment described lie with the sphere of technical knowledge of a skilled expert. Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
In a control for a warp beam drive of a weaving machine, the warp beam drive is regulated at all times by a control which receives input signals representing the number of rotations of the warp beam and representing the tension of the warp threads. If the weaving machine has come to a standstill because of an error which has taken place, then, before the warp beam drive is re-started, the tension on the warp threads is increased to a specific value by rotating the warp beam in reverse, in order, during re-start, to take warp thread tension back to a predetermined normal value again through suitable action on the warp beam drive. The effect of this is that no stop marks or start marks are formed in the woven material as a result of the weaving machine having stood still. This control includes a digital computer, to which the number of rotations of the warp beam is supplied by means of an impulse transmitter, and the tension of the warp threads supplied by means of a motion pickup, which picks up the position of a dancer. The signal from the impulse transmitter guided to the computer is used not only as a number-of-rotations signal, but also as a route signal, especially when the tension on the warp threads is raised to the specific increased value.
3
BACKGROUND OF INVENTION [0001] 1. Technical Field [0002] The present invention related to crocheted balls and, more particularly, relates to crocheted balls having an embroidered portion thereof. [0003] 2. Related Art [0004] The utilization of spherical crocheted objects for toys, games and recreations have been increasingly popular over the past several years. Initially, crocheted balls were made and sold as toys through many retailers. Now crocheted balls have many additional uses in sports and recreational activities because they are soft, colorful and inexpensive to produce. Crocheted balls and bags have become very popular for use in sports that utilize soft balls including footbag, juggling, toss ball, kick ball, dodge ball and others. Thus, due to their popularity and wide distribution, spherically crocheted objects make an excellent item for advertising and promotional purposes. [0005] One of the more popular utilizations of the spherical crocheted objects is for the game of footbag. An originating patent, U.S. Pat. No. 4,151,994, for the game was issued in May 1979 to Robert J. Stahlberger, Jr. the inventor of the game of footbag (Hacky Sack™). The original ball that was used for this game was a leather paneled style of ball shaped like a baseball. Years later, this original invention was improved upon with the introduction of several newer styles of footbags that touted improved characteristics for the playing of the game. These improved characteristics included a softer style of ball and low bounce characteristics that allowed for greater control and ease of use by the footbag players, who enjoyed the ability to “catch” the ball with the foot and perform a much wider array of athletic footbag tricks. One of the more popular ball types for the game has become the crocheted footbag. [0006] Crochet is a fabric construction that utilizes needlework consisting of the interlocking of looped stitches formed with a single thread and a hooked needle. The popular crocheted ball is a successful implementation of crochet stitching in a round form. Thread types used include cotton, rayon, dacron, polyester or a combination of several thread types. The thread used is of varying degrees of thickness. Depending on the thickness and type of the thread, a crocheted ball will contain larger or smaller stitches which give the ball an appearance of being fuzzier, thicker or rougher. Crocheted balls are made of varying sizes, weights and looseness based on the game played, preference of the participants of the sport, durability and cost. All spherical crocheted objects can be woven by machine or by hand. [0007] Spherical crocheted objects are woven such that rows contain increasing numbers of stitches expanding outward in a spiral form. Thus, the start of a crocheted ball (the “bottom”) starts with a single stitch; which is added to in a spiral pattern. This spiral construction soon forms a round disc. The spherical shape forms as the disc construction expands and the stitches are tightened to create a curvature. In the middle of the crocheted ball, the rows contain their maximum number of stitches and determine the diameter of the crocheted ball. For instance, if there are 10 stitches per inch then a ball 8 inches in diameter will contain 80 stitches. [0008] As a crocheted sphere is woven, and after it reaches its maximum diameter, the number of stitches per row is reduced. Thereafter the reduction of each successive row gives the ball its shape and the stitches get tighter and closer together. Before the crocheted sphere weaving is completed, a small hole remains. Before the final closure, the ball is filled with a filling type, which is often plastic resin pellets, bird seed or other types of small or inert filling; then the crocheted object is sealed shut with the final crocheted weave and tied off in a knot. A spherical crocheted object is usually seamless and durable with the final sewing termination. [0009] The filling of a crocheted ball determines its characteristics: slackness, feel and the best utility. [0010] Manufacturers have chosen many different filling types and sizes. Crocheted balls are quite durable, seldom rupture and thus can be used in the most active and aggressive games with little chance of breaking open. [0011] The simplicity and low production cost of the crocheted ball is ideal for many applications in games, sports and toys. Crocheted balls are superior for the purpose of game balls because they are very durable while being malleable and soft at the same time. This offers a longevity not found with paneled balls which tend to break open at the seams. The stresses on the fabrics during the use of crocheted balls are dissipated throughout the stitches of the ball as compared to that of a paneled ball which have limited stitches. [0012] Prior to this invention, spherical crocheted objects have been limited in their ability to purport messages. Previous utilizations were predominantly limited to fabricating crocheted balls with designs built entirely into the crocheted construction. Thus, the primary method has been to directly crochet images into the actual weaving by means of changing the colors of the threads on each individual stitch, usually by hand, to create the necessary contrast to create such images. Although images and logos implemented on existing crocheted balls can be quite complicated and intricate, the fact remains that crocheted balls are limited by the number of stitches per inch inherent in the manufacture of such balls, usually 10 stitches per inch or less, depending on the thickness of the thread used. [0013] Alternative utilizations applied to crocheted balls for the purpose of creating a more useful advertising medium have included other attempts to modify their construction. One known attempt has been the addition of a round panel of fabric sewn into the crocheted ball. This panel, which can be of imitation suede or another durable material, is suitable for screen printing and other suitable advertising purposes; however, there are problems with this incarnation. The basic strength of the ball is dubious due to a fixed fabric seam that is incapable of handling the stresses of hard play, and has been known to come undone. Additionally, the fabric is less flexible than the original crocheted stitches so the ball does not function as well for the preferred active sports that require a softer ball. [0014] Still other manufacturers have attempted variants on crocheted balls to enhance the ability to purport messages or logos. Directly dyeing the crocheted threads is a less successful method of applying words, logos or advertising messages since it is often messy and unprofessional in outcome. Further still, a panel of fabric has been sewn to the exterior of crocheted balls as a means of applying a logo or message. This application is also limited because the size of these fabric pieces must be very small and do not stick well to spherical objects when glued or sewn. [0015] In summary, spherical crocheted objects are inexpensive and mass-produced items used for various sporting, recreational and advertising purposes. To date, the several known attempts to extend the message-carrying functionality of these crocheted objects have had limited success. SUMMARY OF INVENTION [0016] The invention changes the procedure and method by which a spherical crocheted object is made. The spherical object no longer contains the limits of low quality or low resolution graphics for the purpose of adding an image, a message, logo, words, name or motif. Utilizing our specific production process allows for the inclusion of an embroidery step during the construction of the spherical crocheted object, enhancing the usefulness of products, games and diversions that utilize them. [0017] The embodiment specifies fabrication steps that allow for the addition of an embroidered logo of a limited size. The size restrictions depend upon the size of the final crocheted ball and more specifically, the size of the initial disc of crocheted fabric upon which the embroidery is sewn. This initial disc should not be more than about 30% of the size of the diameter of the spherical crocheted object. Thus, even though crocheted balls are round, our embodiment avoids attempting to crochet on a round object since current technology embroidery equipment does not effectively sew on spherically constructed objects of closed construction, particularly on crocheted or woven balls of loose and fairly thick thread. [0018] In the current embodiment, spherical crocheted objects, such as crocheted balls, are the recipients of the placement of an embroidery message or logo. Crocheted balls are popularly utilized as toys as well as the primary object of several games and sports, such as juggling and Hacky Sack™, also known as the game of footbag, and other games that require a low impact or soft ball that is durable and often malleable. [0019] Prior to our embodiment previous methods of carrying logos or other publicity images on spherical crocheted object were limited, of low quality, too complicated and of a decorative or ornamental nature mainly. The inherent limitations of the medium of construction the loose and thick crocheted stitching meant that inexpensive crocheted balls were less effective tools for promotion by those seeking inexpensive toys or objects for advertising or incentive purposes. Previous attempts at utilizing crocheted balls required that the messages or advertising images be constructed during the initial construction of the spherical crocheted object, on a stitch-by-stitch level, by using different colored threads that were woven to form a crocheted ball. Still other methods have proven less effective on crocheted balls as compared to direct embroidery processes that allow for a much higher quality and higher resolution output. [0020] Of further importance, but no less significant, is the fact that spherical crocheted object can be quite inexpensive to manufacture. This production process has solved the conundrum of utilizing the inexpensive crocheted ball for the purposes of carrying a high quality embroidered figure or message so that the ball may be utilized more effectively in publicizing an embroidered logo, name, motif, image, worded message, monogram, picture or illustration. Thus, the popular inexpensive crocheted ball can now be utilized as a higher quality medium for publicity purposes, advertising tools, corporate premiums, logo messages, or sports tool touting a team logo. [0021] The invention calls for the modification of the fabrication of the crocheted ball so that it is capable to be sewn by high production embroidery machinery. After the embroidery is finished and the ball is completed according to the guidelines contained herein, the crocheted ball retains its round shape, its noteworthy durability and at the same time becomes a more useful advertising and promotion tool. BRIEF DESCRIPTION OF DRAWINGS [0022] For a fuller understanding of the invention and the process of producing a spherical crocheted object inclusive of embroidery steps, please refer to these drawings in which: [0023] [0023]FIG. 1 illustrates a three dimensional view from an elevated and angled aspect of an unadorned ball in a typical size constructed using standard crocheted weaving; [0024] [0024]FIG. 2 illustrates a bottom view of a crocheted ball that contains the figure of a star that has been embroidered directly onto the crocheted ball according to the present invention; [0025] [0025]FIG. 3 illustrates a three dimensional view from an elevated and angled aspect of a ball containing a star in a contrasting color to that of the base color and that has been crocheted entirely within the ball according to the prior art; [0026] [0026]FIG. 4 illustrates a bottom view of a representation of the crocheted initial disc showing individual crocheted stitch detail according to the present invention; [0027] [0027]FIG. 5 illustrates a bottom view of a representation of the crocheted initial disc showing individual crocheted stitch detail after the placement of a representative embroidered star figure according to the present invention; [0028] [0028]FIG. 6 illustrates a three dimensional view from an elevated and angled aspect of a representation of a crocheted initial disc showing individual crocheted stitch detail after the start of the cylindrical walls according to the present invention; [0029] [0029]FIG. 7 illustrates a three dimensional view from an elevated and angled aspect of a representation of a crocheted ball construction showing individual crocheted stitch detail inclusive of nearly complete cylindrical walls according to the present invention; and [0030] [0030]FIG. 8 illustrates a three dimensional view from an elevated and angled aspect of a representation of a crocheted ball construction showing individual crocheted stitch detail inclusive of cylindrical walls and woven top preceding final seamless closure according to the present invention. DETAILED DESCRIPTION [0031] The invention is embodied in the process by which a basic spherical crocheted object, such as a ball, FIG. 1, is fabricated. Additional fabrication steps transform this simply and inexpensively manufactured object, consisting of crocheted rows of thread 11 , into a more functional object for displaying a message, logo, words or logo. [0032] [0032]FIG. 2 demonstrates the detail when applied to a crocheted ball according to the present invention. A star, 12 , is directly embroidered on top of the crocheted ball. Sewing of the embroidery is preferably a step separate and outside of the basic crocheted fabrication. The nature of the embroidery sewing disclosed herein possesses great detail advantages over crocheted objects. Although images, figures and logos fabricated on crocheted objects can be quite complicated and intricate, the fact remains that crocheted objects are restricted in the number of stitches per inch inherent in the manufacture of such objects. jects. [0033] The limitations of the crocheted construction are further evident in FIG. 3 which shows a crocheted star, 14 , woven directly into a crocheted ball as is known in the art. This is the most common method of adding artwork or a logo to a crocheted object. It is apparent in FIG. 3 that the star does not elucidate a sharp image. The crocheted star is crude, “blocky,” and of minimal detail. [0034] The embroidery sewing of the star 12 , in FIG. 2, on the other hand, elucidates a sharp image. One reason for the sharpness of the embroidery sewing is that the stitches in a crocheted object are large as compared to embroidery stitches. Crocheted thread typically contains more plies, or bundles, of heavier weight thread than embroidery thread. Crocheted thread must be thicker and more rigid to be more effectively used with a hooked crochet needle. [0035] Crocheting, although appropriate for knitting sweaters and afghans, does not serve well for highly detailed tasks that call for a high amount of detail. On the other hand, embroidery, especially machined embroidery, can utilize many types of thread of a thinner and more supple variety with fewer plies. Embroidering equipment usually uses rayon or polyester thread, which is strong and thin, but can also use thread as fine as silk for highly detailed embroidery stitching. [0036] In FIG. 3 the crocheted stitches contain typically, 10 stitches, or lines, per inch. By contrast, the embroidered stitches 13 , in FIG. 3, reveal lines of thread as depicted by the comb teeth-like edge between the black and white arms of the star figure and contain high resolution detail. [0037] For every crocheted stitch, there are approximately 8 lines of embroidery. This equates to about 80 lines per inch, or 8 times the number of lines per inch as compared to the crocheted ball examples. Other crocheted objects, when compared to embroidery objects, educe similar quality comparisons. [0038] Specific steps contained herein must be followed to permit the addition of the more detailed embroidery process upon spherical crocheted objects. In the drawings, the fabrication of a crocheted ball is being shown. An initial step in creating the ball is to establish a starting point, 16 , and crochet in a circular pattern as depicted in FIG. 4. Each individual crocheted stitch is represented by a cross hatched unit because thread used in a crocheted project typically contains multiple plies. In actuality, a crocheted stitch is less clear as the drawing representation in FIG. 4 because crochet thread tends to twist, fray and coalesce, becoming less distinct than the drawing depicts. The first three drawings are better representations of an actual crochet object which shows the thread as thick filaments. [0039] As the crochet stitches are added, they are attached to each proximate stitch as shown in item 15 . Likewise, as the stitches are added in a circular motion, they are attached to the proximate row as shown in item 17 using the hooked crocheted sewing technique as depicted in item 18 . This technique is the origin for the durability of spherical crocheted objects. In addition, the crocheted object attains the ability to stretch and deform due to a general slackness in this type of multi-plied weaving. [0040] An aspect of producing a spherical crocheted object is the creation of an “initial disc,” the product shown in FIG. 4. This initial disc is the base from which the embroidery is fashioned. It is imperative that the last stitch in the construction of the initial disc be tied off so that it does not come unwound. The initial disc must be substantially flat so that it can fit into the commercial embroidery machines for quick and effective stitching. Thus the stitches of the initial disc should not be tightened with each successive woven row. The stitching is created as one would create a flat weaving such as a placemat, coaster or other woven article with the stitches flaring out so that no shape is started. This differs from the current construction of spherical crocheted objects and is one important element of the invention. [0041] The initial disc can be of any crocheted stitch combination upon which embroidery is placed. A solid color is a common choice although crocheted designs can still be used for the initial disc creation. Usually contrasting colors are chosen so the embroidery is visually recognizable and distinct. Any combination of thread colors can be chosen for the embroidery step. Many commercial embroidery machines can be loaded many different color threads so that an entire multi-color design can be done in a few seconds. [0042] It is also important that a diameter of the initial disc is not larger than about 30% of the final circumference of the spherical crocheted object. Thus, for example, in a preferred embodiment, if the spherical crocheted object will have a final circumference of approximately 7.5″ inches, the initial disc must be no more than approximately 2.25″ inches in diameter when lying flat in order to work best for the embroidery. As the width of the initial disc exceeds 30%, the crocheted object will turn out less spherical, and will look oblong or misshapen. The diameter of the initial disc can be smaller than 30% of the final total circumference; however, a smaller initial disc reduces the area available for the embroidery. It is the upper threshold to which must be observed and adhered in the embodiment. Since the aim is to create an area upon which the higher quality embroidery may be sewn, and a discernible message may be advertised, the goal of maximizing the initial disc size is advised by keeping the diameter of the initial disc about 30% of the final circumference of the spherical crocheted object. [0043] A next step of the invention is to utilize a commercial grade, high quality modern embroidery machine to directly embroider the logo on a substantially flat or the non-curved initial disc. Examples of commercial grade embroidery machines are the Tajima Bridge Type Cylindrical Frame Machine line, the SWF model 1508 multi-head embroidery machine or other equivalent commercial grade machines, either multi-head or single head. Other embroidery machines can be utilized for this step, but for quantity production, the multi-headed machines will function better than the single headed machines. Although machine embroidery is preferred, the embroidery can also be applied by hand. Some embroidery equipment is made for special functions and a wide range of options are available to individuals seeking to create artistically appealing thus effective logos or images. [0044] It is, however, important that the embroidery does not exceed the diameter of the initial disc. In FIG. 5, the length of the embroidery is less than 2.25 inches because, in our drawing, this is the diameter of the initial disc. The needle of the embroidery machine should, in fact, remain at least one, preferably two embroidery rows away from the edge of the initial disc as depicted by the separation of the two pointers in item 19 . This way a solid and a well defined embroidery logo can be woven firmly onto the intial disc, such as the sample star, 12 . It is advised that no paper or fabric backing is used during the embroidery, which is a common step when embroidering with high quality embroidery machines. These backings tend to offer support to the embroidery whereas the article in question for this embroidery is a crocheted disc that needs to remain soft and pliable after the embroidery fabrication step. However, it is up to the manufacturer to determine the final “feel” of the spherical crocheted object. Selecting or not selecting an embroidery backing will affect this result. [0045] The embroidery should then be finished off. Once disconnected from the embroidery machine, all loose threads should be tied off or cut on the front side of the “initial disc.” The back side the initial disc may contain loose and unfinished threads. This is acceptable because this portion of the initial disc will be located on the inside of a spherical crocheted object. Although not important to the embodiment, it may be the choice of the manufacturer to trim the extra threads to avoid difficulties in the later fabrication steps, although the economy and complexity of the project may influence this decision. With the completion of the embroidery, the initial disc is ready for the next step of the weaving process. [0046] The next step of the process of an embodiment is illustrated in FIG. 6 and performed on our initial disc. The final stitch that had been tied off is untied and the crochet process continues, only this time the rows are tightened so that the row of stitches bends upward, item 22 , starting at point 21 . Each successive row of crocheted stitches are woven in a spiral fashion flaring out from the initial disc, 20 , and each stitch is hooked into the row beneath it as with the initial disc construction. [0047] This is a crucial point in the fabrication process of the embodiment. Since the initial disc is flat, the ball must be woven so that it forms a spherical object or ball, and to accomplish this, each stitch must be pulled upward as woven at 23 , and tightened before they are hooked together. The loose threads, 24 and 25 , are crocheted and build upon the rows consecutively. If the color of the crocheted ball is to be solid, then the continuation of the weaving should include the identical color thread; if additional designs are to be included in the final spherical crocheted object, this is a logical point to initiate a thread color change for the creation of a crocheted design on the object. [0048] As successive rows are added to the previous row, a cylinder takes shape as shown in the FIG. 7, which looks somewhat like a cylindrical wall with successive and stacked rows of crocheted stitches, 35 through 43 . As noted in FIG. 7, the construction of the cylindrical wall is akin to the “side” of the crocheted ball and the bottom, the initial disc, being the initiation point and center that contains the embroidered figure. The top will be the final termination and closure point of the ball. Thus, the ball has a top and bottom for the purposes of our embodiment description and the cylindrical wall will have a center, or point of maximum diameter, which in our drawing lies between rows 38 and 39 because there is an even number of rows. For a construction with an odd number of rows, there would be one row designated as the row of maximum diameter, or center. [0049] A crucial aspect at this important construction stage of an embodiment is in calculating and duplicating the number of stitches per row. The number of stitches per row will vary depending on the size of the initial disc which, as mentioned before, is determined by the desired size of the embroidery logo and the desired size of the crocheted ball. Independent of the ball size, a formula can be utilized for the purposes of the embodiment that will direct the manufacturer to make a crocheted ball that will retain its all important round shape. [0050] In the first row of the crocheted cylindrical wall, it is important to note the number of stitches and abide by some conditions when building upon the cylindrical wall rows. First, the number of stitches should never be reduced when building up the cylindrical walls. The counted stitches may be kept the same or increased slightly to the point that which the maximum diameter of the ball is attained. Reducing the stitches in the successive rows will cause the ball to be misshapen, an undesired result. In FIG. 6, the successive rows contain 60 stitches each. All the rows in the cylindrical walls contain 60 stitches. If rows 35 through 38 contained less stitches than the previous, then the ball may end up misshapen. However, if row 35 contained 61 stitches and row 36 contained 62 stitches, this would be an acceptable iteration for this construction. [0051] The point that which the maximum diameter of the spherical crocheted object is attained is another calculation that is important in the construction in accordance with our embodiment. It has been found that to make a spherical crocheted object like a ball, the cylindrical sides of the ball should have a number of rows that is between around 36% and around 46% of the total number of rows in the construction of the ball. In our drawing, FIG. 5 contains 10 crocheted rows in the cylindrical wall of this crocheted ball which is approximately 38.5% of the total number of rows of this ball construction. In this drawing and in this sample, there are 10 rows on the cylindrical wall. In our drawing it can be determined that the center, or diameter, of the ball is between rows 38 and 39 from the bottom of the cylindrical wall. However, this value can be determined in advance by calculating the midway point in the cylindrical wall using our estimate of acceptable wall size, which can be estimated in advance to be between rows 38 and 39 . [0052] Next, once the maximum diameter of the ball is attained, it is acceptable to reduce the number of stitches per row, for rows 39 through 43 ; or to maintain the same number of stitches in the ball, in order to maintain a round ball. It is not recommended to increase the number of stitches or again a misshapen ball will result. In large scale production, it may be unreasonable to count stitches, so maintaining the same number of stitches for each row in the middle is an acceptable and advisable practice. Once the ball is complete, due to the nature of crocheted stitches, the threads will stretch giving the ball its desired round shape. [0053] It must be noted that the construction of a spherical crocheted object is not a precise science and variations will arise. Variables include the thickness of the thread, size of the stitches and slackness of the stitches. In addition, for the construction of a spherical crocheted object, there is often no definite demarcation as to where the cylindrical wall starts and the bottom construction ends, particularly once the first row in the cylindrical wall is begun and tightened, which tends to warp the entire construction upwards, forcing it into the shape of a ball. Thus, we have supplied relative percentages for the purposes of calculating the proper construction of the embroidered crocheted ball; however, these values are quite close and have been determined over repeated testing and constructions. [0054] In our embodiment, the point at which it can be determined that the cylindrical walls have ended (FIG. 7, item 44 and 45 ) we complete the top of the embodiment. Taking the remaining loose threads, 46 , we start to crochet the top of the ball, bending them as stitches are added as shown in FIG. 8. This crocheting step will generally match the bottom initial disc, 20 , of the crocheted ball (in terms of size and number of rows) which contains the embroidered portion of the construction. The embroidery portion can not be viewed in FIG. 8 because it is on the bottom of the ball. [0055] It is important to leave a small hole, 28 , in the top of a spherical crocheted object. This hole is where a filling is inserted and a final closure is made. The ball is typically filled with plastic pellets or some other desired filling. The volume percentage of the filling will determine how slack or firm the ball feels. A large number of manufacturers that utilize the crocheted ball for the game of footbag use plastic pellet filling of approximate 2 millimeters diameter in size, of varying shapes, and choose to loosely fill the crocheted ball with from 40 to 75 fill percentage to give the ball the low bounce characteristics desired by many of the players of the game. Manufacturers of crocheted juggling balls tend to fill the crocheted ball with 100 percent fill to give the ball a harder feel and an easier grip which is more suitable for their sport. Many other fill types and combinations exist. In our embodiment, filling and closure are all part of the normal manufacture found in the production of crocheted balls. Note in FIG. 8 that a hole has been left with two loose threads, 24 and 25 . Commonly the extra thread is left to perform the final closure after filling. The final closure is done using the crochet hooked needle and tied off to seal the construction. [0056] Due to the pliant and soft nature of the thread materials such as those used in the fabrication of spherical crocheted objects, once completed, the object will lose the cylindrical shape and transform into the shape of a ball. This transformation can be accentuated by compressing or kneading the ball under pressure which will stretch out the stitches to give the crocheted ball a more round appearance, and will enhance the playability features desired in a ball of this type. [0057] By following the construction process laid forth herein, a spherical crocheted object will have been successfully created that contains an embroidered logo and that can be duplicated on a large scale.
A spherical crocheted object includes a portion that contains high quality embroidery and is made beginning with a fabric piece called an initial disc. By initially knitting the spherical crocheted object into a flat, round disc of specific and limited dimensions, this initial disc is created for the introduction of an external embroidery process. The crocheted initial disc is tied off to maintain durability during the embroidery step, which is usually performed on specialized embroidery equipment. Thereafter, by vigilantly following specific construction techniques, a ball will be produced that retains its spherical shape resulting in an end product with characteristics similar to that of a spherical crocheted object that does not contain embroidery.
3
CROSS REFERENCE TO RELATED APPLICATION This application is a division of 07/087,789 filed Aug. 25, 1987 now U.S. Pat. No. 4,847,157 which is a continuation-in-part of our now pending application Ser. No. 901,282, filed Aug. 28, 1986 now abandoned. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a continuous, chemical vapor deposition method for producing a coated glass article, particularly, coated heat reflective architectural glass, and to the coated article so produced. In a specific embodiment, the invention relates to such a method for producing a glass article coated with a layer of silicon formed by treatment with a non-oxidizing gas comprising mono-silane (SiH 4 ), and in some instances a mixture of mono-silane and ethylene (C 2 H 4 ), a titanium nitride layer formed on the silicon layer by mixing a titanium tetrahalide, e.g., TiCl 4 , with a reducing gas like ammonia and then reacting the gases at or near the surface of the silicon, and, on the titanium nitride layer, a second layer of silicon formed by treatment with a non-oxidizing gas comprising mono-silane or mono-silane and ethylene. The invention optionally includes the step of forming a protective layer, e.g., an abrasion resistant layer, on the second layer of silicon, which protective layer may comprise tin oxide. 2. The Prior Art The production of architectural glass coated with silicon formed by continuous chemical treatment with a non-oxidizing gas comprising mono-silane is disclosed in U.S. Pat. No. 4,019,887, "Kirkbride et al.". The method disclosed by Kirkbride et al. is suitable for carrying out certain steps of the method of the instant invention, namely, that of forming a layer of silicon coating on a glass surface and on a titanium nitride coating. The addition of ethylene to the Kirkbride et al. non-oxidizing gas comprising mono-silane is disclosed in U.S. Pat. No. 4,188,444 "Landau", as is a benefit derived from such use of ethylene, namely that the silicon coating has significantly improved resistance to alkali. The use of ammonia and TiCl 4 mixtures to produce titanium nitride coatings on glass by chemical vapor deposition is disclosed in U.S. Pat. No. 4,535,000, "Gordon". The production of a glass article having a surface coated with a layer of silicon produced by the method of Kirkbride et al. and additionally coated with a layer of a metal oxide, deposited on the silicon, is disclosed by U.S. Pat. No. 4,100,330 "Donley". Most architectural glass is produced by the "Float Glass Process", a part of which is shown in the drawings of Kirkbride et al. This process involves casting glass onto a molten tin bath which is suitably enclosed, transferring the glass, after it cools sufficiently, to rolls that are aligned with the bath, and cooling the glass as it is advanced on the rolls, first through a lehr and, finally, while exposed to ambient conditions. A non-oxidizing atmosphere is maintained in the float portion of the process, in contact with the tin bath, to prevent oxidation, while an air atmosphere is maintained in the lehr. It will be appreciated that it would be advantageous, when it is desired to coat glass with silicon and titanium nitride and subsequently with tin or another oxide, to do so in conjunction with the production thereof by the float glass process. The glass is at a suitable temperature, as is disclosed by Kirkbride et al. and Gordon, in the float portion of the process for treatment to apply a silicon coating and a titanium nitride coating. It is also at a suitable temperature in some parts of the lehr, which contains air, for treatment of a surface thereof with an oxidizing gas comprising tetramethyl tin to form a tin oxide coating. THE INSTANT INVENTION The present invention is based upon the discovery that a coated or filmed glass article having particular utility for glazing buildings in that the coating possesses a low emittance which enables it to be glazed to the inside of the building and still provide very beneficial solar properties, can be obtained with a structure including a glass substrate, a first silicon coating adhered to the glass substrate, a titanium nitride coating adhered to the silicon coating, a second silicon coating adhered to the titanium nitride coating, and an optional metal oxide coating adhered to the second silicon coating. The low emittance also provides better insulating capability than uncoated glass of equal composition and thickness. The overall heat transfer coefficient or U value of the glass, evaluated under winter time conditions, is significantly reduced with a low emittance coating facing the interior. For example such coating with an emittance of 0.22 has a U value reduced by 30 percent, or a net heat savings of 21 Btu/hr./ft. 2 calculated for 70° F. inside and 0° F. outside for a single thickness of glass over uncoated glass. BRIEF DESCRIPTION OF THE DRAWING The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to structure and method of manufacture, together with additional objects and advantages thereof, will best be understood from the following description of specific embodiments when read in connection with the accompanying drawing, in which: FIG. 1 is a somewhat schematic view in vertical section of apparatus for practicing the float glass process which additionally includes four gas distributors suitably positioned to enable the practicing of the method of the instant invention; FIG. 2 is a broken sectional view of a coated article according to this invention; and FIG. 3 is a broken sectional view illustrating another coated article of the invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawing, apparatus for practicing the float glass process, indicated generally at 10, comprises a float section 11, a lehr 12 and a cooling section 13. The float section 11 has a bottom 14 which contains a tin bath 15, a top 16, sidewalls (not illustrated) and walls 17 which form seals so that there is an enclosed zone 18 within which a non-oxidizing atmosphere is maintained, as subsequently described in more detail, to prevent oxidation of the tin bath 15. In operation of the apparatus 10, molten glass, as indicated at 19, is cast onto a hearth 20, and flows therefrom under a metering wall 21 and downwardly onto the surface of the tin bath 15, from which it is picked up by rolls 22 and conveyed through the lehr 12 and the cooling section 13. A non-oxidizing atmosphere is maintained in the float section 11 by introducing a suitable gas, for example, one composed of 99 percent by volume of nitrogen and 1 percent by volume of hydrogen, into the zone 18 through conduits 23 which are operably connected to a manifold 24. The gas is introduced into the zone 18 from the conduits 23 at a rate sufficient to make up for losses (some of the atmosphere leaves the zone 18 by flowing under the walls 17) and to maintain a slight positive pressure, say 0.001 to 0.01 atmosphere above ambient. The metal bath 15 and the enclosed zone 18 are heated by radiant heat directed downwardly from heaters 25. The atmosphere in the lehr 12 is air, while the cooling section is not enclosed, ambient air being blown onto the glass by fans 26. The apparatus 10 also includes gas distributors 27, 28 and 29 in the float zone 11 and a gas distributor 30 in the lehr 12. The following Examples, which constitute the best mode presently contemplated by the inventors, are presented solely for the purpose of further illustrating and disclosing, and is not to be construed as a limitation on, the invention: EXAMPLE I The apparatus 10 was used to practice the method of the instant invention by producing coated float glass. Heat absorbing, green colored glass containing about 14 percent by weight of Na 2 O, 73 percent by weight of SiO 2 , 8.5 percent by weight of CaO, 0.48 percent by weight of Fe 2 O 3 , 0.18 percent by weight of Al 2 O 3 , 0.01 percent by weight of TiO 2 , 4 percent by weight of MgO, and 0.001 percent by weight of Co 3 O 4 was charged onto the hearth 20 and caused to flow onto the tin bath 15 as a sheet twelve feet (3.6 meters) wide and 3/16 inch (5 mm.) thick. The sheet was advanced through the apparatus 10 at a speed of about 27 feet (8.25 meters) per minute. The glass temperature was approximately 2000° F. (1093° C.) on the hearth 20. A non-oxidizing atmosphere was maintained in the zone 18 by introducing a gas thereinto from the conduits 23 to maintain a positive pressure above ambient of 0.006 atmosphere; the gas was composed of 99 percent by volume of nitrogen and 1 percent by volume of hydrogen. Nothing was done to control the atmosphere in the lehr 12; as a consequence, the oxidizing atmosphere therein was air. The glass was treated as it traveled under the distributor 27 by a gas composed of 90 volume percent of nitrogen and 10 volume percent of mono-silane; as it traveled under the distributor 28, by a gas composed of 6 volume percent titanium tetrachloride, 19 volume percent ammonia, and 75 volume percent nitrogen; and finally as it traveled under the distributor 29 by a gas composed of 95 volume percent nitrogen and 5 volume percent mono-silane. The glass advanced from the distributor 28 to the discharge end of the float zone 11 in from about 44 to 67 seconds. The glass temperature was 1200° F. (660° C.) under the distributor 28. Upon lift out from the zone 18, the coated glass was conveyed into and through the lehr 12 and the cooling section 13 and exited from the latter at a temperature of approximately 100° F. (38° C.). The distributor 30 was not activated during travel of the glass sheet or ribbon through the lehr. The article produced as described in the foregoing Example I is illustrated at 35 in FIG. 2 and comprises a glass substrate 36 and a multi-layer reflective coating 37 adhered to one surface thereof. The reflective coating 37 is composed of a silicon layer 38, 200 to 300 angstroms thick, on the glass; a titanium nitride layer 39, 900 to 1100 angstroms thick, on the silicon; and a second silicon layer 40, 100 to 200 angstroms thick on the titanium nitride and next to air. The coated glass was silver in reflection from the glass side and blue in reflection from the film side. The emissivity of the filmed surface was 0.25 to 0.38. The coated glass had a shading coefficient of 0.25 from the glass side, daylight or visible reflectance of 32 percent from the glass side, daylight or visible transmittance of 6.6 percent and total solar transmittance of 4.5 percent. The article was post-temperable. The procedure described in the foregoing Example I can also be used to coat gray and bronze heat absorbing glass as well as clear glass. While the durability of the coated article of Example I is satisfactory for many applications, it has been found that a significant increase in abrasion and scratch resistance of the filmed surface can be obtained without significantly affecting the excellent optical properties of the article by providing a metal oxide layer, preferably tin oxide, adhered to and covering the second silicon coating. EXAMPLE II The process of Example I was repeated except that when the silicon - titanium nitride - silicon coated sheet was passed beneath the distributor 30 in the lehr 12, and was at a temperature of approximately 950-1000° F. (510-538° C.), such distributor was activated to emit a gas composed of 98.6 volume percent air and 1.4 volume percent of tetramethyl tin into contact with the coated sheet. The article produced in accordance with this Example II is illustrated at 45 in FIG. 3 and comprises, in addition to a first silicon layer 38, a titanium nitride layer 39 and a second silicon layer 40, a tin oxide layer 46 about 200 to 300 angstroms in thickness integrally adhered to and covering layer 40. The coated glass had a low purity blue to silver reflective color from both the glass and coating side. The emissivity of the filmed surface was 0.25 to 0.38. The shading coefficient was 0.25 from the glass surface and 0.28 from the filmed surface. The coated article had a visible reflectance of 32.5 percent from the glass side, a visible transmittance of 7.1 percent from the glass side and a total solar transmittance of 4.0 percent. The article was post-temperable and found to have excellent durability, e.g., scratch and abrasion resistance. EXAMPLE III The process of Example I was repeated except that when the glass traveled under the distributor 27 it was treated by a gas composed of 94 volume percent of nitrogen 4 volume percent of mono-silane, and 2 volume percent ethylene; as it traveled under the distributor 28, by a gas composed of 1 volume percent titanium tetrachloride, 6 volume percent ammonia, and 93 volume percent helium (can use N 2 or other inert gas); and finally as it traveled under the distributor 29 by a gas composed of 95 volume percent nitrogen and 5 volume percent mono-silane. The glass advanced from the distributor 28 to the discharge end of the float zone 11 in from about 44 to 67 seconds. The glass temperature was 1200° F. (660° C.) under the distributor 28. Upon lift out from the zone 18, the coated glass was conveyed into and through the lehr 12 and the cooling section 13 and exited from the latter at a temperature of approximately 100° F. (38° C.). The distributor 30 was not activated during travel of the glass sheet or ribbon through the lehr. The article produced as described in the foregoing Example III comprises a glass substrate and a multi-layer reflective coating adhered to one surface thereof. The reflective coating is composed of a silicon layer, 175 to 225 angstroms thick, on the glass; a titanium nitride layer, 650 to 750 angstroms thick, on the silicon; and a second silicon layer, 200 to 250 angstroms thick on the titanium nitride and next to air. The coated glass was muted rose in reflection, which is also the case if a clear glass substrate is employed rather than a heat absorbing glass. The coated glass had a total solar transmittance of 6.3 percent; a visible transmittance of 11.8 percent; total solar glass side reflectance of 10.2 percent; and visible glass side reflectance of 6.9 percent. The film had an emittance of 0.27; a shading coefficient of 0.28 measured from the glass side and 0.33 from the film side; and a U-value under winter time conditions of 0.81 Btu/hr.ft. 2 (uncoated glass has a U-value of 1.11 in the same thickness). The article was post-temperable. While the precursor for the second silicon layer is noted above to be nitrogen and mono-silane, the same precursor as used to form the first silicon layer, including ethylene, can also be used if it is desired to increase the visible transmittance of the coated article. EXAMPLE IV The process of Example III was repeated except that when the silicon titanium nitride silicon coated sheet was passed beneath the distributor 30 in the lehr 12, and was at a temperature of approximately 950-1000° F. (510-538° C.), such distributor was activated to emit a gas composed of 98.6 volume percent air and 1.4 volume percent of tetramethyl tin. The article produced in accordance with this Example IV comprises in addition to a first silicon layer, a titanium nitride layer and a second silicon layer, a tin oxide layer about 200 to 300 angstroms in thickness integrally adhered to and covering the second silicon layer. The coated glass had a muted rose reflective color from both the glass and coating side. The emissivity of the filmed surface was 0.27. The shading coefficient was 0.28 from the glass surface and 0.33 from the filmed surface. The coated article had a total solar glass-side reflectance of 10.2 percent, a total solar transmittance of 6.3 percent and a visible glass-side reflectance of 6.9 percent. The article was post-temperable and found to have excellent durability, e.g., scratch and abrasion resistance. It will be appreciated that various changes and modifications can be made from the specific details of the invention as incorporated in the foregoing Examples without departing from the spirit and scope thereof as defined in the appended claims. In its essential details, the invention is a continuous chemical vapor deposition method for producing a coated glass article. The method comprises the steps of continuously advancing the article, while hot, past first, second and third successive treating stations, and, optionally, a fourth treating station. The first three treating stations are in a closed zone in which a non-oxidizing atmosphere is maintained. An oxidizing atmosphere is maintained in the vicinity of the optional fourth treating station. In the foregoing Examples, the non-oxidizing atmosphere in the enclosed zone in which the first three treating stations are positioned was maintained by introducing thereinto a gas composed of 99 percent by volume of nitrogen and 1 percent by volume of hydrogen. As is apparent from the results achieved by practicing the process of Examples I, II, III and IV such an atmosphere is entirely suitable. However, other inert gases could be substituted for the nitrogen, and the proportion of hydrogen could be increased or decreased, so long as the necessary result is achieved, namely, oxidation of the tin bath is prevented and silicon and titanium nitride coatings can be applied to the glass substrate. Similarly, in the method of Examples II and IV, air was used to provide an oxidizing atmosphere in the lehr 12, but other oxidizing atmospheres can also be employed for example, air enriched with either oxygen or nitrogen, or even one containing an inert gas other than nitrogen, so long as the required result of deposition of a tin or other oxide coating is achieved without undue detriment to the lehr itself. In practicing the instant invention, a non-oxidizing gas which contains a silane is directed against a surface of the article to form a first silicon coating on that surface and against the titanium nitride layer to form the second silicon layer. In the foregoing Examples, the silane was mono-silane (SiH 4 ). However, the treating gas can contain other silanes, in addition to mono-silane, or in place thereof. Examples of other silanes that can be used include monochlorosilane (ClSiH 3 ), dichlorosilane (Cl 2 SiH 2 ), other halosilanes, alkoxysilanes and di-tri-and higher silanes. Organosilanes, e.g., methyltrichlorosilane, are less desirable reactants than the silanes mentioned above, because it is difficult to break the silicon-to-carbon bond to form the desired silicon coating. Mono-silane is the presently preferred treating agent for reasons of cost and availability and because the by-product of its use (hydrogen) does not constitute an ecological problem (contrast the chlorosilanes mentioned above, where the by-product is hydrogen chloride). In accordance with a preferred embodiment of the invention, a quantity of an olefin, e.g., ethylene, is added to the silane. The addition of ethylene (C 2 H 4 ) to mono-silane provides distinct advantages for the base and top silicon layers. Small amounts of ethylene added to the mono-silane which reacts to form the base layer changes the optical properties such that increases in visible light transmittance can occur without significantly affecting the shading coefficient. Also, the incidence and size of pinholes formed when the titanium nitride is created over the base silicon layer is greatly reduced with small additions of ethylene to the base layer. Addition of ethylene to the mono-silane creating the top layer also increases the visible light transmittance of the film stack. The titanium nitride layer was formed in the Examples by directing a gas containing titanium tetrachloride and ammonia in an inert carrier against the first silicon coating. Typical concentrations of the mixed gases range from 0.5 to 10 mole percent titanium tetrachloride and 3 to 50 (preferably 5-30) mole percent ammonia. The base silicon layer can have oxygen incorporated therein as a transition layer between the glass substrate and the silicon layer. This transition layer is not purposely formed but may inherently result from the process of laying down the silicon layer on the hot glass in the manner described herein. Further, the body of the elemental silicon base layer can have trace amounts of carbon, hydrogen and oxygen where the precursor includes ethylene as well as mono-silane. Similarly, the titanium nitride layer may have incorporated in it carbon, chlorine, and oxygen, as well as traces of other elements from either the precursor materials or the silicon coatings on either side thereof. The second silicon layer, in addition to possibly containing trace amounts of carbon, hydrogen and oxygen throughout, particularly where the precursor includes ethylene, may have a surface oxide film formed thereon upon lift-out from the bath and during travel through the lehr. This surface oxide layer, when present, has been found to inhibit the formation of pin holes in the coated article where a subsequent layer such as tin oxide is formed over the second silicon layer. Thus, while the compositions of the layers are identified herein and in the appended claims as silicon and titanium nitride, it should be understood that these terms are defined to include within their scope the trace elements and transition layers discussed above. The composition of the base or substrate glass does not structurally or chemically affect the composition of the coatings deposited therein, but does affect the final performance of the product because of different solar absorption characteristics for the different types of glasses. The different colors of glass--clear, blue-green, grey, and bronze--absorb differently in the visible and infrared regions of the solar spectrum and change both the appearance and performance of the product. Other glass compositions would affect these traits also. The procedure of the foregoing Examples II and IV, involved the treatment of the coated glass 35 in the lehr with a gas composed of 98.6 volume percent of air and 1.4 volume percent of tetramethyl tin, directed onto the glass from the distributor 30. The purpose of this treatment was to form a tin oxide coating over the silicon - titanium nitride - silicon layers that previously had been formed. An oxidizing atmosphere is required to enable tetramethyl tin to deposit a tin oxide coating. Air is a convenient oxidizing gas to use for this purpose, but air enriched with either oxygen or nitrogen or even another inert gas could be substituted for the air. A mixture of more than about 1.6 volume percent of tetramethyl tin in air is flammable and therefore, should be avoided. Other tin compounds can be substituted for tetramethyl tin, for example, stannic chloride and various organo tin compounds that are available. Indeed, other metal oxides can be employed, for example, titanium oxide coatings can be applied over the silicon - titanium nitride - silicon layers, for example, using titanium tetrachloride; alumina coatings, for example using diethyl aluminum chloride; silica coatings, for example using oxide/boron oxide/aluminum oxide coatings from mixtures of titanium tetrachloride, boron hydride and diethyl aluminum chloride. In the foregoing Examples, the glass temperature at the distributors 27, 28 and 29 was 1200±100° F. (649±55° C.) and 970±20° F. (521±11° C.) under the gas distributor 30. The residence time of the glass in the oxidizing atmosphere (air) of the lehr 12 before it was treated with the air-tetramethyl tin gas from the distributor 30, was about 6 minutes. In general, the coated glass articles in accordance with this invention comprise a glass substrate, a first silicon coating about 100 to 400 angstroms in thickness adhered to a surface of the substrate, a titanium nitride coating about 500 to 1200 angstroms in thickness adhered to the first silicon coating, a second silicon coating about 100 to 400 angstroms thick adhered to the titanium nitride coating and an optional metal oxide coating adhered to the second silicon coating. Preferably, the metal oxide coating, if present, comprises tin oxide and is about 150 angstroms to 300 angstroms in thickness. The coated articles have a visible light transmittance less than 15 percent and a shading coefficient measured on both the glass side and the coating side of less than 0.35, preferably in the range of 0.23 to 0.32, with that measured on the glass side being lower than that measured on the coating side. A particularly advantageous glazing in accordance with the invention and including a tin oxide coating adhered to the second silicon coating, comprises first and second silicon coatings 150 to 300 angstroms in thickness, and a titanium nitride coating 600 to 1100 angstroms thick, with the tin oxide coating being in the range of 150 angstroms to 250 angstroms in thickness. This glazing has a visible light transmittance in the range of 5 to 12 percent and a shading coefficient measured on the glass side in the range of 0.23 to 0.28 and on the coating side in the range of 0.26 to 0.31, but in all events higher than on the glass side. Other changes and modifications from the specific details of the invention as disclosed above will be apparent to those skilled in the art and can be made without departing from the spirit and scope thereof if within the definitions of the appended claims.
This disclosure is directed to a heat reflective glazing including a glass sheet having two generally planar parallel surfaces or sides with a multilayer coating on one of the side, and a method of producing such glazing. The side of the glass sheet having the multilayer coating thereon is designated as the film or coated side while the other side is designated as the glass side of the glass sheet. The multilayer coating comprises a first silicon-containing coating formed directly on the glass surface, a titanium nitride-containing coating overlying the first coating, a second silicon-containing coating covering the titanium nitride-containing coating, and an optional abrasion resistant coating, e.g., comprising tin oxide, on the second silicon-containing coating. The process for producing the coatings is a chemical vapor deposition process preferably carried out during the production of glass by the float process.
1
BACKGROUND OF THE INVENTION 1. Field of the invention This invention relates to an optical confocal scanning microscope. 2. Description of the Related Art U.K. Patent Publication No. 2 184 321A discloses a confocal scanning optical microscope which is especially for the study of fluorescent or reflecting specimens. This instrument depends upon the focussing of light upon a single spot scanned over the specimen, which illuminated spot, after de-scanning, is imaged on a confocal aperture in front of a detector. In the case where an image is to be formed of fluorescence from a specimen, the wavelength of the light directed on to the specimen is selected in such a way as to excite fluorescence. The emitted light is separated from the exciting light by a suitable beam splitter and is passed through wavelength-selective filters in such a way that the detector responds only to the light emitted by fluorescence. Instruments based on this design are commercially available. They contain a provision for subdividing the emitted light into beams of different wavelength ranges by a suitable beam splitter and filters. After this division, two dyes can be employed which emit different colours of fluorescence which can be distinguished at two detectors. Alternatively, a reflectance image can be obtained at the same time as a fluorescence image by the use of suitable beam-splitters, in accordance with accepted optical practice. The prior art instruments work satisfactorily but all confocal scanning microscopes which rely on the use of a single scanning spot suffer from the defect that all the spectral selectivity of the system lies in the separation of the emitted or reflected beam into fractions of different wavelength. If there is considerable overlap between the fluorescent emission spectra of two dyes, they cannot be distinguished. For example, Bacallao et al comment in the Handbook of Confocal Microscopy, Plenum Press, 1990, that the commonly-used dyes fluorescein and rhodamine cannot be separated effectively in a system of this type. In order to achieve acceptable separation, it is necessary to vary the wavelength of excitation. This can be done by changing from one type of laser light to another, of spectrally different properties. First an image is obtained by operating the system with one type of excitation, and then a second image is obtained with a different type of exciting beam. This operation is slow and cumbersome. Awamura, Ode and Yonezawa have described a microscope in which red, green and blue laser beams are scanned independently over the specimen, and the reflected beams are separated by dichroic filters and each executes a scanning motion over one of three separate linear CCD detector arrays. The description was published in the Proceedings of SPIE, The International Society for Optical Engineering (1987) Volume 765 pp 53-60. In principle, the system of Awamura et al might be used as a fluorescence microscope. It would then allow more than one type of dye to be excited in rapid succession during each line scan. However, in the case of two dyes with identical emission spectra, or a single ratiometric dye where the emission spectrum was to be monitored in a single waveband, the system of Awamura et al offers no advantage over that of White (U.K. Patent Application No. 2 184 321A), since neither system is capable of separating the two emission signals. SUMMARY OF THE INVENTION According to the present invention, there is provided a confocal scanning optical microscope comprising: an optical scanning system; means for simultaneously generating two or more input beams of optionally different spectral composition and of differing orientations such that after passage through the scanning system a specimen under test is scanned with two or more distinct and separate elemental areas of illumination; and two or more detectors respectively for receiving two or more output beams after de-scanning by the scanning means, each detector receiving an output beam substantially restricted to output light derived from one of the illuminated elemental areas. The invention allows for two or more microscope channels having different excitation wavebands but identical emission wavebands, in order to make possible excitation ratio image measurements according to accepted practice. The invention also allows for two or more microscope channels having identical excitation wavebands but different emission wavebands, in order to make possible emission ratio image measurements according to accepted practice. The present invention is thus applicable to many kinds of scanning optical microscopes. It provides a means by which two or more spectrally distinct exciting spots or bars can be scanned together over the specimen during each sweep of the scanning system. The emission from each spot is passed individually and separately to a stationary confocal aperture leading to a detector, there being at least one aperture and detector for each spot. The emitted beam from each spot, due to specimen fluorescence or reflection, may be filtered spectrally or subdivided between detectors in accordance with established practice, or may be passed unselectively to the detectors. It is thus possible to obtain, within a single scanning cycle, two or more complete images, each of which may differ in both excitation and emission waveband from the other images. The invention may be considered as "a multiplexed optical system" because it involves two or more sets of independent but near-parallel beam paths passing through the same scanning system and objective lens, the optical paths being multiplexed in the literal sense of being folded together. BRIEF DESCRIPTION OF THE DRAWINGS Further features and advantages of the invention will be apparent from the following description of embodiments, making reference to the accompanying drawings, in which FIG. 1 is a schematic diagram of a confocal scanning microscope incorporating the multiplexed optical system of the present invention; FIG. 2 is a schematic diagram showing an alternative and preferred optical arrangement for the upper part of FIG. 1; and FIG. 3 is a schematic diagram showing an optical means by which several beams of different spectral properties may be obtained from a single (e.g. a multiline) laser, for use in the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings, the present invention provides an optical assembly which allows a number of independent optical channels to be used simultaneously for excitation in a laser confocal scanning microscope with an extended emission beam path, but is not restricted in application to this kind of microscope. The invention can be applied to confocal microscopes in which a bar or slit of light is scanned over the specimen as well as to those in which a single spot is scanned. In FIG. 1, to simplify the diagram, only two independent light paths are shown, but there is no restriction on number in practice. Light from two lasers, L1 and L2, with different spectral qualities, is directed on to a beam splitter BS1. The two beams are at a slight angle to each other, which angle is exaggerated in the diagram for the sake of clarity. The two beams are reflected into a scanning system as shown, which produces an angular scan of both beams simultaneously. The angular separation of the beams is maintained throughout the scan, and results, after passage through suitable microscope optics, typically an eyepiece E and an objective O, in the formation of two distinct moving spots of light S1 and S2 on the specimen. Light is emitted from the specimen at S1 because of reflection or fluorescence and a portion of this emitted light passes back through the optical system, is descanned, i.e. reconverted into a stationary beam by the scanning system, passes through the beam splitter BS1 and falls on a confocal aperture Al leading to a detector D1. Light from S2 passes through the optical system along a similar but distinct path and falls upon detector D2. The preferred angular separation is the smallest possible consistent with a satisfactory separation of the optical channels. To allow image registration, the small difference in time between the scanning of a given point in the specimen by the spots corresponding to S1 and S2 may be compensated by suitable conventional electronic means, for example by image processing software. It is not essential to the functioning of the system that the two or more spots should lie upon the same scan line. In the preferred embodiment of FIG. 2, the scanning device and microscope are not shown in the figure, but should be taken to be the same as in FIG. 1. Beams from lasers L1 and L2 again pass at a small angle on to the beam splitter BS1. The returning beams, after passing through beam splitter BS1, pass to a second beam splitter BS2, which has dichromatic properties, so that most of the light in one of the beams, B2, passes through to confocal aperture A1 and thus to detector D1, while the other beam B1 is preferentially reflected to A2 and D2. This modification is preferred as it allows the use of the second beam splitter BS2 to achieve a selection of emission wavelengths, and also may be implemented by only slight modification of existing instruments. The separation of the emitted beams by wavelength may be improved by the addition of wavelength-selective filters F1 and F2. The aiming of the emission beams, each on to the appropriate aperture A1 or A2, may conveniently be achieved by the use of mirrors (not shown) interposed between BS2 and the detectors D1 or D2. Additional mirrors and dichromatic reflectors may provide convenient means of achieving an appropriate angle between the input beams L1 and L2. For example, FIG. 3 illustrates one of many possible means by which light from a single multiline laser L may be separated into beams of different spectral composition and angle. In this case, a parallel-sided block B of glass or other transparent material is used to produce a small lateral separation of the beams according to wavelength. The angle between the beams is then adjusted by passing them through a prism P, where they undergo different angular deviations because of the dispersing power of the prism. By appropriate orientation of the prism, parallel beams, each corresponding to a single wavelength, are generated, which converge towards the beam splitter BS1. The angle of convergence is determined by the angle of the prism and its refractive index and dispersive power. In the diagram, the solid line S indicates a beam at a shorter wavelength, which is more strongly refracted than the beam, shown by the dashed lines D, corresponding to light of a longer wavelength. Various modifications of the above-described and illustrated arrangements are possible within the scope of the invention hereinbefore defined.
A confocal scanning optical microscope in which a specimen under test is simultaneously scanned with two distinct spots or slits of illumination and two output beams emitted from the specimen due to reflection or fluorescence are descanned and passed to separate stationary confocal apertures and detectors.
6
This patent application claims priority to and the benefit of U.S. patent application Ser. No. 61/521,380, filed Aug. 9, 2011 and entitled “Electronically Augmented Mechanical Trash Container Locking Mechanism”, the entire content of which is herein incorporated by reference. BACKGROUND OF THE INVENTION 1. Field of the Invention The disclosures relate to security and locking mechanisms of residential and commercial trash containers. 2. Description of Prior Art Commercial and residential trash containers that are designed to be used by garbage collection agencies are usually large containers, which are covered by a lid. There are reasons to lock this lid securely including dispersion of trash due to wind, break-in by animals, and unauthorized access by individuals. Therefore, provisions are often made to lock the lid of a trash container. In its most basic form, the weight of the lid itself can prevent access to the trash container. This can be combined with a hinge or a sliding mechanism to ensure proper enclosure. When the weight is not sufficient to securely lock the trash can a mechanical latch and/or a lock is usually added that can only be opened by a key. Such measures can be ineffective or difficult to use as far as the collection process is concerned. A mechanical key usually requires that the operator exit the collection truck to open the container. The operator must also carry and keep track of a large number of keys which can be difficult to manage. Inventions such as U.S. Pat. No. 4,155,584 and U.S. Pat. No. 4,182,530 have been disclosed that take advantage of the mechanical movement of the trash container during the collection process, the weight of the content, the force of gravity, or a combination of these, to unlock upon collection and relock after the container returns to the upright position. Attempts have been made to refine and improve variants of the mechanical arrangement described above (U.S. Pat. No. 5,015,021, U.S. Pat. No. 7,597,365, U.S. Pat. No. 6,666,485, U.S. Pat. No. 5,085,341, and U.S. Pat. No. 5,213,382.) However, most of the above solutions require complex mechanical parts, which are difficult to retrofit into existing trash and recycling containers. Also, most of these solutions are designed for heavy-duty commercial or bulk trash containers instead of common residential containers, which are usually made of a light material such as plastic or aluminum. Gravity operated mechanisms work for commercial and bulk containers because it is difficult for an individual to pick up and tilt them upside down to circumvent the locking mechanism. Most residential containers, however, can be easily flipped over, compromising the lock. Therefore, such gravity operated locks for residential trash containers are not practical. This invention substantially addresses these issues and others. SUMMARY OF THE INVENTION The proposed invention employs a multi step electronically augmented smart locking mechanism for trash containers. The smart lock is attached to the trash container and, in accordance with several embodiments disclosed herein, can be locked and unlocked using electrical, mechanical or a combination of electro-mechanical stimuli. The lock described herein accomplishes two purposes. First, it allows the owner of the container to unlock it to deposit trash and securely lock it again. Secondly, the locking mechanism correctly recognizes the presence of the collection vehicle and unlocks the container without requiring the operators to employ any additional manipulation other than the ones employed in the daily process of garbage collection. In one aspect of the present invention, a smart lock locks a trash container in a manner, which prevents the container from being unlocked by tilting and other methods that might be employed to force open the container. In several embodiments related to this aspect, the smart lock assembly includes one part that can be mounted onto the lid of the trash container and another part that can be mounted onto the trash can. These two parts will interlock through mechanisms to be described below. The top and the bottom parts of the lock may or may not be interchangeable as far as the assembly on the trash container is concerned. Such a smart lock can either retrofit onto existing trash and recycling containers or it can be incorporated into new constructions of such containers. In several of the embodiments related to this aspect, the smart lock assembly consists of at least two locks referred to herein as the primary lock and the secondary lock. In at least one of the embodiments, the primary lock is a small but precise contraption that only opens and/or closes upon the correct detection of the presence of an authorized signal. This signal can be applied by the owner or can be generated by the presence of an authorized collection vehicle. Because of the precision of the primary lock it may have fine features such as small size or low consumption of electricity and, therefore, it may be insufficient to prevent forceful opening of the trash container. The secondary lock is a stronger and larger lock that can be opened by a much coarser mechanism, for example when the owner twists a handle or when the truck lifts the container and the acceleration or the force of gravity is applied to the lock, or a certain movement signature is detected. The secondary lock only opens if the primary lock has already opened and, therefore, the primary lock acts as an enabling agent for the second lock. In another aspect of the invention, the smart lock includes mechanisms to correctly recognize authorized conditions for unlocking the container by the owner of the container. In at least one of the embodiments, the owner unlocks the primary lock using electrical or mechanical stimuli, which also opens the secondary lock, and allows the owner to open the trash container. Another aspect of the invention relates to the unlocking of the smart lock by collection vehicle operators without requiring the vehicle operators to employ any additional manipulation, which would interrupt the daily collection process. In at least one of the embodiments, a device, such as a remote key, uses electrical stimuli to unlock the primary lock. In at least one embodiment, the unlocking of the primary lock in combination with another electrical or mechanical stimulus, such as the collection vehicle lifting the trash container or the force of gravity, opens the trash container during collection. As such, the owner of the container can use a signal to lock it when it is placed on the curb on collection day. When the collection vehicle arrives a transmitter on the truck can unlock the primary lock on the container. When the container is picked up or turned upside down the motion can open the secondary lock, which opens the container. After the container is placed back the owner can use the remote controller to lock the container again. In one form of this invention when the primary lock opens it remains open for a certain preset period of time after which it automatically closes. The same applies to the second lock. This provides not only an automatic mechanism to relock the container after it is opened, it also provides an additional level of security. For example if the presence of the collection truck is sensed but the trash is not collected, and the primary lock is left open indefinitely, the secondary lock may be compromised by intruders if they apply the coarse mechanical motion or electric stimulus that is needed to open the secondary lock. This will also minimize the effort on the side of the container owner to keep it locked. In one variation of this scheme, one or both of the timers can be programmed to open the locks at predefined times. This can be useful if the collection schedule is known and also if the trucks cannot be equipped with the transmitters needed to send the signal to the smart lock. This invention can include a fault detection module that can detect conditions in which the lock is not operating properly, such as low battery which by default unlocks or locks the smart lock according to a predefined setting. Another aspect of this invention is the way energy is supplied to the lock. In one embodiment, where the energy consumption of the lock is low, a solar panel can be attached or built into the surface of the trash container to obtain solar energy. In another embodiment, the lock can be energized by batteries that can be replaced or recharged. In yet another embodiment, energy can be harvested from the mechanical movement of the trash container. In an implementation of this embodiment the mechanical movement of the container, or of the moving parts of the collection truck, can compress a spring or similar energy storing mechanism. DESCRIPTION OF THE DRAWINGS FIG. 1 is a front perspective view of a conventional residential trash container, including the trash can, the lid, and the smart lock assembly of the present invention. FIG. 2 is a partial perspective view of FIG. 1 , showing the top of the trash container with an open lid and the smart locking assembly of the present invention. FIG. 3 shows a front perspective view of the standalone smart locking assembly including a top part that can be mounted onto the lid and a bottom part that can be mounted onto the trash can. FIG. 4 is a front view of the smart locking assembly with partial details shown. FIG. 5 is a perspective view of the collection vehicle picking up a trash container with its moving arms during the collection process. FIG. 6 is a top view of the trash container and the moving arms of the collection vehicle. FIG. 7 is a top view of the part of the collection vehicle's moving arms, which contains the electronics needed for signal transmission in conjunction with the lock in a wired setting. FIG. 8 is a top view of the part of the collection vehicle's moving arms, which contains the electronics needed for signal transmission in conjunction with the lock in a wireless setting. FIG. 9 shows the collection vehicle sending authentication signals to the trash container. FIG. 10 shows the bottom part of the smart lock assembly and the details of one embodiment of the locking mechanism. FIG. 11 shows a flow chart of for the locking algorithm of the smart lock. DETAILED DESCRIPTION OF THE INVENTION The smart lock inventions and its embodiments disclosed herein are described as applied to a residential trash container. However, these inventions can be applied to a broad range of applications which require secure locking and unlocking mechanisms, for example, but without limitation, commercial trash containers, storage and construction containers, and gated fences. In one embodiment, depicted in FIG. 1 , the smart lock 101 - 102 can be retrofitted onto an existing trash can 104 and its lid 103 . In another embodiment, the smart lock can be incorporated into the trash can during the manufacturing process. The smart lock in FIG. 2 can consist of a top 201 and a bottom part 202 that latch into each other and are affixed onto parts of the trash container. In the illustrated embodiment of FIG. 2 , the two parts are bolted onto the trash container lid 203 and the can 204 . FIG. 3 is the general outline of the two parts of the lock. At least four holes 301 - 304 allow the locks to be mounted on the lids securely, for example with a bolt 306 and a nut 305 . The two parts can interlock in a variety of mechanical and electrical ways. In the exemplary depiction of FIG. 4 , the bottom part 402 has a protruding section 408 that can fit into the recessed side 407 of the top part 401 . The shape of the parts of the smart lock and the smart lock's arrangement are not unique. A variety of interlocking mechanisms of the two pieces are disclosed in the claims of this patent. The implementation of the interlocking mechanism is shown in FIG. 4 . The protruding part 408 of one half of the lock assembly 402 includes two wedge shaped latches 405 , 406 that can provide the interlocking. Once the two parts of the smart lock 401 , 402 are pushed together, 405 and 406 latch into the matching cavities 403 and 404 , and stay locked until the smart locking mechanism comprising the primary and secondary locks allows the release of the latches, thereby unlocking the trash container. The unlocking of the primary lock is initiated in one of two ways: either the presence of the collection vehicle is sensed by the smart lock or the owner issues an unlock signal in ways described below. Herein these are referred to as primary lock authentication scenarios. There are many types of locks that can be employed to implement the primary lock. In one embodiment magnetic force can act on pieces of metal to keep them together until the force is removed by proper authentication, hence allowing the lock to open. A common example of this is an electromagnetically driven latch. Another embodiment of the primary lock takes advantage of the force of vacuum to bring separate parts together, thereby interlocking them. Yet another embodiment is to use a hydraulic mechanism in the primary lock to accomplish the same locking effect. There are many ways to implement the unlocking aspect of the primary lock. To unlock the smart lock for the collection process, in one possible embodiment, the primary lock detects the presence of the collection vehicle through electrical signals. These electrical signals have unique patterns that can be applied to the lock via direct contact with parts of the collection vehicle. FIG. 5 shows a possible implementation where the collection vehicle 501 uses a mechanical arm 502 to lift the trash container 503 . The mechanical arm of the collection vehicle marked 603 - 605 in FIG. 6 , which has to lift the container 602 , houses the wires carrying the authorization signals inside mechanical arm. In one embodiment of this aspect, the connection between 603 and 604 and the sides of the trash container 602 can be used as a conductive connection to transfer the signals. This provides a two-wire method for signal transmission from the truck to the trash container. This signal unlocks the primary lock. In another embodiment of this aspect, the part of the mechanical arm 605 that faces the lock 601 includes the wires carrying the authorization signals. As shown in FIG. 7 , this part 701 touches the smart lock 702 and through a conductive contact 703 transfers the signal to the lock, where it is validated to open the primary lock. In yet another embodiment of this aspect depicted in FIG. 8 , the part of the mechanical arm 801 that faces the lock 802 houses the wires carrying the authorization signals. 801 sends the signal through a wireless link 803 , to the smart lock 802 , where it is validated to open the primary lock, using any of the publicly used communication protocols, such as infra-red connection, RFID, Bluetooth, WiFi, and other IEEE 802.11 suites of wireless connectivity, or proprietary communication protocols. In another embodiment shown in FIG. 9 the primary lock in the trash container 902 detects the presence of the vehicle 901 through electrical signals with unique patterns that can be applied via a wireless link 903 to the lock from a transmitter installed inside the vehicle or carried by the vehicle operator. In this embodiment a wireless transmitter that can use any of the publicly used communication protocols such as infra-red connection, RFID, Bluetooth, WiFi, and other IEEE 802.11 suites of wireless connectivity, or proprietary communication protocols, sends the authentication signal to the lock, which, as described above, can unlock the primary lock. In another embodiment, the lock is equipped with a magnetic card reader that can detect the presence of the authorized collection vehicle when a magnetic medium containing authentication information, such as a magnetic card, is swiped on or into it. This can open the primary lock. In yet another embodiment, the lock is equipped with an image-processing device, such as, for example, a camera, that detects a certain visual signature of the truck. The visual signature can, for example, be the shape of the vehicle or a bar code printed on the side of it, or a visual signature of the operator, such as face recognition, finger print, etc., and opens the primary lock. Another possible embodiment is one where the lock is equipped with an audio processing device such as a microphone that detects a unique audio signature of the vehicle or its operator and permits the primary lock to open. Another possible embodiment is one where the lock is equipped with a proximity sensing device, such as a radar or sonar or infra red sensor that detects a certain distance from the vehicle, and permits the primary lock to open. Several of the methods described above can be used to allow the owner of the trash container to unlock it. In particular, the RFID or magnetic cards are the most practical methods that can be used by the owner to unlock the trash container. A variety of embodiments, which include all the abovementioned methods to implement the primary lock, can realize the secondary lock. An exemplary embodiment is shown in FIG. 10 which illustrates the interlocking mechanism and electrical embodiments of the primary and the secondary locks inside the bottom part of the smart lock 402 . When the trash container is closed, the top part of the assembly 401 , which is mounted on the trash container lid, moves down and pushes against the protruding latches 1001 and 1018 . These latches are made of iron or a similar metal that can be affected in a magnetic field. Since the latches are pushed out by the force of small springs 1002 , 1004 , 1016 , and 1017 , the force of the descending top part of the assembly pushes 1001 and 1018 into the frame 1019 , and the top 401 and the bottom 402 parts of the lock come into a complete contact, at which point the latches 1001 and 1018 will be released back by the force of the springs into the cavities 403 and 404 , thereby interlocking the top and bottom parts and securing the trash container. Due to the force of the springs 1002 , 1004 , 1016 , and 1017 which pushes the latches 1001 and 1018 out, pulling the lid up will not result in the opening of the trash container and the assembly remains locked. The primary lock 1013 in this embodiment consists of a detector/timer 1015 that detects one of the various abovementioned authentications such as a wireless signal from the collection vehicle and closes the switch 1014 for a predefined amount of time t 1 . Only during this time, can the secondary lock 1008 be opened. If detector/timer 1009 detects one of the various abovementioned authentications such as the movement signature of the trash container being lifted then it will apply a current to the coil 1010 for a predefined amount of time t 2 . Due to the current flowing in the coil, the magnetic core 1006 is magnetized and pulls the latches 1001 and 1008 into the assembly, thereby allowing the unlocking of the top part 401 attached to the lid and the bottom part 402 attached to the can. Without the closing of the switch 1014 the secondary lock 1008 cannot be activated as this switch is where the current needed to energize the coil 1010 will pass through. In a different embodiment the secondary lock can be opened by use of mechanical and gravitational forces, gated by the primary lock. In yet another embodiment, the secondary lock can be opened by the mechanical parts of the truck such as levers, lifting arms, etc. Other embodiments of this secondary lock may include hydraulic action. FIG. 11 is the flow chart of the unlocking and locking algorithm implemented in the lock during the normal course of operation when a fault is not detected. In the idle state of this system both primary and secondary locks are locked. When either the presence of the collection vehicle is sensed by the smart lock or the owner issues an unlock signal a primary lock authentication scenario occurs. When a collection vehicle is detected and the primary lock is unlocked, for a specified period of t 1 the smart lock awaits the detection of movement signature or other signals needed to open the secondary lock. After the time t 1 lapses the secondary lock will no longer open and the system returns to the idle state. However, if the secondary lock is opened as a result of the detection of movement signature or other authentication signals, it remains open for a period t 2 which subsequently allows the collection vehicle to empty the trash container during this time. After the time t 2 lapses the system returns to the idle state. When the owner issues an unlock signal by various methods discussed above, the system can be designed to respond in at least two different ways: In one implementation, the system can open both the primary and the secondary locks so the owner can easily deposit trash into the container for a period equal to t 1 , after which the locks close and the system returns to the idle state. A second and more secure implementation is one where a secondary authentication by the owner is necessary within time t 1 of the unlocking of the primary lock to open the secondary lock. For example the owner must turn a handle to open the secondary lock. After the secondary lock is opened, the owner can make the deposit into the trash container within a period of t 2 before the locks close and the system returns to the idle state. The preceding sections presented various embodiments of an electronically augmented mechanical trash container locking mechanism and applications thereof to securely lock a trash container and prevent unauthorized entry. As one of average skill in the art will appreciate, other embodiments may be derived from the teaching of the present invention without deviating from the scope of the claims.
A smart lock that can be built into or mounted onto a trash container with a lid and a can consists of two interlocking parts. The smart lock contains a primary lock operably connected to a secondary lock. The primary lock can be opened in presence of the trash collection vehicle or by a command from the owner. The secondary lock can be opened by the same conditions or when it senses mechanical and gravitational movement characteristics of the collection process, only when the first lock is open. Each lock comprises a timer and electronic circuitry that detects authorized commands and opens the lock.
8
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to tone transmission in test call generation systems and more particularly to the automatic sending of coded tones in a particular one of several codes in order to transmit the digits comprising a telephone directory number. 2. Description of the Prior Art In the transmission of telephone directory numbers between switching centers and between a subscriber and a switching center the use of multiple-frequency (MF) signaling and touch calling multiple-frequency signaling (TCMF) respectively, is well known. These signaling schemes employ the use of coded tone signals for the transmission of digits comprising the directory number. A collection of predetermined frequencies forms the basis for each of these signaling codes. Multiplefrequency (MF) signaling selects two out of a group of six frequencies for transmission to form a given digit, whereas touch calling multiple-frequency (TCMF) depends upon the selection of two of eight frequencies for transmission to form a particular digit comprised of a telephone directory number. Historically, these tone codes have been generated by separate circuits in a telephone office. Heretofore, the technology employed has embodied the use of LC oscillators for the generation of these tones in call initiation systems. Such systems have utilized separate circuits for the generation of these tone frequencies. The use of separate tone generation equipment necessitates the use of separate control logic for the application of these tone signals. Such systems are necessarily complex and require extensive maintenance. In addition, these systems present a multiplicity of design problems and prohibit subsystem modularity. U.S. Pat. No. 3,719,897 issued on Mar. 6, 1973, to L. A. Tarr, depicts a system in which a tone generator system is used to diagnose tone receiving equipment in a telephone office. In the Tarr patent a single input signal selects a single frequency of either MF or TCMF. Although in the Tarr patent the use of a crystal controlled clock is disclosed, only a single frequency of the two necessary for digit identification is generated. Therefore, it is an objective of the present invention to provide a single source for the generation of digits comprising a telephone directory number in either the multi-frequency or touch calling multi-frequency codes. Such source provides for simulation of either line or trunk call originations and basic subsystem modularity for simple design. SUMMARY OF THE INVENTION The present invention consists of a tone sender system which provides in a single source the capability to originate telephone calls in either a multi-frequency (MF) or touch calling multi-frequency (TCMF) code. In each of these transmission codes, a combination of analog tone pairs is produced to represent a digit of a telephone number. Each of the tones comprising the telephone number digit is of a predetermined frequency. The tone sender described herein is connected to a telephone central office and generates simulated line or trunk originations depending upon the transmission code selected. This tone sender is designed to be controlled by digital signals applied by an appropriately timed telephone office central processor control system. The control system consists of a central processor with memory. The central processor is connected to bistable latches via bi-directional bus. The bistable latches, in turn, are connected to the initial stage of the tone sender circuitry, the decode logic. The signals sent from the bistable latches to the decode logic comprise a binary coded decimal representation of a telephone digit to be transmitted. Four of such signals from the latches are required for this purpose. The bistable latches further provide an additional set of supervisory signals. These supervisory signals indicate to the tone sender system the particular transmission code in which the given digit is to be sent. The decode logic provides isolation between the bistable latches and the tone sender circuitry. The signals from the bistable latches are decoded from their binary coded decimal form to a collection of binary signals each representing a particular telephone digit. In the MF signaling code, ten of these signals are required to represent the digits (0 through 9) comprising a telephone number and the remaining six of these signals are used for various supervisory signaling purposes; whereas, in the TCMF transmission code twelve of these signals are required to represent the digits (0 through 9 and special functions * and #) leaving four signals remaining for supervisory signaling purposes. These signals are then encoded into a pair of signals in each transmission code (MF and TCMF) which represent the digit to be sent. The pair of signals thereby produced for each transmission code represents the tone frequencies associated with the given digit in that particular code, with each signal representing a particular predefined frequency. For example, the digit 0 is represented by the frequencies 1300 Hz and 1500 Hz in MF and by the frequencies 941 Hz and 1336 Hz in TCMF. The supervisory signals supplied by the bistable latches are utilized to gate the signals representing the given digit in the selected transmission code into a frequency encode network for subsequent processing. Next, the selected pair of digit representative signals is further encoded into two sets of signals, representing the time periods of corresponding frequencies which comprise the given digit. These time period representation signals are applied to two independent counting chains along with an input signal from a 1 MHz crystal controlled clock. The clock provides a constant source of pulses; one pulse per microsecond. Each of the two counting chains produces one of the tone frequency signals comprising the given digit. The frequency signals so produced are in the form of square waves of the desired frequencies. Lastly, these two resultant square waves are combined and converted into a single sine wave of the appropriate frequency by filtering out any undesirable frequency components. The combined output signal is amplified and now is suitable for coupling to a transmission line. This output frequency signal remains present at the output as long as the bistable latches are controlled to provide the signals to the tone sender system. Under control of the central processor, the bistable latches preserve their present signal statuses for a predetermined time period of approximately 60 ms. Upon expiration of the above mentioned time interval, the central processor resets the bistable latches thereby creating an absence of the output frequency signal of the tone sender system. Similar to the signal application interval, a signal absence interval is timed for a period of approximately 60 ms. As a result, a pulse of tone is produced which represents the given telephone digit in the appropriate transmission code. The complete initiation of a line or trunk call origination includes a cyclic repetition of the above process for each of the digits comprising a telephone number. In order to initiate a line origination the TCMF transmission code is utilized and in order to initiate a trunk origination the MF code is employed. The present tone sender system, although embodying TCMF and MF codes, is easily adaptable to send other tone signaling codes. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of a multiple tone code sender system in accordance with the present invention. FIG. 2 is a schematic circuit diagram of a decode logic circuit in the present invention. FIG. 3 is a schematic circuit diagram of a frequency encode network for the transmission of representative frequency signals in the present invention. FIGS. 4 and 5, taken in combination, are schematic circuit diagrams of an encoding circuit for selection of time period representative signals of MF and TCMF frequencies in the present invention. FIGS. 4 and 5 represent schematic diagrams for MF and TCMF low frequencies and MF and TCMF high frequencies respectively. FIG. 6 is a schematic circuit diagram of twin frequency divider circuits for production of frequency signals in the present invention. FIG. 7 is a schematic circuit diagram of a mixer, low pass filter and associated amplifier in the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT In FIG. 1, a block diagram of a multiple code tone sender system is shown in accordance with the present invention. The multiple tone code sender includes decode logic 100 connected to a central processor unit via a bank of bistable latching devices (not shown). The decode logic provides isolation between the remainder of the tone sender circuitry and the bistable latching devices. The central processor sends, via the latches a telephone digit to be transmitted. Input signals DB1 through DB8 which represent the digit in binary coded decimal form are decoded to form signals digit 1 through digit 16 at the output of decode logic 100. Signals digit 1 through digit 16 are combined and coded by frequency encode network 200 to produce four groups of signals, each signal is representative of a predetermined frequency associated with each transmission code (MF and TCMF). Two frequency groups are associated with each transmission code. One frequency in each of the following groups is produced for a given digit: MF low frequency, MF high frequency, TCMF low frequency, and TCMF high frequency. Each of these frequency groups comprises a collection of predetermined frequencies. One frequency in each of the four groups is selected by the application of the telephone digit from the central processor unit. Signals TCEN and MFEN determine which two of the four frequency groups are permitted to be processed further by high-low frequency elect network 300. High-low frequency select network 300 processes the selected two groups of frequency representative signals in the selected transmission code. These signal groups are each further coded to produce signals representing the time periods associated with each of the two selected frequencies representing the digit. Each set of time period representative signals is respectively applied to a corresponding frequency divider 400 and 600. Furthermore, a signal from the 1 MHz crystal controlled clock 500 is applied to each frequency divider. As a result of the application of the combination of these signals, low frequency divider 400 and high frequency divider 600 produce low frequency and high frequency square waves, respectively. These resultant square waves are applied to mixer 700, whereby a single output signal is produced representing the sum in sine wave form of the input square wave frequencies. This is accomplished by filtering out any undesirable frequency components via low pass filter 800. This combined signal is amplified through amplifier 900 and produces an output suitable to be coupled to the transmission line. The central processor unit applies signals DB1 through DB8 and TCEN and MFEN to the bistable latches for a predetermined time period approximating 60 ms. Upon expiration of this time period a like time period of 60 ms. is timed during which the bistable latches are reset thereby producing an absence of any tone frequency signal output from the tone sender system. As a result, a pulse of tone is produced which represents in coded form the given digit to be transmitted. The complete initiation of a telephone call origination includes a repetition of the described process, thereby producing a series of tone pulses which collectively represent the telephone number to be transmitted. Now referring to FIGS. 2 and 3, taken in combination with FIG. 2 to the left of FIG. 3, input signals DB1 through DB8 and supervisory signals TCEN and MFEN are applied to optical-couplers 110 through 115 respectively, thereby producing representative signals which are isolated from the latching circuitry. The signals thereby produced are inverted via inverters 124 through 127. The output signals of the inverters 124 through 127 are applied to the BCD to binary decoders 130 and 140. Each BCD to binary decoding device generates eight output signals. Each of these outputs indicates either a logic "0" of logic "1" state. The signals comprising the frequencies of the digit are marked by a logic "1", all other signals are marked by a logic "0". These binary outputs are interconnected by encoding gates 210-216, 220-226, 230-233 and 240-243 to generate signals each representative of a frequency associated with one of the transmission codes. This encoding structure includes a plurality of NOR gates and inverting gates. The output signals at gates 212 through 216 and 222 through 226 represent the frequencies associated with the given digit in the multi-frequency code and the output signals at gates 230 through 233 and 240 through 243 represent the frequencies associated with the given digit in the touch calling multi-frequency code. These representative frequency signals are combined with the enabling signals output by gates 121 and 123. The output signals of gates 121 and 123 represent the multi-frequency and touch calling multi-frequency enable signals respectively. The MF enabling signal produced by gate 121 is combined with the MF representative frequency signals at gates 250-254 and 260-264. The touch calling enable signal produced at gate 123 is combined with the TCMF representative frequency signals at gates 270-273 and 280-283. Via control of the supervisory signals of gates 121 and 123, the frequency representative signals of either the MF or the TCMF code are gated through for subsequent processing. As shown in FIGS. 4 and 5, each of the frequency representative signals comprising the digit in the selected code is further encoded to produce a set of signals representative of the time periods associated with each of the frequencies comprising the digit. The low frequency of the selected transmission code is encoded by gates 310-315 and 300-339; whereas, the high frequency representative signals are encoded by gates 320-325 and 340-349 to produce the time period signals. Referring now to FIG. 6, each set of time period signals is applied to the appropriate frequency divider. Also applied to each frequency divider is a signal from the 1 MHz clock 500. Each frequency divider network 400 and 600 includes three programmable divide by N 4-bit counters. These programmable divide by N counters are of a standard commercially available type. The low frequency time period signals are applied to divider 400 and the high frequency time period signals are applied to divider 600. The high and low dividers each produce a single output signal H and L respectively. As indicated in FIG. 7, signals H and L, the high and low frequency signals respectively, are applied to flip-flop device 710 thereby producing square waves of the appropriate frequencies. The flip-flop device 710 is conventional and does not form a portion of the present invention. The flip-flop output signals are respectively applied to resistors 720 and 730. The output signals of these resistors are added together by directly connecting the two signals produced by the resistors. The signal thereby produced is applied to amplifier 750. The output signal of amplifier 750 is applied to low pass filter 800 thereby producing a single signal representative of the two predetermined frequencies which comprise a given digit. This signal is applied to amplifier 900 which includes transistors 910, 930 and 940 to produce a suitable signal for coupling to the transmission network. Although a preferred embodiment of the invention has been illustrated, and that form described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
A tone sender system for producing analog tone pairs for transmission of the digits comprising a telephone number. Dual codes, multi-frequency and touch calling multi-frequency, are produced to generate simulated test call originations. This tone sender system provides in a single source the capability to generate telephone call originations requiring either multi-frequency (MF) or touch calling multi-frequency (TCMF) tone pairs for the digit transmission. The tone code to be utilized is selectable.
7
BACKGROUND OF THE INVENTION Throughout public washroom facilities, as a protection against the spread of disease and the waste of water, automatic faucets have been installed. These faucets are activated by placing a hand in the vicinity of the outlet of a faucet spout. Mounted in the faucet spout are sensors (for example, infrared transmitter and receiver assemblies) that detect the presence of an object and activate an electronic circuit to open an automatic water valve controlling the flow to the spout. Because automatic faucets are normally placed in public washrooms, it is desirable that all portions of the automatic faucet be tamper resistant. Also, as with products that will be in the public view, it is desirable that they have a pleasing appearance (aesthetic design) and that multiple models be available from which architects and interior designers may select a particular design. As with all manufactured products, it is desirable that the cost of manufacture, which includes the cost of assembly, is minimized. Numerous automatic faucet designs have been proposed, for example, as found in U.S. Pat. Nos. 4,681,141; 4,735,357; 5,060,323; 5,165,121; and 5,224,509. It is an object, according to this invention, to provide an easily assembled, tamper-resistant faucet assembly for an automatic faucet. It is a further object of this invention to provide a faucet assembly constructed of standardized components for flexibility and variety in the shape of the spout body. SUMMARY OF THE INVENTION Briefly, according to this invention, there is provided an automatic faucet spout assembly that is easily and economically assembled and tamper resistant. The spout assembly comprises a transmitter and a receiver assembly for use in detecting the presence of objects near the spout. It further comprises a hollow spout body that has an inlet opening and an outlet opening. The spout body is shaped so that the inlet opening can be fastened over an opening in a surface with the outlet opening spaced laterally therefrom. A unitary waterway fitting is inserted in the outlet opening of the spout body. The waterway fitting comprises an inlet port and a threaded outlet port and a passage therebetween. The waterway fitting also has one or more sealable compartments for receiving and orienting the transmitter and receiver assembly. A water conduit passes through the spout body and out the inlet opening. The water conduit is connected to the inlet port of the waterway fitting. An aerator is threaded to the outlet port. A cable assembly passes through the spout body and out the inlet opening. It is connected at one end to terminals on the transmitter and receiver. A cap seals the interior side of the sealable compartment. A lens seals the exterior side of the sealable compartment. The waterway fitting is secured in the spout body permanently as by the use of rivets. A liquid-tight seal is provided between the waterway fitting and the outlet opening in the spout body to prevent water splashed back toward the spout from entering the interior of the spout body. According to a preferred embodiment of this invention, the hollow spout body is cast brass which is chrome plated. According to a further preferred embodiment, the lens is a polycarbonate plastic. According to a still further preferred embodiment, the cable assembly exposed outside the spout body is protected by a convoluted stainless steel shroud. According to one embodiment of this invention, the aerator is easily changeable with special tools to provide various desirable flow rates. BRIEF DESCRIPTION OF THE DRAWINGS Further features and other objects and advantages of this invention will become clear from the following detailed description made with reference to the drawings in which: FIG. 1 is a perspective view of a spout assembly according to this invention; FIG. 2 is an exploded view of the spout assembly shown in FIG. 1; FIG. 3 is a top view of the unitary waterway fitting forming an essential portion of the spout assembly; FIG. 4 is an elevation view in section along lines IV--IV of FIG. 3; FIG. 5 is a right side view in section along lines V--V of FIG. 3; FIG. 6 is a left side view of the unitary waterway fitting; FIG. 7 is a bottom view of the unitary waterway fitting; FIG. 8 is a top view of a transmitter and receiver assembly; and FIG. 9 is a front view of a transmitter and receiver assembly. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1, a spout assembly according to this invention comprises a hollow spout body 10 fabricated as a brass casting with external chrome plating. The spout body has a threaded inlet opening 11 and an outlet opening 12. The spout body is shaped so that the inlet opening can be fastened over an opening in a surface, for example, the opening in the surrounding surface of a stationary basin (wash bowl) provided for a faucet. The outlet opening of the hollow spout body is spaced from the inlet opening so that when the spout assembly is attached to the surface, the outlet opening is spaced out over the basin. Inserted in the outlet opening 12 of the spout body 10 is a unitary waterway fitting 13. The unitary waterway fitting is secured in the opening by rivets 14. The waterway fitting supports the aerator 15. The waterway fitting also supports the transmitter and receiver assembly (not shown) which is protected by lens 16 held in place by screw 17. The aerator is an optional flow rate, vandal-resistant aerator. The lens 16 is made from polycarbonate plastic for impact resistance. The lens is held in place by a screw 17 having a tamper-proof head. Typically, it is an internal hex bore head. Threaded to the bottom of the spout body is a shank 19 which engages threaded inlet opening 11. Adjacent the threaded inlet opening and connected thereto is a small opening 11a through which electric cable assembly 18 passes. Referring now to FIGS. 3, 4, 5, 6 and 7, there are shown various views of the unitary waterway fitting. The unitary waterway fitting is a brass forging that is machined to provide an inlet port 22 and a threaded outlet port 23. The unitary waterway can be used with hollow spout bodies of numerous configurations so long as the outlet opening in the spout body is standard. Bores 26 are provided to receive rivets 14. Compartments 24 and 25 are provided for receiving the transmitter and receiver, respectively. An edge of each compartment is arranged at an angle from the centerline between the compartments 24 and 25 for the purpose of aiming the transmitter and receiver when in place. The transmitter and receiver are aimed so that their respective lines of sight converge several inches in front of the spout. Bore 32 is arranged to receive a screw 31 on one end for holding a cap (to be described) in place. A recess 33 is provided for receiving the lens 16. The bore 32 is threaded to receive the screw 17 on its other end for holding the lens in place. The ease of assembling the spout assembly, its tamper resistance and its modularity is to a large extent the result of the configuration of the unitary waterway fitting described herein. Referring now to FIG. 2, a four-wire cable terminates in the connector 35 at one end and in a connector 43 at the other end. A portion of the cable is shrouded by a flexible metal tube 40. A ring 41 is attached to the exterior of the flexible tube so that when the flexible tube is inserted through opening 11a, the flexible tube cannot be pulled out of the spout body. The transmitter 28 and receiver 29 are secured to a terminal board 44 which together define a transmitter and receiver assembly. (See FIGS. 8 and 9 for details.) Two-wire cable 36 is secured to the receiver and two-wire cable 37 is secured to the transmitter at the terminal board. The opposite ends of the two-wire cables 36, 37 are mounted in four-wire connector 38. Cap 30 is arranged to enclose the terminal board 44 and is secured to the unitary waterway fitting by screw 31. Copper tubing 45 forms a water conduit secured to the inlet port of the unitary waterway fitting at one end. At the other end, copper tubing 45 passes into the shank 19. The space between the interior of the shank and the exterior of the copper tubing is liquid-tight sealed by O-ring 46. The assembly of the faucet will now be described. O-ring 48 is lubricated and positioned around the lower edge of the unitary waterway fitting 13. The O-ring is essential to prevent water splashed back toward the spout body 10 from entering the hollow space within the spout body. The transmitter 28 and receiver 29 are positioned in the compartments provided therefor in the unitary waterway and the cap 30 is placed over the terminal board 44 and secured in place by screw 31. Preferably, a nonelectrically conductive silicon sealant is applied to the periphery of the terminal board before the cap is put in place. Cable assembly 18 is inserted through opening 11 so that the ring 41 is within the spout body 10. Connector 35 is then engaged with connector 38. The copper tube 45 is then fed through the spout and the unitary waterway is riveted in place using two rivets 14. Next, the aerator 15 is attached to the waterway. A lens seal 49 is placed in the waterway and the lens 16 is attached using screw 17. The externally threaded shank 19 is then slid over the copper tube and turned into the threaded inlet opening 11. Finally, the O-ring 46 is inserted in the shank 19 to seal the interior of the shank from the exterior surface of the copper tube 45. The simplicity of the above-described assembly results in an automatic faucet spout assembly that is economical to manufacture. As should be apparent, the shape of the hollow spout can be changed, for example, lengthened, and still the same parts can be used in its assembly. The copper tubing and electrical cables may need to be lengthened but no other changes are required. The faucet assembly described herein is particularly useful with a tamper-resistant control unit described in a co-pending application entitled "Control Unit For Automatic Faucet" filed on the same day and assigned to the same assignee, bearing Ser. No. 08/425,841, and incorporated herein by reference. Having thus described our invention with the detail and particularity required by the Patent Laws, what is protected by Letters Patent is set forth in the following claims.
A spout assembly for an automatic faucet that is easily assembled and tamper resistant has a transmitter and a receiver for use in detecting the presence of objects near the spout. The hollow spout body has an inlet opening and an outlet opening. A unitary waterway fitting is permanently fixed in the outlet opening of the spout body. The waterway fitting has a water passage therein and a sealable compartment for receiving and orienting the transmitter and receiver.
4
RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Patent Application 60/977,028 filed on Oct. 2, 2007. NOTICE OF COPYRIGHTS AND TRADE DRESS [0002] A portion of the disclosure of this patent document contains material, which is subject to copyright protection. This patent document may show and/or describe matter, which is or may become trade dress of the owner. The copyright and trade dress owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright and trade dress rights whatsoever. BACKGROUND [0003] This disclosure relates to a system and process for managing photos and specifically to an online system for use by print media and newspapers to directly link a photo of an item for sale with a classified advertisement. SUMMARY [0004] These and other embodiments are described in more detail in the following detailed descriptions and the figures. [0005] The foregoing is not intended to be an exhaustive list of embodiments and features of the inventive subject matter. Persons skilled in the art are capable of appreciating other embodiments and features from the following detailed description in conjunction with the drawings. DESCRIPTION OF THE DRAWINGS [0006] FIG. 1 is a block diagram of a system for photo management system. [0007] FIG. 2 is a flow chart of a process for managing photos. [0008] FIG. 3 is a flow chart of a process for accessing a photo management system by a registered user. [0009] FIG. 4 is a flow chart of a process for accessing a photo management system by an unregistered user. [0010] FIG. 5 is a flow chart of a process for accessing a photo management system by a registered advert user. [0011] FIG. 6 is a flow chart of a process for accessing a photo management system by an unregistered advert user. [0012] FIG. 7 is a flow chart of a process for accessing a photo management system by a print media business. DETAILED DESCRIPTION [0013] Representative embodiments according to the inventive subject matter are shown in FIGS. 1-7 , wherein the same or generally similar features share common reference numerals. [0014] FIG. 1 is a block diagram of a photo management system which may include at least one server for storing and managing photos submitted by users. Although FIG. 1 shows a single server, the functions of the photo management system may be partitioned between a plurality of servers, some of which may be dedicated to specific functions, such as a Web server or a file server. In this context, a “server” is any computing device capable of performing all or part of the functions of the photo management system. [0015] The server may be connected to at least one network, which may be the Internet. The server may be connected to other networks, such as a local area network, storage network, or wide area network, in addition to the Internet. Registered and unregistered users may interact with the server by means of network-connected devices or by means of mobile communication devices via an intermediary wireless service provider (WSP). Although FIG. 1 shows a laptop computer as an example of a network-connected device, any network-connected device may be used including personal computers, tablet computers, personal digital assistants, and any other network-connected devices. Similarly, although FIG. 1 shows a cellular phone as an example of a mobile communication device, other mobile devices, such as wireless email appliances and two-way messaging pagers, may be used. The server may interact with newspaper or other print media users by means of the Internet or other network. [0016] The server may be connected with, or may include, an interactive voice response (IVR) system to allow interaction with users who are unable or unwilling to use text messaging or other simple message service (SMS) messages from a mobile communication device. [0017] FIG. 2 is a flow chart of a process for managing photos. This process may be consistent with the photo management system of FIG. 1 . [0018] The process for managing photos may begin when a seller, having an item for sale, contacts a newspaper or other print publication to place a classified advertisement. The print publication may offer the seller the opportunity to have one or more photographs of the item connected to the print advertisement. The print publication may explain that, for a small additional fee, a photo of the item may be sent to prospective buyers via the buyer's mobile communication device or may be accessed via a website. [0019] If the customer accepts the additional service, the photo management service fee may be included in the total advertisement fee and billed by the print publication through their traditional order processing methods. The print publication may conclude the sale using their existing processes and may inform the seller that instruction for uploading the photo(s) of the item will be provided by email. [0020] The print publication may then establish a discrete code for the advertisement and submits information on the seller and the advertisement to the photo management system. Conveniently, the seller's phone number may be used as the discrete code. [0021] Upon receipt of the information from the print publication, the photo management system may establish an account for the seller as a registered advertising user. The photo management system may then send an email message or a text message to the registered advertising user (the seller) including instructions for submitting photos. [0022] The registered advertising user may then upload one or more photos to the photo management system. Photos may be submitted directly from the registered advertising user's cell phone, by e-mail attachment, or via the photo management system Web site. [0023] Potential buyers may then view photos using their cell phones. For example, the potential buyers may dial a five-digit short code to access the photo management system and then enter the phone number printed in a classified advertisement to access the appropriate photos. [0024] The photo management system may not be limited to receiving and managing only photos specifically linked to advertisements. For example, the photo management system may be used to manage photos for previously registered users who do not have current print media advertisements. [0025] FIG. 3 is a flow chart of a process that may be used by a normal registered user, herein termed a “CPIXX user”, to access the photo management system. The CPIXX user may add multiple photos to a profile associated with the registered user (herein termed a “CPIXX profile”) and stored on the server. A CPIXX user may add photos to their CPIXX profile by means of text messages from a mobile communication device, by means of a network-connected device, or by means of e-mail. [0026] A CPIXX user may take a picture from a mobile device and sent it to their CPIXX profile using a gateway number provided by their mobile service provider. The Mobile service provider may receive the photo and the gateway number sent by user. The Mobile service provider may authenticate the gateway number. If the gateway number is correct, the service provider may pass the photo and the user's mobile number to the photo management system with a parameter which contains type of data. (0=Photo and 1=Text message). If the gateway number is incorrect, the mobile service provider may send an “incorrect gateway number” message to the CPIXX user. [0027] When the photo management system receives the data from the mobile service provider with the parameter, the photo management system may authenticate the CPIXX user by his/her mobile number or some other method. If the CPIXX user is registered, the photo management system may store the photo into the CPIXX user's profile in the database. If the CPIXX user is unregistered, the photo management system may send an “invalid user” message to mobile service provider and mobile service provider may forward the message to mobile user. [0028] Alternatively, a CPIXX user may upload photos to his/her CPIXX profile using a network-connected device. The CPIXX user may first login to the photo management system by passing credentials which may include a user name and a password. The photo management system may then authentic the credentials entered by user. If the entered user name and password are valid, the CPIXX user may be enabled to add new photos to their CPIXX profile. [0029] Additionally, a CPIXX user may also upload photos to their CPIXX profile using e-Mail. The CPIXX user may attach one or more photos to an email, include the CPIXX number as the email subject and send the email message to the photo management system. The photo management system may parse the received email message to retrieve the CPIXX number and the attached photos. The photo management system may authenticate the CPIXX number. If the CPIXX number is valid, the photo management system may add the attached photos to the CPIXX user's profile. [0030] FIG. 4 shows a flow chart of the process that may be used by an unregistered user to access the photo management system. An unregistered user may view permitted photos uploaded to the photo management system by registered CPIXX users. An unregistered user can view a CPIXX user's photos using text messages from a mobile communication device, using a computer connected to the network, or using an interactive voice response system (IVR). [0031] An unregistered user may pass a CPIXX number and a gateway number as SMS messages to their mobile service provider. The unregistered user may also pass a photo number along with the CPIXX number and the gateway number to view a selected photo instead of all photos. When the mobile service provider receives the CPIXX number, the gateway number and the optional photo number sent by the unregistered user, the mobile service provider may authenticate the gateway number. If the gateway number is correct, the mobile service provider may pass the CPIXX number, the gateway number and the optional photo number to the photo management system. If the gateway number is incorrect, the mobile service provider may send an “incorrect gateway number” message to the unregistered user. [0032] When the photo management system receives data from mobile service provider, the photo management system may check availability of the designated CPIXX user. If the CPIXX user is registered, the photo management system may fetch the selected photo if a photo number was provided, or all permitted photos in the CPIXX user's profile from database and send them to the unregistered user's mobile device. If the provided CPIXX number does not correspond to a registered user, the photo management system may send an “invalid user” message to the mobile service provider and the mobile service provider may forward the message to mobile user. [0033] Unregistered users who are unable or unwilling to send SMS messages, may access photos by calling a dedicated phone number and using an IVR system to enter the CPIXX number and optional photo number. After the validity of the CPIXX number is checked, the photos may be sent to the unregistered user's mobile device as previously described. [0034] Alternatively, an unregistered user may view a registered CPIXX user's photos from a device connected to the network by accessing the photo management system web site and entering a CPIXX number. The photo management system may check if the CPIXX number is valid or not. If CPIXX number is valid, the photo management system will show photos to the unregistered user. [0035] FIG. 5 shows a flow chart of the process that may be used by an registered advertising user to access the photo management system. A registered advertising user is a registered user who has purchased an advertising package from a newspaper or other print media. A registered advertising user can upload unlimited photos to his/her CPIXX profile, but can connect photos to advertisements only as defined in the advertising package. A registered advertising user may access the photo management system and upload photos using three techniques that are essentially the same as those previously described in conjunction with FIG. 3 . Once photos are uploaded, the registered advertising user can connect specific photos to advertisements as permitted by the advertising package. [0036] FIG. 6 shows a flow chart of a process that may be used by an unregistered advertising viewer to access the photo management system. The process may be essentially the same as that described in conjunction with FIG. 4 , except that the unregistered advertising viewer may obtain a CPIXX number from a printed classified advertisement, and the CPIXX number may be directed to a specific advertisement, rather than to a registered user. [0037] FIG. 7 shows a flow chart of a process that may be used by a newspaper user to access the photo management system. In this context, “newspaper user” is intended to encompass any form of print media user. A newspaper user may access photo management system by means of a network-connected device running a suitable Web application. [0038] The newspaper user may first login to the photo management system by passing credentials such as a user name and a password. The photo management system may authenticate the credentials entered by the newspaper user. If the credentials are valid, the newspaper user may be allowed to access several program modules to manage advertising users and advertising packages. [0039] Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of the inventive subject matter, and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein. [0040] All patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes. [0041] While the inventor understands that claims are not a necessary component of a provisional patent application, and therefore has not included detailed claims, the inventor reserves the right to claim, without limitation, at least the following subject matter.
A photo management system is described herein consisting of a server, a mobile device, and the internet; furthermore systems and software located on the server and the mobile device provide connectivity and functionality for the exchange of photos.
6
BACKGROUND OF THE INVENTION The invention relates to a method and apparatus for the production of yarn. Synthetic fibers are commonly produced by extruding molten polymer through a spinneret. In order to produce yarns which have properties approximating those of wool or other natural materials, it is common practice to subject the extrudate from the spinneret to a texturing process. This can be accomplished by a variety of procedures known in the art, such as stuffer-box crimping, false twisting, and fluid jet texturing. One particularly effective procedure involves passing the yarn to be textured and a high velocity fluid to a first passage. Subsequently, the yarn and the fluid are passed to an enlarged passage and then to a zone where the yarn is restrained and cooled. In the restraining zone individual stacked members, such as balls are used to exert a force on the yarn to restrain the yarn, which is in the form of a yarn wad. The fluid escapes from the yarn through the voids between the stacked members and a textured yarn is removed from the restraining zone. Although this procedure produces a high quality textured yarn, a particularly troublesome problem involves loss of the stacked members from the restraining zone. Frequently, stacked members become entrained in the yarn wad and are carried away from the restraining zone. Also sudden disruptions in the texturing process cause the stacked members to be thrown from the restraining zone. In addition, operators occasionally knock stacked members from the restraining zone during string up and maintenance of the equipment. Further, recovering the stacked members from the floor and/or replacing them with new ones involves considerable expense, particularly where a number of such processing lines are used. Although it would appear such a problem could be easily solved, this has not been the case. In order for the stacked members to function properly, they must be free to act upon the yarn wad, and in addition, the restraining zone containing the stacked members must be designed to allow the operator to easily string up and maintain the equipment. It has been very difficult to satisfy both of these conditions simultaneously. However, the present invention achieves such a result. It is an object of the invention to restrain yarn. Another object of the invention is to restrain and cool yarn textured using a fluid jet texturing process. Another object of the invention is to eliminate the loss of stacked members from a restraining zone. Still another object of the invention is to provide an apparatus useful for restraining yarn. Yet another object of the invention is to provide an apparatus useful to cool and restrain yarn textured with a fluid jet wherein the apparatus contains individual stacked members which are not removed from the apparatus by the operation thereof. Other aspects, objects, and advantages of the invention will be apparent to those skilled in the art upon studying the drawings, specification, and the appended claims. SUMMARY OF THE INVENTION In accordance with the invention, a textured yarn is passed to a restraining zone containing a flexible sleeve through which the yarn is passed and a plurality of individual stacked members, said flexible sleeve being positioned so as to prevent said stacked members from being removed from said restraining zone as the stacked members exert a force upon the flexible sleeve which in turn exerts a restraining force upon the yarn. Further according to the invention, an apparatus for restraining yarn comprises a chamber having an inlet and an outlet and an inner and outer surface; a flexible sleeve having an inlet and an outlet through which the yarn is directed and an inner and an outer surface, the inlet of the flexible sleeve being attached to the inlet of the chamber and the sleeve being positioned in and extending through the chamber; and a plurality of individual stacked members positioned in the chamber between the inner surface thereof and the outer surface of the flexible sleeve. DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates an embodiment of the apparatus of this invention and a fluid jet which is employed to texture the yarn. FIG. 2 is a plan view of the embodiment of FIG. 1. FIG. 3 illustrates another embodiment of the invention used with a fluid jet. DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings and to FIG. 1 in particular, there is shown a crimping or texturing apparatus generally designated by reference numeral 10. This apparatus comprises an elongated sleeve 11 which has a hollow needle 12 positioned in the inlet section thereof. An elongated plug 14 is disposed in the outlet section of sleeve 11. Plug 14 has a central opening 14b therethrough. The inlet of opening 14b is tapered to provide a seal 14a adjacent the tip of the needle 12. The outlet of central opening 14b constitutes a section 14c of increased diameter. A conduit 17 communicates with sleeve 11 adjacent needle 12 to introduce a fluid, such as steam or air, at an elevated temperature. The above described apparatus is generally known as a fluid jet for texturing yarn. Further according to the invention, a hollow chamber 18 having an inlet 18a is mounted immediately above sleeve 11 to receive yarn which is crimped in the fluid jet. A large number of relatively small individual stacked members, such as balls, 19a and 19b, are disposed within chamber 18. Chamber 18 can be provided with an outlet conduit 21 which is connected to a drain or to a source of reduced pressure, not shown. A screen 21a is positioned across conduit 21 to retain balls 19a and 19b within chamber 18. A plurality of rigid members 24, generally defining a rigid cylindrical sleeve, are used to guide the yarn wad 20c. A flexible sleeve 26 is attached to the inlet 18a of chamber 18 using a clamp 27 and is positioned between the stacked members 19a, 19b and the yarn wad 20c. The upper end of sleeve 26 can be loose or, as shown in FIG. 3, the flexible sleeve 26 can be extended to enclose the stacked members 19a, 19b by clamping an extended portion of the flexible sleeve 26a to the hollow chamber 18 with clamp 28. In the operation of the apparatus of FIG. 1, one or more filaments 20a are inserted through needle 12 into the central passage of plug 14. These filaments can be delivered to the apparatus by any suitable feed means, not shown. In the normal start-up operation, the filaments are threaded completely through the apparatus. Fluid is introduced through conduit 17 and flows upwardly through plug 14 into chamber 18. In the present embodiment which employs a fluid jet to texture the yarn, chamber 18 functions both as a restraining zone and a cooling zone. The fluid so introduced surrounds needle 12 to elevate the temperature of the incoming filaments. The velocity of the introduced fluid is sufficiently high to produce a zone of substantial turbulence in the outlet region 14c of plug 14. The yarn 20b in the turbulent zone passes upwardly to form an elongated generally cylindrical wad 20c in the center of chamber 18 which is guided by a plurality of rigid members, such as rods 24. This wad 20c passes through the flexible sleeve 26 which is surrounded by a plurality of stacked members, such as balls 19a and 19b. The balls confine and restrain the yarn wad, but they are prevented from becoming entrained in the yarn wad by the flexible sleeve. The fluid passes through pores in the flexible sleeve and into the voids between the individual stacked members. The yarn is cooled in passing through chamber 18 so that permanent crimps are imparted. The resulting textured yarn 20d is removed through a take-up device 30 and passed to a storage zone, not shown. The velocity and temperature of the fluid introduced through conduit 17 are such as to impart the desired degree of crimp in the yarn. If desired, an external heater can be employed to assist in elevating the temperature of the crimping apparatus 10. The texturing fluid passes upwardly through the central opening 14b of plug 14, into chamber 18, and out through flexible sleeve 26 and voids between the stacked members, such as balls 19a, and 19b. The stacked members can be formed of metal, glass or any other material which is inert to the yarn at the temperatures encountered. Stacked members in the shape of spheroids or balls have produced good results; however, the invention is not limited to the use of balls as the stacked members, since other configurations of stacked members are also suitable, such as for example ellipsoids. As illustrated, stacked members 19a are larger than stacked members 19b to provide better packing; however, the stacked members can be all the same size. The height of the stacked members in chamber 18 should be sufficient to produce the desired degree of restraint. It is important to point out that when the restraining zone of the present invention is in communication with a fluid jet texturing zone, and thus is used therewith, the restraining zone also functions as a cooling zone, particularly where the flexible sleeve contains pores through which the fluid can pass. However, it is equally important to point out that although the present invention finds particular applicability when used in conjunction with a fluid jet texturing zone, that the invention should not be limited thereby in its broadest aspect. In general, the present invention can be used with most any process or apparatus in which it is desirable to use a container of stacked members through which a product passes and in which it is desirable to prevent the stacked members from being removed from the container. As for the construction of flexible sleeve 26, a variety of materials are suitable. For example, flexible materials such as nylon, polyester, polyolefins, glass, metal wire and polytetrafluoroethylene can be used to advantage. Suitable materials are usually woven or formed into the flexible sleeve. Generally, flexible sleeve 26 is constructed with a cross-sectional area larger than that of section 14c; however, the cross-sectional area of the flexible sleeve can be smaller than that of section 14c if the flexible sleeve is capable of expanding sufficiently to permit the stacked members to exert the primary restraining force on the yarn wad rather than the flexible sleeve. It is emphasized that the purpose of the flexible sleeve is to isolate the stacked members from the yarn, that is, to prevent the stacked members from becoming entrained in the yarn; but at the same time the flexible sleeve permits the stacked members to restrain the yarn. When used with a fluid jet, the flexible sleeve 26 should contain pores which are of sufficient size to permit passage of the fluid but not the stacked members or balls 19a, 19b as shown in FIG. 1. In FIG. 2, the rigid sleeve as indicated by rods 24, is positioned on the yarn side of the flexible sleeve 26; however, the flexible sleeve can be positioned on the yarn side of the rigid sleeve if desired. In one specific example of this invention utilized in conjunction with a fluid jet as illustrated in FIG. 1, balls 19a had a diameter of about one-fourth inch; and balls 19b had a diameter of about one-eighth inch. Approximately 70 percent of the total number of balls in chamber 18 were balls of 1/4-inch diameter. Chamber 18 had an internal diameter of about 3 inches, with the depth of balls being about 4 inches. The diameter of the yarn wad produced in the fluid jet was approximately three-fourth inch. The flexible sleeve was constructed from nylon 6, 6 double knit, which had 44 courses per inch and 32 wales per inch. The nylon double knit was made from 100 denier, 34 filament yarn. The flexible sleeve was 13/4 inches inside diameter and 53/4 inches long. In one specific mode of operation, a bundle of 126 polypropylene filaments having a denier of about 1800-2000 was introduced into the above described fluid jet at a velocity of about 1000-1100 meters per minute. Superheated steam at 90 psig and 365°F was introduced at a rate of about 20 pounds per hour. The textured yarn was removed at a velocity of about 800 meters per minute. Approximately 30 pounds of textured yarn were produced employing the above apparatus. No balls were carried away from the hollow chamber of entrainment in the yarn wad or thrown from the hollow chamber due to disruptions in the texturing process. Also string up by the operator was readily accomplished. While this invention has been described in conjunction with presently preferred embodiments, it obviously is not limited thereto.
Yarn is passed to a texturing zone wherein a yarn wad is formed, and the yarn wad is then passed through a flexible sleeve in a restraining zone wherein the yarn wad is restrained by a plurality of individual stacked members. In addition an apparatus is provided useful in the method of the invention.
3
CROSS-REFERENCES TO RELATED APPLICATIONS [0001] This application claims priority based on U.S. provisional application 61/039,234, filed Mar. 25, 2008. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH [0002] Not Applicable. BACKGROUND OF THE INVENTION [0003] The present invention relates to devices for dispensing toilet bowl treating chemicals (e.g. cleaners, disinfectants, deodorizers, etc.). More specifically, it relates to devices that allow a consumer to direct a toilet treatment tablet into the toilet bowl when a button is actuated. [0004] Toilet bowls require care to prevent the buildup of unsightly deposits, to reduce odors and to prevent bacteria growth. Traditionally, toilet bowls have been cleaned, deodorized and/or disinfected by manual scrubbing with a liquid or powdered cleaning/sanitizing agent that is added to the bowl water by hand. This task has required manual labor to keep the toilet bowl clean. [0005] To reduce or in some cases eliminate the need for such manual scrubbing, various automatic toilet bowl cleaning systems have been proposed. One type of system delivers the cleaning chemical by adding it to the flush water while the flush water is still stored in the toilet tank. Some embodiments of this type of system add the chemical to the flushing cycle in liquid form. Others place a block of cleaning chemical in the toilet tank, to slowly dissolve over several weeks or longer. [0006] However, in systems which rely on adding the chemical to the toilet tank, precise control over the quantity of chemical to be delivered may be difficult. For example, different water hardness from the supply may cause different cleaning blocks to dilute at different rates. Further, the objective is to keep the toilet bowl clean, not the water holding tank. Since all the cleaner is dispensed into the toilet tank, rather than the toilet bowl, much of the cleaner may be flushed down the drain without cleaning the toilet bowl at all. [0007] An alternative type of system hangs a dispenser adjacent and/or immediately under the toilet bowl rim. Water flowing from the rim washes over the dispenser, thereby triggering dispensing of the stored chemical directly into the bowl water. However, some consumers may prefer not to have the ornamental exterior of their toilet disrupted by the presence of a hook hanger. [0008] In any event, such systems are designed to dispense in response to each flush. In some situations where increased amounts of flushing are occurring (e.g., a large number of guests) cleaning chemicals may not be necessary after every flushing. Thus, some of these systems may use up more cleaning chemicals than is actually needed. [0009] There have been attempts to associate toilet bowl chemical dispensers with the lids or other coverings of toilets, or near them. See, for example, U.S. Pat. Nos. 713,978, 749,963, 979,386, 988,178, 3,840,914, 4,216,553, 4,819,276 and 6,745,417, and U.S. Patent Application Publication No. 2006/0097189. However, these systems suffer from various of the deficiencies noted above. For example, it is typical with many of such systems to have dispensing occur with every toilet lid movement, regardless of need. [0010] It can therefore be seen that improvements are desired with respect to toilet bowl cleaning devices that dispense toilet bowl treatment chemicals. SUMMARY OF THE INVENTION [0011] In one aspect, the invention provides a toilet bowl cleaning device including a plurality of solid tablets stored in a stacked configuration in a tablet dispenser so as to be dispensable from the dispenser. The tablets can include one or more components that perform cleaning and/or disinfecting and/or deodorizing functions in the toilet bowl and/or the toilet tank. By the term “tablet”, it is intended to mean a solid mass of a size larger than what would be viewed as powder, regardless of shape. Hence, the tablets may be disk shaped, or spherical, or elongated, or have other configurations. The tablets preferably will be supplied in a refill unit which can be separated from the dispenser when the tablets have all been dispensed from the dispenser. The solid tablets can be stored in the dispenser in a stack with adjacent tablets abutting each other in face-to-face fashion. [0012] In one aspect, the invention provides a device for dispensing a toilet treatment chemical to a toilet bowl. The device includes: (i) a cover (e.g. the toilet lid or seat) suitable to be pivotably mounted to a rearward portion of the toilet bowl so as to pivot between a somewhat upright position and an essentially horizontal position; (ii) a dispenser mounted to the cover; (iii) a plurality of solid tablets stored in the dispenser so as to be dispensable therefrom, wherein at least one of the tablets includes a toilet treatment chemical; and (iv) an actuator for moving a tablet from a ready position of the dispenser into the toilet bowl. The cover can be a toilet seat or a toilet lid. [0013] The actuator moves the tablet from the ready position of the dispenser into the toilet bowl in response to a manual force having been applied to the actuator. The actuator can be linked to a return spring such that after a tablet is moved from the ready position of the dispenser into the toilet bowl the spring will cause the actuator to move back to a rest position. The actuator can include a slide for driving the tablet from the ready position of the dispenser into the toilet bowl. The actuator can include a button accessible at a top surface of the cover. In one form, the cover includes a delivery slot, and the actuator moves the tablet from the ready position of the dispenser through the delivery slot and into the toilet bowl. The actuator can include a lock which inhibits use of the actuator when the cover is in the upright position. [0014] In another aspect, the invention provides a handheld device for dispensing a toilet bowl treatment tablet into the toilet bowl. The device includes a body having a cover and a hollow wall connected to the cover. The cover and the wall define an interior space in the body, and the cover includes a dispensing slot. The device also includes a removable tablet holder suitable for holding a plurality of solid tablets. The tablet holder can be provided as a refill unit. At least one of the tablets can include a toilet treatment chemical. The tablet holder is dimensioned to fit within the interior space of the body. The tablet holder has a tablet retainer at a dispensing end of the tablet holder, and the tablet retainer is located within the cover when the tablet holder is installed within the space of the body. The tablet retainer retains a tablet in a ready position for dispensing. The device also includes an actuator disposed in the cover. The actuator is suitable for moving a tablet from the ready position out through the dispensing slot. [0015] In one form, the tablet retainer includes opposed elastic arms for retaining a tablet in the ready position for dispensing. At least one of the arms can include an inwardly directed flange for preventing movement of a tablet longitudinally beyond the flange. The tablet retainer can include a notch, and the actuator can include a slide dimensioned to be movable into the notch for pushing a tablet from the ready position out through the dispensing slot. The actuator can include a button arranged in a surface of the cover. The actuator can move the tablet from the ready position out through the dispensing slot in response to a manual force having been applied to the actuator by a user. The actuator can be linked to a return spring such that after a tablet is moved from the ready position out through the dispensing slot the spring will cause the actuator to move back to a rest position. [0016] In one form, the tablet holder includes a locking mechanism for holding the tablet holder within the space of the body. The locking mechanism can include a pin attached to an outer surface of the tablet holder and a throughhole in a section of the wall of the body. The throughhole receives the pin in a mating locking connection. The section of the wall of the body having the throughhole is movable with respect to the wall of the body to assist in mating the pin and the throughhole. [0017] In yet another aspect, the invention provides a refill unit for a device for dispensing a tablet wherein the dispensing device includes a body having a cover and a hollow wall connected to the cover, and an actuator disposed in the cover. The cover and the wall of the dispensing device define an interior space in the body, and the cover includes a dispensing slot. The actuator is suitable for moving a tablet from a ready position within the cover out through the dispensing slot of the dispensing device. The refill unit includes a housing suitable for holding a plurality of solid tablets, and a tablet retainer connected to the housing at a dispensing end of the housing. The tablet retainer is suitable for retaining a tablet in a ready position for dispensing. The housing and the tablet retainer of the refill unit are dimensioned to fit within the interior space of the body of the dispensing device, and the housing and the tablet retainer of the refill unit are dimensioned such that tablet retainer is located within the cover of the dispensing device when the refill is installed within the space of the body of the dispensing device. [0018] In one form of the refill unit, the tablet retainer includes opposed elastic arms for retaining a tablet in the ready position for dispensing. At least one of the arms includes an inwardly directed flange for preventing movement of a tablet longitudinally beyond the flange. The tablet retainer can include a notch dimensioned for receiving the actuator such that a tablet may be moved by the actuator from the ready position out through the dispensing slot of the dispensing device. The housing of the refill unit can include a locking mechanism for the holding the tablet holder within the space of the body of the dispensing device. A plurality of tablets can be stored in the housing of the refill unit, and at least one of the tablets comprises a toilet treatment chemical. The plurality of tablets can be stored in the housing in a stack with adjacent tablets abutting each other in face-to-face fashion. A spring can be used for biasing the tablets toward the tablet retainer of the refill unit. [0019] In still another aspect, the invention provides a method for cleaning and/or disinfecting and/or deodorizing a toilet bowl. The method uses a handheld device including a body, a tablet holder, and an actuator. The body has a cover and a hollow wall connected to the cover. The cover and the wall define an interior space in the body, and the cover includes a dispensing slot. The tablet holder holds a plurality of solid tablets. The tablet holder is located within the interior space of the body, and the tablet holder retains a tablet in a ready position within the cover for dispensing. The actuator is disposed in the cover, and is suitable for moving a tablet from the ready position out through the dispensing slot. A user applies a manual force to the actuator to move a tablet from the ready position out through the dispensing slot and into the toilet bowl where the tablet dissolves to clean and/or disinfect and/or deodorize the toilet bowl. [0020] The foregoing and other advantages of the present invention will become apparent from the following description. In that description reference will be made to the accompanying drawings which form a part thereof, and in which there is shown by way of illustration example embodiments of the invention. The example embodiments do not limit the full scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS [0021] FIG. 1 is a top, front, left perspective view of an embodiment of a dispensing device according to the invention integrated into a toilet lid resting on a toilet seat. [0022] FIG. 2 is exploded perspective view of the device of FIG. 1 showing a top section of the toilet lid removed from a base section of the toilet lid. [0023] FIG. 3 is a cross-sectional view of the base section of the toilet lid of FIG. 2 taken along line 3 - 3 of FIG. 2 . [0024] FIG. 4 is a detailed cross-sectional view of the tablet dispenser and actuator of the base section of the toilet lid of FIG. 3 with the toilet seat removed taken along line 4 - 4 of FIG. 3 . [0025] FIG. 5 is a detailed view of the tablet dispenser and actuator of FIG. 4 taken along line 5 - 5 of FIG. 4 . [0026] FIG. 6 is an exploded top, front, left perspective view of another embodiment of a dispensing device according to the invention showing a refill unit and the dispenser body. [0027] FIG. 7 is an exploded top, front, left perspective view of the dispensing device of FIG. 6 showing a refill unit installed in the dispenser body. [0028] FIG. 8 is a front view of the dispensing device of FIG. 7 . [0029] FIG. 9 is a left side view of the dispensing device of FIG. 7 . [0030] FIG. 10 is a right side view of the dispensing device of FIG. 7 . [0031] FIG. 11 is a cross-sectional view of the dispensing device of FIG. 7 taken along line 11 - 11 of FIG. 10 . DETAILED DESCRIPTION OF THE INVENTION [0032] Turning first to FIGS. 1 to 5 , there is shown a dispensing device 10 according to a first example embodiment of the invention. The dispensing device 10 is integrated into a toilet lid 12 resting on a toilet seat 14 . The toilet lid 12 and the toilet seat 14 are pivotably mounted in a conventional manner to a rearward portion of a toilet bowl (not shown) so as to pivot between a somewhat upright position and an essentially horizontal position on the rim of the toilet bowl. The toilet lid 12 shown is generally oval shaped. However, the invention is not limited to oval shaped lids. Other shapes for the lid (e.g. more round) are also suitable. [0033] Looking at FIG. 2 , the toilet lid 12 includes a separate top section 16 having a top surface 17 that may optionally include a transparent window 18 for viewing toilet treatment tablets 19 that are dispensed to the toilet bowl as described below. The window 18 helps show when the tablets 19 need to be replaced. The top section 16 of the toilet lid 12 has a downwardly directed curved forward wall 21 having opposed elastic mounting tabs 22 L, 22 R at the rear of the forward wall 21 . A mounting rib 23 is at the rear of the top section 16 , and an arcuate opening 24 with a downwardly directed support wall 25 with openings 26 is provided at the front portion of the top surface 17 of the top section 16 of the toilet lid 12 . [0034] Still referring to FIG. 2 , the toilet lid 12 includes a separate base section 27 that rests on the toilet seat 14 . The base section 27 includes a bottom wall 28 and a curved rear wall 30 that extends upwardly from the bottom wall 28 . The bottom wall 28 includes a rectangular dispensing slot 29 . The rear wall 30 includes an inwardly directed flange 31 that creates a space 32 at the rear of the base section 27 . The rear wall 30 that opposed mounting holes 33 L, 33 R at the forward ends of the rear wall 30 . The top section 16 of the toilet lid 12 is installed on the base section 27 by inserting mounting rib 23 in the space 32 and inserting the mounting tabs 22 L, 22 R in the mounting holes 33 L, 33 R. The top section 16 of the toilet lid 12 is removed from the base section 27 by pushing mounting tabs 22 L, 22 R out of the mounting holes 33 L, 33 R and pulling forwardly and upwardly on the top section 16 . The top section 16 and the base section 27 of the toilet lid 12 may be formed from a polymeric material such as polyethylene or polypropylene. [0035] Looking at FIGS. 2-5 , the base section 27 of the toilet lid 12 includes a tubular tablet dispenser housing 35 mounted to the bottom wall 28 of the base section 27 of the toilet lid 12 . The tablet dispenser housing 35 receives a tablet bottle 37 containing the tablets 19 by way of open end 38 of the tablet dispenser housing 35 . The base section 27 of the toilet lid 12 may hold two tablet bottles 37 at one time as shown in FIGS. 2-5 , that is, one tablet bottle 37 may be installed in the tablet dispenser housing 35 and one tablet bottle 37 may be clipped to the bottom wall 28 of the base section 27 of the toilet lid 12 by way of clips 39 . In this configuration, when the last tablet 19 in the tablet bottle 37 in the tablet dispenser housing 35 is dispensed into the toilet bowl, the tablet bottle 37 in the tablet dispenser housing 35 can be removed and the tablet bottle 37 held by clips 39 can be inserted in the tablet dispenser housing 35 . [0036] The tablet bottle 37 includes a transparent tubular outer wall 41 that is closed off at one end by bottom wall 43 . The opposite end of the outer wall 41 is open end 45 . A finger indent 47 for ease of handling the tablet bottle 37 is below bottom wall 43 of the outer wall 41 . A mounting protrusion 48 is provided on an outer surface of the outer wall 41 of the tablet bottle 37 . The outer wall 41 may be formed from a polymeric material such as polyethylene or polypropylene. [0037] The tablets 19 are held in the tablet bottle 37 between a compression spring 49 and a tablet retainer 55 which partially covers the open end 45 of the tablet bottle 37 . The tablet retainer 55 may be formed from an elastic material such as nylon or acetal. The tablet retainer 55 has a curved body 56 with arms 58 a, 58 b that terminate in ends 59 a, 59 b that define an open spacing 61 between the ends 59 a, 59 b of the tablet retainer 55 . Inwardly directed flanges 63 a, 63 b, 63 c, 63 d are located at the end 64 of the tablet retainer 55 . A notch 65 is located in the end 64 opposite the spacing 61 . Mounting arms 66 a, 66 b (not shown) hold the tablet retainer 55 on the open end 45 of the tablet bottle 37 . Looking at FIGS. 3-5 , it can be seen that the spring 49 biases a stack of the tablets 19 away from the bottom wall 43 of the tablet bottle 37 toward the tablet retainer 55 . The arms 58 a, 58 b and the flanges 63 a, 63 b, 63 c, 63 d of the tablet retainer 55 hold an end tablet 19 e of the stack in a ready position for dispensing, which is explained below. [0038] A full stack of tablets may include any number of tablets depending on the size of the tablets 19 and the size of the tablet bottle 37 . For example, thirty tablets could be provided in a full stack for a thirty day supply of once a day tablets. While the solid tablets 19 are shown being stored in the tablet bottle 37 in a stack with adjacent tablets 19 abutting each other in face-to-face fashion, the tablets can also be stored in an edge-to-edge orientation. Also, the tablets can be any shape, with circular disc tablets being preferred. The tablets can include various components such as cleaners (e.g., anionic, non-ionic, cationic, amphoteric and zwitterionic surfactants), disinfectants (e.g., chlorinating agents), and deodorizers (e.g., zinc ricinoleate). [0039] Referring to FIGS. 1-5 , the dispensing device 10 includes an actuator 68 for moving a tablet 19 from a ready position of the dispensing device 10 into the toilet bowl. The actuator 68 includes an arcuate push button 70 having a top wall 72 and a side wall 74 that depends downwardly from the top wall 72 . Protrusions 76 a, 76 b, 76 c, 76 d extend outward from the side wall 74 of the button 70 . The button 70 may be formed from a polymeric material such as polyethylene or polypropylene. [0040] The button 70 is slidingly arranged in the opening 24 of the top section 16 of the toilet lid 12 . Each of the protrusions 76 a, 76 b, 76 c, 76 d of the button 70 are placed in a mating opening 26 in the support wall 25 (see FIG. 2 ) to guide the each of the protrusions 76 a, 76 b, 76 c, 76 d in an associated opening 26 in the support wall 25 . Looking at FIGS. 4 and 5 , compression springs 78 a, 78 b are arranged between a bottom surface 79 of the button 70 and a top surface 81 of the bottom wall 28 of the base section 27 of the toilet lid 12 . The compression springs 78 a, 78 b bias the button 70 upward. The button 70 also includes a slide 85 that protrudes outwardly from the protrusion 76 a. The actuator can also comprise other configurations. For example, the actuator can include spaced apart separate buttons that both need to be pressed in order to deliver a tablet to the toilet bowl. [0041] Looking at FIGS. 3 and 4 , the top surface 81 of the bottom wall 28 of the base section 27 of the toilet lid 12 includes an inverted L-shaped lock 88 that pivots in direction R around a pivot pin 89 of a mounting bracket 91 on the top surface 81 of the bottom wall 28 of the base section 27 of the toilet lid 12 . A top surface 92 of the lock 88 interfaces with a lower surface 98 of a stop 96 that depends downwardly from the top wall 72 of the button 70 . [0042] Having described the parts of the dispensing device 10 , its operation can be explained further. The top section 16 of the toilet lid 12 is removed from the base section 27 by pushing mounting tabs 22 L, 22 R out of the mounting holes 33 L, 33 R and pulling forwardly and upwardly on the top section 16 . A user then inserts a tablet bottle 37 into the open end 38 of the tablet dispenser housing 35 . The tablet bottle 37 is inserted with the tablet retainer 55 going into the open end 38 first. The finger indent 47 provides for ease of handling of the tablet bottle 37 . Mounting protrusion 48 of the tablet bottle 37 engages a recess on the base section 27 of the toilet lid 12 to retain the tablet bottle 37 in the tablet dispenser housing 35 . The top section 16 of the toilet lid 12 is then installed on the base section 27 by inserting mounting rib 23 in the space 32 and inserting the mounting tabs 22 L, 22 R in the mounting holes 33 L, 33 R. [0043] Looking at FIGS. 3-5 , the spring 49 biases the stack of the tablets 19 against the tablet retainer 55 . The arms 58 a, 58 b and the flanges 63 a, 63 b, 63 c, 63 d of the tablet retainer 55 hold an end tablet 19 e of the stack in a ready position for dispensing. A user applies a downward force F on the top wall 72 of the button 70 (see FIG. 4 ) overcoming the biasing force of springs 78 a, 78 b, and slide 85 of the button 72 moves downward in notch 65 of the tablet retainer 55 . The slide 85 moves tablet 19 e downward in direction D (see FIG. 4 ) and elastic arms 58 a, 58 b move in directions O in FIG. 5 thereby releasing tablet 19 e downward through rectangular dispensing slot 29 in the bottom wall 28 of the base section 27 of the toilet lid 12 and into the toilet bowl. The user then releases the downward force F on the button 70 and the button 70 returns to the rest position shown in FIG. 4 because of the upward biasing force of the springs 78 a, 78 b. The spring 49 in the tablet bottle 37 then moves the stack of tablets 19 toward the tablet retainer 55 such that the next tablet in the stack is now the end tablet 19 e of the stack in a ready position for dispensing. [0044] In certain positions of the toilet lid 12 , the button 70 is prevented from being pushed. In the view of FIG. 4 , the toilet lid 12 is in an essentially horizontal position, and the top surface 92 of the lock 88 is clear of the lower surface 98 of the stop 96 such that button 70 can be depressed using a downward force F. However, when the toilet lid 12 is raised into a somewhat upright position, the lock 88 rotates in direction R 1 of FIG. 4 until the top surface 92 of the lock 88 is placed adjacent or in contact with the lower surface 98 of the stop 96 . When the top surface 92 of the lock 88 is adjacent or in contact with the lower surface 98 of the stop 96 a and a user presses the button 70 using a downward force F downward motion is inhibited due to the lock 88 blocking the stop 96 . Thus, the button 70 is locked when the toilet lid 12 is open in a somewhat upright position, and as the toilet lid 12 is closed, the lock 88 releases by rotating away from the stop 96 . [0045] Turning now to FIGS. 6 to 11 , there is shown a handheld dispensing device 110 according to a second example embodiment of the invention. The dispensing device 110 has a tubular body 112 having an outer wall 114 with an upper end 116 and a lower end 118 . A lower opening 120 is provided at the lower end 118 of the body 112 . A pair of slots 122 in the lower end 118 of the body 112 define a tab 124 that can flex inward and outward. The tab 124 has a throughhole 126 . The outer wall 114 has ribs 128 that provide a hand grip for the fingers of a user. The body 112 may be formed from a polymeric material such as polyethylene or polypropylene. [0046] The dispensing device 110 also has a cover 133 that along with the outer wall 114 of the body 112 defines an interior space 135 of the body 112 . The cover 133 has a top wall 139 , and a side wall 141 that extends downwardly from the top wall 139 . A dispensing slot 143 is provided in the side wall 141 . A bottom section 145 of the cover 133 is attached to the upper end 116 of the body 112 . The top wall 139 , the side wall 141 and the bottom section 145 of the cover 133 define an interior space 147 of the cover 133 . The cover 133 may be formed from a polymeric material such as polyethylene or polypropylene. [0047] The dispensing device 110 also has removable tablet holder 150 . The tablet holder 150 can be sold as a refill unit. The tablet holder 150 includes a bottom wall 151 and a tubular side wall 153 that extends upwardly from the bottom wall 151 . The side wall has a pin 154 that extends outwardly from the side wall 153 . The tablet holder 150 has a handle 156 and a finger indent 158 for ease of handling the tablet holder 150 . The tablet holder 150 has a longitudinal axis A (see FIG. 6 ). The tablet holder 150 may be formed from an opaque or transparent polymeric material such as polyethylene or polypropylene. [0048] At an end of the tablet holder 150 opposite the bottom wall 151 , there is provided a tablet retainer 161 having a curved body 162 with arms 164 a, 164 b that terminate in ends 165 a, 165 b that define an open spacing 166 between the ends 165 a, 165 b of the tablet retainer 161 . Inwardly directed flanges 168 a, 168 b, 168 c, 168 d are located on the tablet retainer 161 . A notch 170 is located in the tablet retainer 161 opposite the spacing 166 . Looking at FIG. 11 , a spring 171 biases a stack of the tablets 172 away from the bottom wall 151 of the tablet holder 150 toward the tablet retainer 161 . (In FIG. 11 , the central tablets in the stack are not shown.) The arms 164 a, 164 b and the flanges 168 a, 168 b, 168 c, 168 d of the tablet retainer 161 hold an end tablet 172 e of the stack in a ready position for dispensing, which is explained below. [0049] The dispensing device 110 also includes an actuator 176 for moving a tablet 172 from a ready position of the dispensing device 110 into the toilet bowl. The actuator 176 includes a push button 178 arranged in the side wall 141 of the cover 133 . The push button 178 has a side wall 179 and a slide 180 that extends away from the side wall 179 . The push button 178 also has a skirt 182 that extends away from the side wall 179 . The actuator 176 also includes a compression spring 185 positioned between an end section 186 of the skirt and shoulders 188 a, 188 b of the inside of the cover 133 . The spring 185 biases the push button 178 away from the interior space 147 of the cover 133 . [0050] Having described the parts of the dispensing device 110 , its operation can be explained further. A user inserts the tablet holder 150 into the lower opening 120 at the lower end 118 of the body 112 as shown in FIG. 6 . The pin 154 of the tablet holder 150 enters the throughhole 126 of the body 112 to retain the tablet holder 150 in the body 112 (see FIG. 7 ). [0051] Looking at FIG. 11 , the spring 173 biases the stack of the tablets 172 against the tablet retainer 161 . The arms 164 a, 164 b and the flanges 168 a, 168 b, 168 c, 168 d of the tablet retainer 161 hold an end tablet 172 e of the stack in a ready position for dispensing. A user applies a force F on the side wall 179 of the button 178 (see FIG. 11 ) overcoming the biasing force of spring 185 and slide 180 of the button 178 moves sideways in notch 170 of the tablet retainer 161 . The slide 180 moves tablet 172 e in direction O (see FIG. 11 ) and elastic arms 164 a, 164 b move apart in directions X in FIG. 6 thereby releasing tablet 172 e sideways through dispensing slot 143 in the side wall 141 of the cover 133 and into the toilet bowl. The user then releases the force F on the button 178 and the button 178 returns to the rest position shown in FIG. 11 because of the outward biasing force of the spring 185 . The spring 173 in the tablet holder 150 then moves the stack of tablets 172 toward the tablet retainer 161 such that the next tablet in the stack is now the end tablet 172 e of the stack in a ready position for dispensing. The flanges 168 a, 168 b, 168 c, 168 d of the tablet retainer 161 prevent the end tablet 172 e from moving longitudinally along axis A beyond the flanges 168 a, 168 b, 168 c, 168 d. [0052] In another version of the invention, the handheld dispensing device 110 can be mounted to the underside of a toilet lid or toilet seat by using a fastener that mounts the tubular body 112 to the underside of the toilet lid or toilet seat. Non-limiting examples of fasteners include one or more clips on the underside of the toilet lid or toilet seat that engage the tubular body 112 . In one configuration, the handheld dispensing device 110 can be mounted to the underside of the toilet lid or toilet seat with the dispensing slot 143 facing laterally from the center of the underside of the toilet lid or toilet seat and with the push button 178 facing laterally in a opposite direction from the center of the underside of the toilet lid or toilet seat. [0053] Thus, the invention provides devices that allow a consumer to direct a toilet treatment tablet into the toilet bowl when a button is actuated. In one version of the invention, there is provided a device that incorporates a dispenser type unit in the top of a toilet lid and dispenses a tablet into the toilet when the lid is closed and a button is actuated. A stop prevents a tablet ejecting from any position (up or down) except when the lid is fully closed (down). The stop is positioned behind the actuator button in a way that it is assisted by gravity that when the toilet lid is up such that the safety stop renders the button inoperable. This prevents any chance of consumer contact whether it is an adult or an unattended child. As the lid is closed and is near to its bottom resting point, the safety stop rotates 90 degrees such that the dispenser will now allow a tablet to be ejected. [0054] In another version of the invention, there is provided a hand held device that dispenses tablets. The device fits in a user's hand. To use, one takes aim in the toilet, and the thumb depresses the button to send a tablet into the toilet. The refill unit is accessed on the bottom by overcoming the locking pin on the side of the unit. The device could be stored in many places such as hanging off the side of the toilet reservoir, or on top of the reservoir. The device can also be mounted on the underside of the toilet lid or toilet seat during use. [0055] The above description has been that of example embodiments of the present invention. It will occur to those that practice the art, however, that still other modifications may be made without departing from the spirit and scope of the invention. Hence, the scope of the invention should not be entirely judged by just the example embodiments. INDUSTRIAL APPLICABILITY [0056] The present invention provides dispensers that allow a consumer to direct a tablet into the toilet bowl when a button is actuated.
Devices for dispensing toilet treatment tablets into toilet bowls when a button is actuated are disclosed. In one version, the device includes: (i) a toilet cover; (ii) a dispenser mounted to the cover; (iii) a plurality of solid tablets stored in the dispenser so as to be dispensable therefrom, wherein at least one of the tablets includes a toilet treatment chemical; and (iv) an actuator for moving a tablet from a ready position of the dispenser to a release position. In another version, the invention provides a handheld device including a body having a cover and a hollow wall connected to the cover. The cover and the wall define an interior space in the body, and the cover includes a dispensing slot. The device also includes a removable tablet holder suitable for holding a plurality of solid tablets. A tablet retainer of the tablet holder is located within the cover when the tablet holder is installed within the body. The tablet retainer retains a tablet in a ready position for dispensing. An actuator is disposed in the cover for moving a tablet from the ready position out through the dispensing slot.
4
FIELD OF INVENTION The invention relates to jack bar assemblies for use on straight bar knitting machines (such as Cotton's Patent type machines). BACKGROUND OF THE INVENTION: On straight bar knitting machines bearded needles are mounted on a common needle bar which causes all the needles to move simultaneously during a knitting operation. Jacks of jack bar assemblies are used to advance sinkers in a predetermined manner successively between adjacent needles so as to form kinks of yarn. The jacks are actuated by a slurcock. In known straight bar knitting machines, a slurcock engages jacks midway at their rear. The slurcock cams the jacks forward and the jacks in turn slide sinkers forward on a sinker bar. The slurcocks have an increasingly steep profile so that the sinkers are advanced rapidly at the final part of their advance. Such sinker actuating systems, using slurcocks and jacks are noisy, subject to wear and may malfunction at high draw speeds (that is the speed of slurcock traverse along the rear of the jacks). SUMMARY OF THE INVENTION It is the object of the invention to provide a jack assembly providing a smooth operation and capable, if required, of use with high draw speeds. According to the invention, the jacks operate in pairs so that one jack receives an input of motion from the slurcock and engages the other jack of the pair which in turn imparts motion to the sinker. Thus the one jack can be arranged to cooperate optimally with the slurcock which moves sideways with respect to the jacks whilst the sinker operating jack can be arranged for efficient motion in the plane of the jacks. DESCRIPTION OF THE INVENTION According to the invention there is preferably provided a jack bar assembly comprising first jacks mounted on a first pivot and engageable at a rear edge by a slurcock, second jacks mounted on a second pivot and engageable at a rear edge by the respective associated first jacks for advancing an associated sinker. Thus the sinkers are advanced as a result of pivotal movement of at least two cooperating, independently pivoted jacks. Preferably two jacks only are used, the first jacks serving to engage the slurcock and the second jacks to engage the associated sinker. It has been found surprisingly that, in spite of an increase in operating parts, such jack assemblies can be used to provide a sinker actuating system operable at high speed and/or with reduced noise. It becomes feasible to reduce advance provided by the slurcock and increase mechanical leverage provided by the cooperating first and second jacks. Wear on the jack pivots may be reduced. Preferably the first jack is mounted on the first pivot at one end, has a nose for engaging the second jack at the other end and forms a bluged rear edge for engaging the slurcock substantially midway of the nose and the first pivot. Suitably then the second jack is mounted on the second pivot at one end of the second jack substantially level with the bulged rear edge of the first jack, has a nose for engaging the sinker at the other end and forms a bluged rear edge for engaging the nose of the first jack substantially midway between the second jack nose and the second pivot. Thus the sinker advance provided by the second jack nose is from 3 to 5 times preferably 4 times the advance of the bluged rear edge of the first jack when engaged by the slurcock. As the number of sinkers in the process of being advanced at any time need not be changed at high speed, the extent of the slurcock lift can be halved compared with conventional slurcocks engaging a single jack at a leverage of 3. It has been found that at a leverage of approximately 3 smooth operation may be achieved whilst measuring a stable amount of yarn. That is to say the amount of yarn drawn (which governs the stitch length) is substantially unaffected by the speed of slurcock traverse which may be low when operating manually and high when operating under power. At leverages of 4 operation is smooth under power at high speed but the amount of yarn measured may not always be the same. The first and second jacks may be accommodated in a compact manner, being behind and below a sinker bar and above a head rail, by making the first and second jacks of similar dimensions and arranging them substantially parallel and upright. Advantageously, the second pivot is substantially at the same level as the slur bar and the first pivot is below the level. Thus both pivots are located close to one another and the head rail. The jacks may be optimally designed and mounted for their respective functions, the first jacks being arranged to absorb the sideways force exerted by the slurcock without risk of misalignment between second jacks and associated sinkers. The first and second jacks thus may have each a reduced cross-section having regard to conventional jacks. Preferably the jacks are mounted between jack walls arranged so as to expose the tips of the second jacks and a rear edge part of the first jacks only. Thus the first jacks engage the second jacks at a position between the jack walls so reducing the risk of their misalignment and jack malfunction. Conveniently the first and second jacks are arranged so that the leverage increases towards the end of the pivotal movement of the jacks. Preferably the first jack is adapted to engage a jack spring both in its forward and its retracted position by providing a pair of spaced bevel edges at the top of the first jack. This permits mounting of a jack spring bar over a slur bar. The jacks may be of small size, be rigid and of small inertia and be advanced at high slurcock traverse speeds. DESCRIPTION OF DRAWINGS FIG. 1 shows a second through jack bar assembly according to the invention associated with a head-rail sinker bar assembly and slur bar assembly, the jacks being fully advanced; FIG. 2 shows a section through part of FIG. 1 with the jacks fully retracted; and FIG. 3 shows a profile of slurcock for use with the jack bar assembly of FIGS. 1 and 2; FIG. 4 is a schematic partial plan showing the sinkers, jacks and slurcock. DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to the FIGS. 1, 2 and 4 a jack bar assembly, generally indicated at 2, has primary jacks 4 mounted on a longitudinally extending pivot wire 6. The jacks 4 have a rear edge forming a bluge at 8 engaged by a slurcock 10 which is reciprocable in usual manner on a slur bar 34. Suitable means for driving the slurcock is described in Max C. Miller "Knitting Full-Fashioned Hosiery" published by McGraw-Hill Book Company, New York, N.Y. The assembly 2 further has secondary jacks 12 mounted on another longitudinally extending pivot wire 14. The jacks 12 have a rear edge with a curved part at 16. Each pair of associated primary and secondary jacks 4 and 12 cooperate to actuate a sinker 18 slidably mounted in a sinker bar 20. Sinker 18 penetrate between adjacent needles 56 carried by a needle bar 58 as illustrated in FIG. 4. The primary jacks 4 have pivot portions 22 with a central aperture for holding the pivot wire 6 at one end and noses 24 at the other end which bear against the curved parts 16 of the rear edges of the jacks 12 at other end. The secondary jacks 12 have pivot portions 26 at one end and noses 28 for engaging the sinkers 18 at the other end. The noses 24 engage the curved parts 16 halfway between the ends of the jacks 12. FIG. 2 shows the proportions in more detail, L1 being about half of L2. The leverage obtained is the ratio of sinker advance L3 over the slurcock advance L4. In this case a leverage of 3 is obtained. The leverage may be varied if required by raising or lowering the slur bar 34 with respect to the primary jacks 4. The high leverage can be obtained with a jack assembly of dimensions similar to conventional ones which use only one jack to actuate each sinker and have a leverage of about 2. L5 shows the vertical spacing of the pivot wire 6 and 14, which is only a small part of the overall vertical spacing L6 between the lower pivot wire 6 and the uppermost nose 28. The horizontaspacing L7 between the pivot wire 6 and 14 is small. The primary jacks 4 have bevelled edges at angularly spaced positions along the top edges for engaging jack springs 30 in the forward position (See FIG. 1). No shifting of the jack springs 30 in a horizontal sense is required. The jack bar assembly 2 can be compactly accommodated to the rear of the sinker bar 20, above the head rail 42 and in front of a jack spring bar 32 and a slur bar 34. The jacks 4 and 12 can be retained in the jack bar assembly 2 in appropriate register with the sinkers 18 by a housing comprising a jack bar base 40 attached to the head rail 42, jack bar pillars (not shown) being provided at each end of the jack bar base 40. The jack pillars mount the ends of the pivot wires 6 and 14, alignment bars 41 and trick cut bars 50 which serve to locate one jack wall 48 between each pair of jacks 4 and 12. To avoid obscuring the drawing, jack walls are not shown in FIG. 4. The jack walls 48 are held onto the base 40 by a clamping plate 52 and each have a recess 54 to enable the slurcock 10 to pass along the rear of the jacks 4. The slurcock profile (adapted for a leverage of 3) is shown in FIG. 3. Using the high leverage, the slope α at the forward extremity of the slurcock 10, which is the steepest part of the profile, can be made small. The slurcock engages the jacks 4 about halfway between the pivot 14 and the nose 24. The jack bar may provide a set of first and second jacks for every sinker.
In a jack bar assembly for a straight bar knitting machine, a pair of jacks is used for each jack-operated sinker. A first jack mounted on a first pivot has a rear edge engaged by the slurcock. A second jack mounted on a second pivot has a rear edge engaged by a nose of the first jack and a nose which engages and actuates the sinker. An increased mechanical leverage provided by the cooperating first and second jacks permits reduction in the advance provided by the slurcock and faster smoother operation.
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CROSS-REFERENCE TO RELATED APPLICATIONS This U.S. National Stage Application claims priority under 35 U.S.C. §119(a) to Japanese Patent Application No. 2009-272686, filed in Japan on Nov. 30, 2009. The entire disclosure of Japanese Patent Application No. 2009-272686 is hereby incorporated herein by reference. TECHNICAL FIELD The present invention relates to a folding system for a fabric product. BACKGROUND ART A variety of “folding devices for automatically folding a fabric product such as a shirt” have been proposed so far. Depending on folding methods, the folding devices are roughly classified into slide type folding devices (see Japan Laid-open Patent Application Publication Nos. JP-A-H08-215500, JP-A-H08-215499, JP-A-H08-215498, JP-A-H08-215497, JP-A-2008-18100, JP-A-2000-202200 and JP-A-H05-294552), a flip-up-to-the-bottom type folding device (see Japan Laid-open Patent Application Publication Nos. JP-A-H06-304399 and JP-A-H10-218485), a flip-up-to-the-top type folding device (see Japan Laid-open Patent Application Publication Nos. JP-A-H07-61703, JP-A-2008-264316, JP-A-2003-532451, JP-A-2003-181200 and JP-A-2002-119800) and a rotary type folding device (see PCT International Application Publication No. WO2008/032826). The folding devices as described above are mutually provided with a platen for putting a fabric product thereon. Every time the fabric product size is changed, the platen width is required to be suitably adjusted to the changed fabric product size. For example, the following methods are required for implementing the above. Every time the fabric product size is changed, a platen is replaced with another one with a width suitable for the fabric product size. Alternatively, the platen width is adjusted by means of a width adjusting mechanism as described in a brochure of International Patent Application Publication No. WO2008/032826 and etc. The latter method is herein preferable in consideration of a workload imposed on a worker. Now, there exist a variety of fabric products for a variety of age groups (e.g., clothing of a grandfather, a grandmother, a father, a mother, a child and etc.) at home. Therefore, frequent width adjustment is required for the platen when the folding device as described above is installed in a home. A workload imposed on a worker is accordingly increased. SUMMARY OF THE INVENTION It is an object of the present invention to reduce worker's workload required for adjusting the platen width in a folding system for a fabric product. A folding system for a fabric product according to a first aspect of the present invention includes an information obtaining device, a folding device and a width controlling device. The information obtaining device is configured to obtain first information held by the fabric product. It should be noted that the term “first information” may herein refer to identification information (including image information, identification number information, etc.), or alternatively, “information of the width directional length of a platen member”. When the first information is the identification information, “information of the width directional length of a platen member” is required to be derived from the identification information. Further, the first information may be obtained from an information medium fixed to the fabric product. Examples of the information medium herein include a RFID tag, a barcode (e.g., one-dimensional barcode, two-dimensional barcode, further, a barcode made of fluorescent paint), fluorescent paint (forming information, for instance, by means of emission wavelength when being irradiated by black light), a metal piece (forming information depending on metal elements contained therein) and a magnetic recording medium. Alternatively, the first information may be data of the shape, the pattern, etc. of the fabric product (corresponding to the identification information in this case), in other words, imaging data (note the information obtaining device is herein an imaging device, i.e., a camera). The folding device includes a platen member, a width adjusting mechanism and a folding mechanism. It should be noted that examples of the folding mechanism include a rotary type folding mechanism as described in the brochure of PCT International Application Publication No. WO2008/032826, a flip-up-to-the-bottom type folding mechanism as described in Japan Laid-open Patent Application Publication Nos. JP-A-H06-304399 and JP-A-H10-218485, a flip-up-to-the-top type folding device as described in Publication of Japanese Translation of PCT International Application No. JP-A-2003-432451 and Japan Laid-open Patent Application Publication Nos. JP-A-H07-61703, JP-A-2008-264316, JP-A-2003-181200 and JP-A-2002-119800, and a slide type folding mechanism as described in Japan Laid-open Patent Application Publication Nos. JP-A-H08-215500, JP-A-H08-215499, JP-A-H08-215498, JP-A-H08-215497, JP-A-2008-18100, JP-A-2000-202200 and JP-A-H05-294552. The platen member is a member for putting the fabric product thereon. The width adjusting mechanism is configured to adjust a width directional length of the platen member. The folding mechanism is configured to fold the fabric product to be put on the platen member. The width controlling device is configured to control the width adjusting mechanism using the first information obtained by the information obtaining device. According to the folding system for a fabric product of the first aspect of the present invention, the width controlling device is configured to control the width adjusting mechanism using the first information obtained by the information obtaining device. Therefore, the folding system for a fabric product requires a worker to execute only a work for assisting input of the first information into the information obtaining device (e.g., a work of disposing a fabric product to be closer to the information obtaining device). In other words, the folding system for a fabric product can reduce worker's workload required for adjusting the width of the platen. A folding system for a fabric product according to a second aspect of the present invention relates to the folding system for a fabric product according to the first aspect of the present invention. In the folding system, the first information is identification information for the fabric product. The folding system further includes a first storage device and a second information deriving device. The first storage device is configured to store a first association table. In the first association table, the first information is associated with second information. The second information deriving device is configured to check the first information obtained by the information obtaining device against the first association table and derive the second information associated with the first information therefrom. The width controlling device is configured to control the width adjusting mechanism using the second information derived by the second information deriving device. According to the folding system for a fabric product of the second aspect of the present invention, it is possible to reduce the information amount of the first information. Therefore, the folding system for a fabric product can reduce the cost of a medium holding the first information and reduce chances of causing troubles, for instance, in repurchase of fabric products (e.g., clothing). A folding system for a fabric product according to a third aspect of the present invention relates to the folding system for a fabric product according to the first aspect of the present invention. The folding system further includes a sorting device. The sorting device is configured to sort the fabric product folded by the folding device using the first information. It should be herein noted that the first information may contain “sorting information (e.g., owner information, storage position information, etc.)”. According to the folding system for a fabric product of the third aspect of the present invention, the fabric products can be sorted depending on owners of or storage positions of the fabric products. Therefore, the folding system for a fabric product can eliminate a sorting-related workload of a worker. A folding system for a fabric product according to a fourth aspect of the present invention relates to the folding system for a fabric product according to the third aspect of the present invention. In the folding system, the first information is identification information for the fabric product. The folding system further includes a second storage device and a third information deriving device. The second storage device is configured to store a second association table. In the second association table, the first information is associated with third information. The third information deriving device is configured to check the first information obtained by the information obtaining device against the second association table and derive the third information associated with the first information therefrom. Further, the sorting device is configured to sort the fabric product folded by the folding device using the third information derived by the third information deriving device. According to the folding system for a fabric product of the fourth aspect of the present invention, it is possible to reduce the information amount of the first information. Therefore, the folding system for a fabric product can reduce the cost of a medium holding the first information and reduce chances of causing troubles, for instance, in repurchase of fabric products (e.g., clothing). A folding system for a fabric product according to a fifth aspect of the present invention relates to the folding system for a fabric product according to the third aspect of the present invention. The folding system further includes a transporting device. The transporting device is configured to transport the fabric product sorted by the sorting device to a predetermined storage position using the first information. It should be herein noted that the first information may contain “transportation position information”. According to the folding system for a fabric product of the fifth aspect of the present invention, the fabric product is automatically transported to a predetermined storage position after being sorted depending on an owner of or a storage position of the fabric product. Therefore, the folding system for a fabric product can eliminate a storage-related workload of a worker. A folding system for a fabric product according to a sixth aspect of the present invention relates to the folding system for a fabric product according to the fifth aspect of the present invention. In the folding system, the first information is identification information for the fabric product. Further, the folding system further includes a third storage device and a fourth storage device. The third storage device is configured to store a third association table. In the third association table, the first information is associated with fourth information. The fourth information deriving device is configured to check the first information obtained by the information obtaining device against the third association table and derive the fourth information associated with the first information therefrom. Yet further, the transporting device is configured to transport the fabric product sorted by the sorting device to a predetermined storage position using the fourth information derived by the fourth information deriving device. According to the folding system for a fabric product of the sixth aspect of the present invention, it is possible to reduce the information amount of the first information. Therefore, the folding system for a fabric product can reduce the cost of a medium holding the first information and reduce chances of causing troubles, for instance, in repurchase of fabric products (e.g., clothing). A folding system for a fabric product according to a seventh aspect of the present invention relates to the folding system for a fabric product according to one of the fifth and sixth aspects of the present invention. In the folding system, the sorting device is disposed below or lateral to the folding device, while the transporting device is disposed below the sorting device. According to the folding system for a fabric product of the seventh aspect of the present invention, the folding system for a fabric product can supply the fabric product to the transporting device by means of inertia forth (gravity force) after sorting by the sorting device. Therefore, the folding system for a fabric product is expected to contribute to energy saving. A folding system for a fabric product according to an eighth aspect of the present invention relates to the folding system for a fabric product according to one of the first to seventh aspects of the present invention. In the folding system, the fabric product is provided with a medium containing the first information. The medium is herein fixed to a predetermined position on the fabric product. It should be herein noted that examples of “the medium” include a RFID tag, fluorescent paint (including the patterned one), a metal piece and a magnetic recording medium. Moreover, the folding system for a fabric product further includes a position detecting device, a clamping device and a clamping device controlling device. The position detecting device is configured to detect a position of the first information. The clamping device is configured to clamp the fabric product. The clamping device controlling device is configured to control the clamping device for causing the clamping device to hold the position of the fabric product detected by the position detecting device and put the fabric product on the platen member. According to the folding system for a fabric product of the eighth aspect of the present invention, it is possible to cause the clamping device to easily clamp the fabric product at an appropriate clamping position. Therefore, the folding system for a fabric product can appropriately put the fabric product on the platen member of the folding device. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic configuration diagram of an automatic wash-dry-fold system according to an exemplary embodiment of the present invention. FIG. 2 is a schematic diagram of a control device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 3 is a conceptual diagram of a matching table stored in a storage unit of the control device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 4 is a side view of a folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 5 is a front view of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 6 is a plan view of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 7 is a front view of a folding mechanism, set to be in a second state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 8 is a front view of the folding mechanism, set to be in a third state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 9 is a front view of the folding mechanism, set to be in a fourth state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 10 is a front view of the folding mechanism, set to be in a fifth state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 11 is a side view of a transporting mechanism, set to be in a second state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 12 is a side view of the transporting mechanism, set to be in a third state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 13 is a side view of the transporting mechanism, set to be in a fourth state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 14 is a plan view of the folding mechanism, set to be in a sixth state, of the folding device of the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 15 is a plan view illustrating an arrangement relation among the folding device, a sorting device and the transporting device in the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 16 is a diagram illustrating a condition where a laundry is moved from the transporting device to a closet in the automatic wash-dry-fold system according to the exemplary embodiment of the present invention. FIG. 17 is a schematic configuration diagram of an automatic wash-dry-fold system according to a modification (G). DETAILED DESCRIPTION OF THE EMBODIMENTS An automatic wash-dry-fold system 100 according to an exemplary embodiment of the present invention is configured to wash, dry and fold a laundry in a fully automatic manner. As illustrated in FIG. 1 , the automatic wash-dry-fold system 100 mainly includes a washing machine 200 , a drying machine 250 , RFID tag readers 331 to 333 , a laundry transporting robot arm 310 , a dried laundry transporting robot arm 320 , a folding device 400 , a sorting device 700 , a transporting device 800 and a closet 850 . It should be noted in the present exemplary embodiment that each of all the laundries LD includes two passive-type RFID tags (not illustrated in the figures) attached to two specific portions thereof (e.g., “shoulder parts” for a shirt, “waist parts” for pants and etc.). Further, each RFID tag stores identification number data D 0 (see FIG. 3 ) uniquely set for each laundry LD (e.g., clothing). The aforementioned elements will be hereinafter described in detail. <Elements of Automatic Wash-Dry-Fold System> (1) Washing Machine The washing machine 200 is a normal washing machine and is communicatively connected to a control device 900 as represented in FIG. 2 . Further, the washing machine 200 is configured to automatically open or close a cover, put therein a detergent and/or a softener from a dispenser 220 (see FIG. 2 ), and start or stop an operation in response to a command from the control device 900 . Further, the washing machine 200 includes a first weight sensor 210 (see FIG. 2 ) attached thereto. The first weight sensor 210 is configured to measure the weight of the laundries LD put into a washing tub of the washing machine 200 . Further, the washing machine 200 is configured to transmit a measured value of the weight to the control device 900 at predetermined time intervals. (2) Drying Machine The drying machine 250 is a normal drying machine and is communicatively connected to the control device 900 as represented in FIG. 2 . Further, the drying machine 250 is configured to automatically open or close a cover, and start or stop an operation in response to a command from the control device 900 . Further, the drying machine 250 includes a second weight sensor 260 (see FIG. 2 ) attached thereto. The second weight sensor 260 is configured to measure the weight of the laundries LD put into a drying drum of the drying machine 250 . The drying machine 250 is configured to transmit a measured value of the weight to the control device 900 at predetermined time intervals. (3) RFID Tag Readers The RFID tag readers 331 to 333 are readout devices for RFID tags. Each of the RFID readers 331 to 333 is configured to irradiate radio waves towards a RFID tag for actuating the RFID tag and receive the identification number data D 0 from the RFID tag. Further, the present system 100 includes three sets of RFID tag readers ( 331 to 333 ) installed therein. Each of the RFID tag readers 331 to 333 is communicatively connected to the control device 900 as represented in FIG. 2 . The RFID tag readers 331 to 333 are herein configured to transmit intensity data of reflective waves from the RFID tags to the control device 900 . In response, the control device 900 is configured to detect the positions of the RFID tags by means of the triangulation method based on the intensity data of the reflective waves received from the respective RFID tag readers 331 to 333 . (4) Laundry Transporting Robot Arm The laundry transporting robot arm 310 is a robot arm including a two-finger hand attached to the tip thereof. As represented in FIG. 2 , the laundry transporting robot arm 310 is communicatively connected to the control device 900 . The laundry transporting robot arm 310 is configured to move the laundries LD from a laundry basket to the washing machine 200 and move the laundries LD from the washing machine 200 to the drying machine 250 in response to a command from the control device 900 . It should be noted that the laundry transporting robot arm 310 is configured to sequentially pick up the RFID tags in response to a command from the control device 900 , starting from the one positioned on the top of the RFID tags (i.e., the specific part of the laundry LD). (5) Dried Laundry Transporting Robot Arm Similarly to the laundry transporting robot arm 310 , the dried laundry transporting robot arm 320 is a robot arm including a two-finger hand attached to the tip thereof. As represented in FIG. 2 , the dried laundry transporting robot arm 320 is communicatively connected to the control device 900 . In response to a command from the control device 900 , the dried laundry transporting robot arm 320 is configured to pick up one of the dried laundries LD from the drying machine 250 and halt in a predetermined position. It should be noted that the dried laundry transporting robot arm 320 is configured to sequentially pick up the RFID tags in response to a command from the control device 900 , starting from the one positioned on the top of the RED tags, (i.e., the specific part of the laundry LD). (6) Folding Device As illustrated in FIGS. 4 to 6 , the folding device 400 mainly includes a frame 420 , a folding mechanism 500 and a transporting mechanism 600 . As illustrated in FIG. 1 , the folding device 400 is disposed under the roof of a house or the like. As represented in FIG. 2 , the folding device 400 is further communicatively connected to the control device 900 . The folding device 400 is configured to adjust the width between platen plates (to be described), fold the laundry LD, and deliver the laundry LD to the sorting device 700 in a folded state in response to a command from the control device 900 . Elements of the folding device 400 will be hereinafter respectively described in detail. (6-1) Frame As illustrated in FIGS. 4 to 6 , the frame 420 is mainly formed by a front frame 430 , side frames 440 and a rear frame 450 . As illustrated in FIGS. 4 to 6 , the front frame 430 is mainly formed by four first pillar members 431 , four first upper beam members 432 , four first intermediate beam members 433 , a second intermediate beam member 434 and four first lower beam members 435 . The first pillar members 431 are disposed while the axes thereof are arranged along a vertical direction Dv. The first upper beam members 432 are extended among the first pillar members 431 in a horizontal direction Dh in order to connect the top ends of the first pillar members 431 . The first intermediate beam members 433 are extended among the first pillar members 431 in the horizontal direction Dh in order to connect the intermediate parts of the first pillar members 431 in the height direction. It should be noted that the folding mechanism 500 is fixed to the first intermediate beam members 433 as illustrated in FIGS. 4 to 6 . The second intermediate beam member 434 is extended between rear-frame side two of the first pillar members 431 in the horizontal direction Dh in order to connect parts, positioned slightly above the bottom ends, of the rear-frame side two first pillar members 431 . The first lower beam members 435 are extended among the first pillar members 431 in the horizontal direction Dh in order to connect the bottom ends of the first pillar members 431 . As illustrated in FIGS. 4 to 6 , the side frames 440 are two beam members, each of which connects a lower part of the front frame 430 and that of the rear frame 450 . Further, four leg members 441 are attached to the side frames 440 . As illustrated in FIGS. 4 to 6 , the rear frame 450 is mainly formed by two second pillar members 451 , a second upper beam member 452 and a second lower beam member 453 . It should be noted that the transporting mechanism 600 is attached to the rear frame 450 . The second pillar members 451 are disposed while the axes thereof are arranged along the vertical direction Dv. The second upper beam member 452 is extended between the second pillar members 451 in the horizontal direction Dh in order to couple the top ends of the second pillar members 451 . The second lower beam member 453 is extended under the second pillar members 451 in the horizontal direction Dh in order to couple the bottom ends of the second pillar members 451 . (6-2) Folding Mechanism As described above, the folding mechanism 500 is fixed to the first intermediate beam members 433 . As illustrated in FIGS. 4 to 6 , the folding mechanism 500 mainly includes a pair of platen plates 501 , four folding plates 511 to 514 , dual nested shaft rotary mechanisms 520 , an inter-platen-plate distance adjusting mechanism 530 and folding plate sliding mechanisms 540 . It should be noted that the folding plates with reference numerals of 511 , 512 , 513 and 514 may be hereinafter referred to as “a first folding plate”, “a second folding plate”, “a third folding plate” and “a fourth folding plate”. Elements of the folding mechanism 500 will be hereinafter respectively explained in detail. The platen plates 501 are a pair of roughly rectangular plate members. As illustrated in FIG. 4 , each platen plate 501 is extended towards the rear frame in the horizontal direction. In an initial state, the laundry LD is put on the platen plates 501 . When the folding device 400 receives a command signal and platen plate width data D 1 sent from the control device 900 , the inter-platen-plate distance adjusting mechanism 530 is configured to adjust the width between the platen plates 501 based on the platen plate width data D 1 . The folding plates 511 to 514 are members for serving to fold the laundry LD put on the platen plates 501 . As illustrated in FIGS. 4 to 6 , each of the folding plates 511 to 514 has a roughly rectangular shape. The folding plates 511 to 514 are disposed beside the platen plates 501 while being arranged perpendicularly thereto in an initial state. As illustrated in FIGS. 5 and 6 , the dual nested shaft rotary mechanisms 520 are a pair of mechanisms disposed in the right-and-left direction. Each dual nested shaft rotary mechanism 520 mainly includes a dual nested shaft 521 , an inner shaft rotary motor 522 , an outer shaft rotary motor 523 , an inner shaft pulley 524 , an outer shaft pulley 525 , a first pulley belt 526 and a second pulley belt 527 . Each dual nested shaft 521 is formed by an inner shaft 521 a and an outer shaft 521 b . It should be noted that each inner shaft 521 a is a columnar shaft that the folding plate 511 / 512 is attached to the tip thereof. On the other hand, each outer shaft 521 b is a cylindrical shaft that the folding plate 513 / 514 is attached to the tip thereof. Further, each inner shaft 521 a is rotatably inserted into each outer shaft 521 b while the base end thereof is partially protruded from each outer shaft 521 b . Each inner shaft pulley 524 is fitted into the base end of each inner shaft 521 a . Each outer shaft pulley 525 is fitted into the base end of each outer shaft 521 b . Each first pulley belt 526 is stretched over a shaft of each inner shaft rotary motor 522 and each inner shaft pulley 524 . Each first pulley belt 526 serves to transfer rotary power of each inner shaft rotary motor 522 to each inner shaft 521 a for rotating each inner shaft 521 a . Each second pulley belt 527 is stretched over a shaft of each outer shaft rotary motor 523 and each outer shaft pulley 525 . Each second pulley belt 527 serves to transfer rotary power of each outer shaft rotary motor 523 to each outer shaft 521 b for rotating each outer shaft 521 b . Each inner shaft rotary motor 522 and each outer shaft rotary motor 523 are forwardly and reversely rotatable. As illustrated in FIGS. 4 and 5 , the inter-platen-plate distance adjusting mechanism 530 mainly includes a first ball screw 531 , first nuts (not illustrated in the figures), a first rail member (not illustrated in the figures), a platen plate attachment member (not illustrated in the figures) and a first ball screw driving motor 532 . The first ball screw 531 is formed by a right-handed thread ball screw portion and a left-handed thread ball screw portion. It should be herein noted that the right-handed thread ball screw portion and the left-handed thread ball screw portion are disposed concentrically to each other. Further, the first ball screw 531 is rotatably fixed to the first rail member while the axis thereof is arranged in parallel to the rail portion (not illustrated in the figures) of the first rail member. The first nuts are screwed onto the right-handed thread ball screw portion and the left-handed thread ball screw portion of the first ball screw 531 , respectively. The first nuts are configured to be slid and moved on the rail portion along the axial direction of the first ball screw 531 in conjunction with driving of the first ball screw driving motor 532 . It should be noted in the present exemplary embodiment that the first nuts are configured to be slid and moved in opposite directions due to the structure that the first nuts are respectively screwed onto the right-handed thread ball screw portion and the left-handed thread ball screw portion of the first ball screw 531 . In other words, the first nuts are configured to be slid and moved closer to or away from each other. Further, the platen plate attachment member serves to fix the platen plates 501 to the first nuts. Yet further, the platen plate attachment member includes a rail engaging portion (not illustrated in the figures) on the back face thereof. The rail engaging portion is meshed with the rail portion of the first rail member. The first ball screw driving motor 532 is coupled to an end of the first ball screw 531 while the shaft thereof is arranged along the axis of the first ball screw 531 . A pair of the folding plate sliding mechanisms 540 is disposed correspondingly to the dual nested shaft rotary mechanisms 520 in the right-and-left direction. As illustrated in FIGS. 4 to 6 , the folding plate sliding mechanisms 540 mainly include the third ball screws 541 a and 541 b , third nuts (not illustrated in the figures), third rail members 543 , third ball screw driving motors 545 , 31 st pulleys 546 , 32 nd pulleys 547 and third pulley belts 548 . Further, in the following explanation, the third ball screws with reference numerals of 541 a and 541 b may be respectively referred to as “a 31 st ball screw” and “a 32 nd ball screw”. As illustrated in FIGS. 4 to 6 , two third ball screws 541 a and 541 b are disposed in roughly parallel to the first ball screw 531 . The third nuts are screwed onto two third ball screws 541 a and 541 b , respectively. The dual nested shaft rotary mechanisms 520 are attached to the third nuts, respectively. Each 31 st pulley 546 is fitted onto the tip of each third ball screw driving motor 545 . Each 32 nd pulley 547 is fitted onto the base end of each third ball screw 541 a / 541 b . Each third pulley belt 548 is stretched over each 31 st pulley 546 and each 32 nd pulley 547 . Each third pulley belt 548 serves to transfer rotary power of each third ball screw driving motor 545 to each third ball screw 541 a / 541 b through each 31 st pulley 546 and each 32 nd pulley 547 in order to rotate each third ball screw 541 a / 541 b . Each third ball screw driving motor 545 is forwardly and reversely rotatable. (6-3) Transporting Mechanism As illustrated in FIGS. 4 to 6 , the transporting mechanism 600 mainly includes a pull-out plate 601 , a pull-out plate up-and-down transporting mechanism 610 , a pull-out plate rotary mechanism 620 and a pull-out plate back-and-forth transporting mechanism 630 . Elements of the transporting mechanism 600 will be hereinafter respectively explained in detail. The pull-out plate 601 is a roughly rectangular plate member. It should be noted that the pull-out plate 601 includes two protrusions 603 and a rotary bar 602 as illustrated in FIG. 6 . The protrusions 603 are backwardly extended, while the rotary bar 602 is fixed to the protrusions 603 . Further, a 21 st pulley (not illustrated in the figure) is attached to the rotary bar 602 . As illustrated in FIGS. 4 to 6 , the pull-out plate up-and-down transporting mechanism 610 mainly includes a fourth ball screw 612 , a fourth ball screw driving motor 611 , a fourth nut 614 , an attachment plate 613 , an 11 th pulley 615 , a 12 th pulley belt 616 and a 12 th pulley 617 . As illustrated in FIGS. 4 to 6 , the fourth ball screw 612 is disposed while the axis thereof is arranged along the vertical direction Dv. The fourth nut 614 is screwed onto the fourth ball screw 612 . The fourth nut 614 is configured to be moved along the axial direction of the fourth ball screw 612 in conjunction with driving of the fourth ball screw driving motor 611 . The fourth nut 614 is fixed to the attachment plate 613 . Further, the attachment plate 613 includes rail portions 613 a and 613 b on the both ends thereof. It should be noted that the rail portions 613 a and 613 b are fitted onto the second pillar members 451 of the rear frame 450 . Therefore, the attachment plate 613 is configured to be moved up and down along the second pillar members 451 when the fourth nut 614 is moved up and down along the fourth ball screw 612 . Further, the pull-out plate 601 is attached to the front face of the attachment plate 613 through the pull-out plate rotary mechanism 620 . As illustrated in FIGS. 4 to 6 , the 11 th pulley 615 is attached to the shaft of the fourth ball screw driving motor 611 . As illustrated in FIG. 4 , the 12 th pulley 617 is attached to the bottom end of the fourth ball screw 612 . The 12 th pulley belt 616 is stretched over the 11 th pulley 615 and the 12 th pulley 617 . In other words, in conjunction with driving of the fourth ball screw driving motor 611 , rotational power of the fourth ball screw driving motor 611 is transferred to the fourth ball screw 612 through the 11 th pulley 615 , the 12 th pulley belt 616 and the 12 th pulley 617 . As a result, the fourth ball screw 612 is rotated about the axis thereof. The attachment plate 613 is consequently moved up and down along the second pillar members 451 . As illustrated in FIG. 6 , the pull-out plate rotary mechanism 620 mainly includes rotary bar support bodies 622 a and 622 b , a 22 nd pulley 623 , a 22 nd pulley belt 624 and a rotary bar driving motor 621 . The rotary bar support bodies 622 a and 622 b support the rotary bar 602 disposed rearwards of the pull-out plate 601 for allowing it to rotate. The 22 nd pulley 623 is attached to the shaft of the rotary bar driving motor 621 . The 22 nd pulley belt 624 is stretched over the 22 nd pulley 623 and the 20 pulley attached to the rotary bar 602 . In short, in conjunction with driving of the rotary bar driving motor 621 , rotational power of the rotary bar driving motor 621 is transferred to the rotary bar 602 through the 22 nd pulley 623 , the 22 nd pulley belt 624 and the 21 st pulley. As a result, the pull-out plate 601 is upwardly pivoted and lifted up. In reverse driving of the rotary bar driving motor 621 , by contrast, rotary power of the rotary bar driving motor 621 is transferred to the rotary bar 602 through the 22 nd pulley 623 , the 22 nd pulley belt 624 and the 20 pulley. As a result, the pull-out plate 601 is downwardly pivoted and tilted downwards. The pull-out plate back-and-forth transporting mechanism 630 is disposed for implementing back-and-forth movement of the transporting mechanism 600 . As illustrated in FIG. 5 , the pull-out plate back-and-forth transporting mechanism 630 mainly includes a back-and-forth driving motor 631 , a wire (not illustrated in the figure) and a wire support portion 632 . In conjunction with driving of the back-and-forth driving motor 631 , the wire is configured to be moved along the wire support portion 632 . In conjunction with the wire movement, the transporting mechanism 600 is configured to be moved back and forth. (6-4) Actions of Folding Device Actions of the folding device 400 will be hereinafter explained with reference to FIGS. 4 to 14 . In the folding device 400 , the folding mechanism 500 is firstly set to be in a state illustrated in FIG. 5 . In other words, the folding device 400 is set to be in a state (initial state) that the folding plates 511 to 514 are hung down roughly in the vertical direction in a front view. In the state, a laundry LD is put on the platen plates 501 . It should be noted that the width between the platen plates 501 is adjusted by the inter-platen-plate distance adjusting mechanism 530 as described above. Next, the inner shaft rotary motor 522 of the dual nested shaft rotary mechanism 520 rotates the second folding plate 512 leftward (clockwisedly) at an angle of roughly 90 degrees in FIG. 7 (see an arrow R 1 in FIG. 7 ). The second folding plate 512 is thereby set to be in a state illustrated in FIG. 7 (a second state). In other words, the second folding plate 512 is disposed adjacent to the bottom face of the platen plate 501 . It should be herein noted that a part of the laundry LD, hung down from the right side of the platen plates 501 in FIG. 7 , is interposed and folded between the second folding plate 512 and the platen plate 501 . Next, the inner shaft rotary motor 522 of the dual nested shaft rotary mechanism 520 rotates the first folding plate 511 rightward (counterclockwisedly) at an angle of roughly 90 degrees in FIG. 8 (see an arrow R 2 in FIG. 8 ). The first folding plate 511 is thereby set to be in a state illustrated in FIG. 8 (a third state). In other words, the first folding plate 511 is disposed adjacent to the bottom face of the second folding plate 512 . It should be herein noted that a part of the laundry LD, hung down from the left side of the platen plates 501 in FIG. 8 , is interposed and folded between the first folding plate 511 and the second folding plate 512 . Next, the outer shaft rotary motor 523 of the dual nested shaft rotary mechanism 520 rotates the fourth folding plate 514 leftward (clockwisedly) at an angle of roughly 90 degrees in FIG. 9 (see an arrow R 3 in FIG. 9 ). The fourth folding plate 514 is thereby set to be in a state illustrated in FIG. 9 (a fourth state). In other words, the fourth folding plate 514 is disposed adjacent to the bottom face of the first folding plate 511 . It should be herein noted that a part of the laundry LD, hung down from the right side of the first folding plates 511 in FIG. 9 , is interposed and folded between the fourth folding plate 514 and the first folding plate 511 . Next, the outer shaft rotary motor 523 of the dual nested shaft rotary mechanism 520 rotates the third folding plate 513 rightward (counterclockwisedly) at an angle of roughly 90 degrees in FIG. 10 (see an arrow R 4 in FIG. 10 ). The third folding plate 513 is thereby set to be in a state illustrated in FIG. 10 (a fifth state). In other words, the third folding plate 513 is disposed adjacent to the bottom face of the fourth folding plate 514 . It should be herein noted that a part of the laundry LD, hung down from the left side of the fourth folding plate 514 in FIG. 10 , is interposed and folded between the third folding plate 513 and the fourth folding plate 514 . Next, the pull-out plate up-and-down transporting mechanism 610 lifts up the pull-out plate 601 to a predetermined height as illustrated in FIG. 11 (a second state). The pull-out plate back-and-forth transporting mechanism 630 then forwardly moves the pull-out plate 601 to a predetermined position as illustrated in FIG. 12 (a third state). It should be noted that the pull-out plate 601 is herein positioned while the plate face thereof is arranged along the vertical direction Dv. The pull-out plate rotary mechanism 620 then rotates the pull-out plate 601 to a position where the pull-out plate 601 is disposed roughly in parallel to the third folding plate 513 as illustrated in FIG. 13 (a fourth state). Subsequently, the right-side folding plate sliding mechanism 540 rightwardly slides and moves the right-side dual nested shaft rotary mechanism 520 in FIG. 10 , while the left-side folding plate sliding mechanism 540 leftwardly slides and moves the left-side dual nested shaft rotary mechanisms 520 in FIG. 10 (see arrows L 1 and L 2 in FIG. 14 ). The folding device 400 is thereby set to be in a state illustrated in FIG. 14 (a sixth state). The folding plates 511 to 514 are herein removed from the laundry LD, and the laundry LD can be easily pulled out by means of the pull-out plate 601 . Then, the pull-out plate 601 is lifted down by the pull-out plate up-and-down transporting mechanism 610 , while being backwardly moved by the pull-out plate back-and-forth transporting mechanism 630 . The pull-out plate 601 is thereby set to be in a state illustrated in FIG. 4 . Subsequently, the pull-out plate rotary mechanism 620 rotates the pull-out plate 601 to a position where the pull-out plate 601 is downwardly tilted. With the action, the folded laundry LD on the pull-out plate 601 slips down to a sorting table 720 disposed below in a stand-by state. (7) Sorting Device As illustrated in FIG. 15 , the sorting device 700 mainly includes a rail 710 , the sorting table 720 and sorting table detection sensors (not illustrated in the figures). As represented in FIG. 2 , the sorting device 700 is communicatively connected to the control device 900 . As illustrated in FIG. 15 , the rail 710 is linearly extended oppositely to the folding device 400 from a position below the folding device 400 . The sorting table 720 mainly includes a rail engaging portion (not illustrated in the figures), wheels, a driving motor (not illustrated in the figures), a platen plate 730 , a 90-degree rotary mechanism (not illustrated in the figures) and a tilting mechanism (not illustrated in the figures). The rail engaging portion is engaged with the rail 710 . The wheels are a pair of wheels disposed in the inside of the rail engaging portion. The wheels are disposed on the both lateral sides of the rail 710 while interposing the rail 710 therebetween. The wheels are configured to be driven by the driving motor. The driving motor is configured to be forwardly rotated, reversely rotated and stopped in response to a command from the control device 900 . The platen plate 730 is a plate for being put thereon the laundry LD folded by the folding device 400 . The platen plate 730 is disposed on the 90-degree rotary mechanism and the tilting mechanism. The 90-degree rotary mechanism is configured to rotate the platen plate 730 at an angle of 90 degrees (see the platen plate 730 depicted with a broken line in FIG. 15 ) in response to a command from the control device 900 . The tilting mechanism is configured to tilt the platen plate 730 in response to a command from the control device 900 so that the plate face of the platen plate 730 is downwardly tilted towards a platen plate 840 a (to be described) of a transporting table 810 a (to be described). Each of the sorting table detection sensors mainly includes a light emitter and a light receiver. The sorting table detection sensors are disposed in the vicinity of the rail 710 while being opposed to the positions where the transporting tables 810 a to 810 d are respectively disposed. It should be noted in the present exemplary embodiment that the light receivers are positioned higher than the sorting table 720 while the light emitters are positioned lower than the sorting table 720 . In the present exemplary embodiment, when receiving a command signal and storage position data D 2 from the control device 900 , the sorting device 700 is configured to cause the corresponding one of the sorting table detection sensors associated with the storage position data D 2 to execute a sensing processing (i.e., emit light from the light emitter to the light receiver) and cause the other sorting table detection sensors to stop executing the sensing processing (i.e., stop light emission from the light emitter). (8) Transporting Device As illustrated in FIGS. 1 , 15 and 16 , the transporting device 800 mainly includes the transporting tables 810 a to 810 d , level sensors (not illustrated in the figures) and transporting mechanisms 820 a and 820 d . It should be noted in the present exemplary embodiment that each of sections 850 a to 850 d of the closet 850 is independently provided with a pair of the transporting table ( 810 a to 810 d ) and the transporting mechanism ( 820 a to 820 d ). Further, the transporting device 800 is communicatively connected to the control device 900 as represented in FIG. 2 . It should be noted that the transporting tables with the reference numerals of 810 a to 810 d are identical to each other. Therefore, only the transporting table with the reference numeral of 810 a will be hereinafter explained. Likewise, the transporting mechanisms with the reference numerals of 820 a to 820 d are also identical to each other. Therefore, only the transporting mechanism with the reference numeral of 820 a will be hereinafter explained. The transporting table 810 a mainly includes a belt joint portion (not illustrated in the figures), the platen plate 840 a and a pusher device 830 a . The belt joint portion is joined to a transporting belt (to be described) provided for the transporting mechanism 820 a . The platen plate 840 a is a plate for putting thereon the laundry LD sorted by the sorting device 700 . The platen plate 840 a is disposed on the belt joint portion. The pusher device 830 a is disposed on the platen plate 840 a while being positioned lateral to a laundry put area. The pusher device 830 a is configured to push a piston in response to a command from the control device 900 (see FIG. 16 ). Each level sensor mainly includes a light emitter and a light receiver. Each level sensor is disposed above the laundry put area on each of the transporting tables 810 a to 810 d while the laundry put area is interposed between the light emitter and the light receiver. When laundries are laminated to a predetermined height on the laundry put area, each level sensor is configured to detect it and transmit a detection signal to the control device 900 . When receiving the detection signal, the control device 900 is configured to command the transporting device 800 to drive the corresponding one of the transporting tables 810 a to 810 d associated with the level sensor by means of the corresponding one of the transporting mechanisms 820 a to 820 d. The transporting mechanism 820 a mainly includes a transporting belt (not illustrated in the figures), a transporting belt driving mechanism (not illustrated in the figures) and a sensor (not illustrated in the figures). The transporting belt is an annular endless belt. The transporting belt driving mechanism is a mechanism configured to drive the transporting belt. The transporting belt driving mechanism is configured to start and stop driving of the transporting belt in response to a command from the control device 900 . In the present exemplary embodiment, when receiving a command signal and the storage position data D 2 from the control device 900 , the transporting device 800 is configured to drive the corresponding one of the transporting tables 810 a to 810 d by means of the corresponding one of the transporting mechanisms 820 a to 820 d and stop the transporting table (e.g., 810 a ) in front of the corresponding one of the storage spaces associated with the storage position data D 2 , and cause the transportation table (e.g., 810 ) to push the piston thereof. (9) Closet As illustrated in FIG. 1 , the closet 850 is divided into four sections, i.e., the first section 850 a , the second section 850 b , the third section 850 c and the fourth section 850 d . Further, each of the sections 850 a to 850 d includes seven storage spaces aligned along the up-and-down direction. (10) Control Device As represented in FIG. 2 , the control device 900 mainly includes a control unit 910 , an arithmetic-and-logic unit 920 , a storage unit 930 and a communication unit 940 . The control unit 910 is configured to control the arithmetic-and-logic unit 920 , the storage unit 930 and the communication unit 940 . The arithmetic-and-logic unit 920 is configured to run a program stored in the storage unit 930 in response to a command from the control unit 910 in order to execute a variety of computations. The storage unit 930 stores the aforementioned program, and further, a matching table Tr as represented in FIG. 3 . In the matching table Tr, the platen plate width data D 1 and the storage position data D 2 are associated with the identification number data D 0 . As represented in FIG. 2 , the communication unit 940 is communicatively connected through a communication line to an electronic meter 50 , the washing machine 200 , the drying machine 250 , the RFID tag readers 331 to 333 , the laundry transporting robot arm 310 , the dried laundry transporting robot arm 320 , the folding device 400 , the sorting device 700 and the transporting device 800 . The communication unit 940 is configured to receive data and a notifying signal from the aforementioned devices and send a variety of command signals thereto. <Actions of Automatic Wash-Dry-Fold System> The control device 900 is configured to send a first command signal to the washing machine 200 when the weight of a laundry basket disposed in a predetermined position reaches a first threshold value (note the electronic meter 50 (see FIG. 2 ) is disposed under the laundry basket). When receiving the first command signal, the washing machine 200 is configured to open the lid thereof. Next, the control device 900 is configured to send a second command signal to the laundry transporting robot arm 310 . When receiving the second command signal, the laundry transporting robot arm 310 is configured to pick up the laundries LD from the laundry basket on a one-by-one basis and put them into the washing machine 200 . Next, the control device 900 is configured to send a third command signal to the laundry transporting robot arm 310 and send a fourth command signal to the washing machine 200 when the weight measured value of the first weight sensor 210 embedded in the washing machine 200 reaches a second threshold value. When receiving the third command signal, the laundry transporting robot arm 310 is configured to be automatically stopped. When receiving the fourth command signal, the washing machine 200 is configured to close the lid thereof, put a detergent and a softener into the washing tub from the dispenser 220 , and start a washing operation. When washing is completed (i.e., when the washing operation is stopped), the washing machine 200 is subsequently configured to send a washing completion notifying signal to the control device 900 , and simultaneously, open the lid thereof. When receiving the washing completion notifying signal, the control device 900 is then configured to send a fifth command signal to the drying machine 250 and send a sixth command signal to the laundry transporting robot arm 310 . When receiving the fifth command signal, the drying machine 250 is configured to open the lid thereof. When receiving the sixth command signal, on the other hand, the laundry transporting robot arm 310 is configured to pick up the laundries LD from the washing machine 200 on a one-by-one basis and put the laundries LD into the drying machine 250 . Subsequently, the control device 900 is configured to send a seventh command signal to the laundry transporting robot arm 310 , send an eighth command signal to the washing machine 200 , and further send a ninth command signal to the drying machine 250 , when the weight measured value of the first weight sensor 210 embedded in the washing machine 200 reaches a third threshold (less than the second threshold). When receiving the seventh command signal, the laundry transporting robot arm 310 is configured to be automatically stopped after a predetermined period of time elapses. When receiving the eighth command signal, on the other hand, the washing machine 200 is configured to close the lid thereof. When receiving the ninth command signal, the drying machine 250 is configured to close the lid thereof and start a drying operation. When drying process is completed (i.e., the drying operation is stopped), the drying machine 250 is configured to send a drying completion notifying signal to the control device 900 , and simultaneously, open the lid thereof. When receiving the drying completion notifying signal, the control device 900 is configured to send a tenth command signal to the dried laundry transporting robot arm 320 . When receiving the tenth command signal, the dried laundry transporting robot arm 320 is configured to pick up one of the dried laundries LD from the drying machine 250 and stop moving at a predetermined position. When halting at the predetermined position, the dried laundry transporting robot arm 320 is then configured to send a first halt notifying signal to the control device 900 . When receiving the first halt notifying signal, the control device 900 is configured to send an eleventh command signal to the laundry transporting robot arm 310 . When receiving the eleventh command signal, the laundry transporting robot arm 310 is configured to clamp another part of the laundry LD currently clamped by the dried laundry transporting robot arm 320 . In other words, the laundry LD is clamped by both of the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 . When clamping the laundry LD, the laundry transporting robot arm 310 is configured to send a clamp completion notifying signal to the control device 900 . When receiving the clamp completion notifying signal, the control device 900 is configured to send a twelfth command signal to the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 . When receiving the twelfth command signal, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 are configured to transport the laundry LD clamped by the both rams 310 and 320 to a readable range for the RFID tag reader 332 and stop moving in the position. When transporting the laundry LD to the readable range for the RFID tag reader 332 and halting in the position, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 are configured to send a second halt notifying signal to the control device 900 . When receiving the second halt notifying signal, the control device 900 is configured to send a thirteenth command signal to the RFID tag reader 332 . When receiving the thirteenth command signal, the RFID tag reader 332 is configured to irradiate radio waves to the RFID tags attached to the laundry LD and receive the identification number data D 0 from the RFID tags. When receiving the identification number data D 0 from the RFID tags, the RFID tag reader 332 is configured to send the identification number data D 0 to the control device 900 . When receiving the identification number data D 0 , the control device 900 is configured to check the identification number data D 0 against the matching table Tr stored in the storage unit 930 and derive the platen plate width data D 1 and the storage position data D 2 , both of which are associated with the identification number data D 0 . Subsequently, the control device 900 is configured to send the platen plate width data D 1 to the folding device 400 , and simultaneously, send the storage position data D 2 to the sorting device 700 . When receiving the platen plate width data D 1 and a fourteenth command signal, the folding device 400 is configured to adjust the width between the platen plates 501 based on the platen plate width data D 1 . When completing the width adjustment, the folding device 400 is then configured to send an adjustment completion notifying signal to the control device 900 . When receiving the adjustment completion notifying signal, the control device 900 is configured to send the fourteenth command signal to the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 . When receiving the fourteenth command single, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 are configured to put the laundry LD on the platen plates 501 of the folding device 400 . After unclamping the laundry LD, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 are subsequently configured to send a laundry release notifying signal to the control device 900 . When receiving the laundry release notifying signal, the control device 900 is then configured to send a fifteenth command signal to the folding device 400 . When receiving the fifteenth command signal, the folding device 400 is configured to fold the laundry LD and transport the folded laundry LD to the sorting table 720 of the sorting device 700 . When completing transportation of the laundry LD to the sorting table 720 , the folding device 400 is configured to send a transport completion notifying signal to the control device 900 . When receiving the transport completion notifying signal, the control device 900 is configured to send a tenth command signal to the dried laundry transporting robot arm 320 . When receiving the tenth command signal, the dried laundry transporting robot arm 320 is configured to pick up one of the dried laundries LD from the drying machine 250 and halt at a predetermined position. The aforementioned processing will be subsequently repeated as described above. Next, the control device 900 is configured to send a sixteenth command signal to the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 and send a seventeenth command signal to the drying machine 250 , when a sensor value of the second weight sensor (see FIG. 2 ) embedded in the drying machine 250 reaches a fourth threshold (i.e., when the dryer drum becomes empty). When receiving the sixteenth command signal, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 are configured to automatically stop. When receiving the seventeenth command signal, on the other hand, the drying machine 250 is configured to close the lid thereof. Meanwhile, when receiving the storage position data D 2 and an eighteenth command signal, the sorting device 700 is configured to cause one of the sorting table detection sensors corresponding to the storage position data D 2 to execute a sensing processing (i.e., cause the light emitter thereof to irradiate light to the light receiver thereof) and cause the other sorting table detection sensors to stop executing a sensing processing (i.e., cause the light emitters thereof to stop irradiating light). Accordingly, the sorting table 720 is configured to stop in front of one of the transporting tables 810 a to 810 d corresponding to the storage position data D 2 . Next, the sorting device 700 is configured to send a detection notifying signal of the sorting table detection sensor to the control device 900 . When receiving the detection notifying signal, the control device 900 is configured to send a nineteenth command signal to the sorting device 700 . Next, when receiving the nineteenth command signal, the sorting device 700 is configured to cause the 90-degree rotary mechanism to rotate the platen plate 730 at an angle of 90 degrees (see the platen plate 730 depicted with a broken line in FIG. 15 ) and then cause the tilting mechanism to tilt the platen plate 730 so that the plate face of the platen plate 730 is downwardly tilted towards the corresponding one of the platen plates 840 a to 840 d of the transporting tables 810 a to 810 d . Accordingly, the laundry LD slides down onto one of the transporting tables 810 a to 810 d corresponding to the storage portion data D 2 from the platen plate 730 of the sorting table 720 (see FIG. 15 ). When the laundries LD are thus laminated on each of the transporting tables 810 a to 813 d to a predetermined height, the top one of the laundries LD is detected by the level sensor. When confirming detection by the level sensor, the transporting device 800 is configured to send a detection notifying signal to the control device 900 . When receiving the detection notifying signal, the control device 900 is configured to send a twentieth command signal to the transporting device 800 . When receiving the twentieth command signal, the transporting device 800 is configured to drive one of the transporting tables 810 a to 810 d corresponding to the aforementioned level sensor by means of the corresponding one of the transporting mechanisms 820 a to 820 d . Further, the transporting device 800 is configured to cause the corresponding one of the transporting tables 810 a to 810 d to stop in front of one of the storage spaces corresponding to the storage position data D 2 and then push the piston for moving the laundry LD to the storage space corresponding to the storage position data D 2 . <Features of Automatic Wash-Dry-Fold System> (1) The automatic wash-dry-fold system 100 according to the present exemplary embodiment is configured to completely automatically wash, dry, fold, sort and store laundries. Therefore, the automatic wash-dry-fold system 100 only requires a worker to put laundries on a laundry basket. Therefore, it is possible to remarkably reduce worker's workload required for washing, drying and folding laundries. (2) In the automatic wash-dry-fold system 100 according to the present exemplary embodiment, the RFID tag reader 332 is configured to obtain the identification number data D 0 from the RFID tags and the control device 900 is configured to check the identification number data D 0 against the matching table Tr. Accordingly, the platen plate width data D 1 and the storage position data D 2 are derived based on the matching. Therefore, the RFID tags are required to hold a less amount of information in the automatic wash-dry-fold system 100 . As a result, the automatic wash-dry-fold system 100 can reduce the cost required for the RFID tags and reduce chances of causing troubles, for instance, in repurchase of fabric products (e.g., clothing). (3) The automatic wash-dry-fold system 100 according to the present exemplary embodiment is provided with the sorting device 700 . Further, the sorting device 700 is configured to sort the laundries LD based on the storage position data D 2 . Therefore, the automatic wash-dry-fold system 100 can sort the laundries LD based on owners of the laundries LD or storage positions. Therefore, the automatic wash-dry-fold system 100 can eliminate sorting-related workload of a worker. (4) The automatic wash-dry-fold system 100 according to the present exemplary embodiment is provided with the transporting device 800 . Further, the transporting device 800 is configured to move the laundries LD to the storage spaces based on the storage position data D 2 . Therefore, the automatic wash-dry-fold system 100 can eliminate a storage-related workload of a worker. (5) In the present exemplary embodiment, all the laundries LD include the passive-type RFID tags (not illustrated in the figures) attached thereto at two predetermined positions (e.g., “a shoulder part” for a shirt, “a waist part” for pants, etc.). Further, the automatic wash-dry-fold system 100 according to the present exemplary embodiment is provided with three RFID tag readers 331 to 333 configured to detect the positions of the RFID tags by means of the triangulation method. Yet further, the automatic wash-dry-fold system 100 is provided with the laundry transporting robot arm 310 , the dried laundry transporting robot arm 320 and the control device 900 . Therefore, the automatic wash-dry-fold system 100 can cause the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 to easily clamp the laundry LD at appropriate clamping positions. Therefore, the automatic wash-dry-fold system 100 can properly put the laundry LD on the platen plates 501 of the folding device 400 . <Modifications> (A) In the aforementioned exemplary embodiment, the RFID tags contain the identification number data D 0 . However, the RFID tags may contain the platen plate width data D 1 and the storage position data D 2 instead of the identification number data D 0 . With the configuration, the matching table Tr and the matching processing are not required. (B) The automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment uses the RFID tags as the storage media of the identification number data D 0 . However, a barcode (e.g., a one-dimensional barcode, a two-dimensional barcode, etc.) may be used as the storage medium of the identification number data D 0 . It should be noted that a barcode reader is herein required instead of the RFID tag readers 331 to 333 . Further, the positional detection of the barcode is herein very difficult. Therefore, the positional detection is not herein executed and a worker is required to manually cause the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 to clamp the laundry LD. Yet further, the barcode is herein preferably attached to the lining of the laundry LD without being outstandingly visible to the outside. Moreover, the platen plate width data D 1 and the storage position data D 2 may be converted into barcodes without using the identification number data D 0 , as described in the aforementioned exemplary modification (A). (C) In the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment, the identification number data D 0 of the RFID tags is configured to be checked against the matching table Tr and the platen plate width data D 1 and the storage position data D 2 are configured to be derived therefrom. However, the following configuration may be employed instead of the above. First, an imaging device such as a camera is configured to preliminarily obtain the imaging data of the laundry LD or the imaging data of a distinctive part of the laundry LD. Then, a matching table is preliminarily created by associating the imaging data with the platen plate width data D 1 and the storage position data D 2 . It should be herein noted that the imaging data may be obtained by irradiating light or the like from the back of the laundry LD. Next, the imaging device such as a camera images the laundry LD, and the control device 900 checks the imaging data (either partially or entirely) against the aforementioned matching table and derives the platen plate width data D 1 and the storage position data D 2 therefrom. It should be herein noted that the imaging device used for creating the matching table and the imaging device used for checking the matching table may be identical to or different from each other. When the imaging data of the entirety of the laundry LD is used for creating the matching table, positional detection is quite difficult. Therefore, a worker is required to manually cause the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 to clamp the laundry LD without executing positional detection. By contrast, when the imaging data of the distinctive part of the laundry LD is used for creating the matching table, positional detection of the distinctive part may be executed and the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 may be caused to clamp the distinctive part of the laundry LD. (D) In the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment, the RFID tags are used as the storage media of the identification number data D 0 . However, fluorescent paint of a variety of colors may be used as the storage media of the identification number data D 0 . It should be herein noted that a black light and an imaging device are required instead of the RFID tag readers 331 to 333 . Further, barcodes may be herein formed using the fluorescent paints. In this case, a matching table is preliminarily created by associating the data of colors and/or shapes of the fluorescent paint with the platen plate width data D 1 and the storage position data D 2 . Further, the laundry LD is imaged while being irradiated by a black light. The control device 900 checks the color and/or the shape of the fluorescent paint in the imaging data (either partially or entirely) against the aforementioned matching table and derives the platen plate width data D 1 and the storage position data D 2 therefrom. It should be herein noted that the fluorescent paint may be applied to two predetermined positions (e.g., “a shoulder part” of a shirt, “a waist part” of pants, etc.) and positional detection of the fluorescent-paint applied parts may be executed. Further, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 may be caused to clamp the fluorescent-paint applied parts of the laundry LD. Moreover, the platen plate width data D 1 and the storage position data D 2 may be converted into barcodes without using the data of the color and/or the shape of the fluorescent paint, as described in the aforementioned exemplary modification (A). (E) In the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment, the RFID tags are used as the storage media of the identification number data D 0 . However, metal pieces made of a variety of metal elements may be used as the storage media of the identification number data D 0 . It should be herein noted that a metal detector is required instead of the RFID tag readers 331 to 333 . In this case, a matching table is preliminarily created by associating the data such as detection sensitivity with the platen plate width data. D 1 and the storage position data D 2 . Further, the metal detector is actuated with respect to the laundry LD, and the control device 900 checks the detection sensitivity of the metal detector against the matching table and derives the platen plate width data D 1 and the storage position data D 2 therefrom. It should be herein noted that two metal pieces may be disposed on two predetermined positions (e.g., “a shoulder part” of a shirt, “a waist part” of pants, etc.) and positional detection of the metal pieces may be executed. Further, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 may be caused to clamp the metal piece embedded portions of the laundry LD. (F) In the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment, the RFID tags are used as the storage media of the identification number data D 0 . However, magnetic recording media may be used as the storage media for the identification number data D 0 . It should be herein noted that a magnetic recording reader is required instead of the RFID tag readers 331 to 333 . It should be herein noted that two magnetic recording media may be disposed on two predetermined positions (e.g., “a shoulder part” of a shirt, “a waist part” of pants, etc.) and positional detection of the magnetic recording media may be executed. Further, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 may be caused to clamp the magnetic recording media embedded portions of the laundry LD. Moreover, the platen plate width data D 1 and the storage position data D 2 may be stored instead of the identification number data D 0 , as described in the aforementioned exemplary modification (A). (G) In the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment, the transporting device 800 is configured to move the laundry LD sorted by the sorting device 700 to one of the storage spaces corresponding to the storage position data D 2 . Alternatively, an automatic wash-dry-fold system 100 a may be structured as illustrated in FIG. 17 . In the automatic wash-dry-fold system 100 a , the laundry LD sorted by the sorting device 700 is transported by means of free fall. It should be noted that the automatic wash-dry-fold system 100 a as described above includes falling spaces 870 a to 870 d for the sections 850 a to 850 d , respectively, and each of the storage spaces is provided with a pull-in slide plate 880 . In response to a command from the control device 900 , a driving device (not illustrated in the figure) is configured to drive the pull-in slide plates 880 to protrude towards the falling spaces for receiving the falling laundries LD and then retract the pull-in slide plates 880 for pulling the received laundries LD into the storage spaces. The configuration is expected to contribute to energy saving. (H) In the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment, laundries are completely automatically washed, dried, folded, sorted and stored. However, laundries may be manually washed and dried. In this case, the laundry LD may be manually taken out of the drying machine 250 and may be manually passed over the RFID tag readers 331 to 333 . Subsequently, the laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 may be manually caused to clamp the laundry LD. Even in this configuration, a worker is only required to execute a work for assisting input of the identification number data D 0 into the control device 900 (e.g., a work for taking a fabric product closer to the control device 900 ). Therefore, it is possible to reduce worker's workload required for width adjustment of the platen plates 501 . The washing machine 200 as described above is employed in the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment. However, any other washing machines may be employed without departing from the scope of the present invention. (J) The drying machine 250 as described above is employed in the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment. However, any other drying machines may be employed without departing from the scope of the present invention. (K) The laundry transporting robot arm 310 and the dried laundry transporting robot arm 320 , as described above, are employed in the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment. However, any other robot arms may be employed without departing from the scope of the present invention. (L) The flip-up-to-the-bottom type folding mechanism 500 is employed for the folding device 400 in the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment. However, a rotary type folding mechanism, a flip-up-to-the-top type folding mechanism or a slide type folding mechanism may be employed as the folding mechanism of the present invention. (M) The sorting device 700 as described above is employed in the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment. However, any other sorting devices may be employed without departing from the scope of the present invention. (N) The transporting device 800 as described above is employed in the automatic wash-dry-fold system 100 of the aforementioned exemplary embodiment. However, any other transporting devices may be employed without departing from the scope of the present invention. INDUSTRIAL APPLICABILITY The folding system for a fabric product according to the present invention is characterized in that worker's workload required for width adjustment of a platen can be reduced, and is especially useful as a home-use folding system for a fabric product.
A folding system for a fabric product is provided. The folding system includes an information obtaining device, a folding device and a width controlling device. The information obtaining device obtains first information held by a fabric product. The folding device includes a platen member, a width adjusting mechanism and a folding mechanism. The platen member is for holding the fabric product. The width adjusting mechanism adjusts the width directional length of the platen member. The folding mechanism folds the fabric product on the platen member. The width controlling device controls the width adjusting mechanism by using the first information obtained by the information obtaining device.
3
FIELD OF THE INVENTION This invention relates to a cable array for connecting multiple transducer probes to a medical ultrasound imaging system. BACKGROUND OF THE INVENTION Physicians and medical technicians use ultrasound imaging systems in a variety of medical imaging applications. In an attempt to fully utilize these expensive imaging systems, several specialized transducer probes, each designed to view a different part of the human body, are connected to a single imaging system. For example, a transthoracic probe for cardiac imaging, a Doppler probe for arterial blood flow imaging and an abdominal probe for soft tissue imaging of the stomach may each be connected to the imaging system using separate transducer cables. Typically, the imaging system has wheels to provide mobility, enabling the imaging system to be shared by physicians and technicians throughout a hospital or clinic. Because transducer cables are designed to be long enough to reach from the imaging system to a patient, when the imaging system is moved, the transducer cables often become entangled with the wheels, knocking the transducer probes to the ground. Transducer cables also become inter-twined with one another, causing transducer probes to fall to the ground, or otherwise, restricting maneuverability of a transducer probe while it is being used. Unfortunately, the transducer probes are easily damaged when dropped and they are expensive to repair or replace. SUMMARY OF THE INVENTION In accordance with the illustrated preferred embodiment of the present invention a cable management system collates transducer cables connecting multiple transducer probes to an ultrasound imaging system and reduces the risk of damage to transducer probes. The transducer cables and the cable management system form a cable array. Each transducer cable within the cable array is held by a retaining clip that is slidably mounted in a common slot assembly. The cable management system enables individual transducer probes to be used without entanglement by other transducer cables in the cable array, which reduces the likelihood of the transducer probes being knocked to the ground and reduces the risk of damage to the transducer probes. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an ultrasound imaging system including a cable array that is constructed in accordance to the illustrated preferred embodiment of the present invention; FIG. 2 shows a detailed view of the cable array of FIG. 1 including a cable management system that is constructed in accordance to the illustrated preferred embodiment of the present invention; and FIG. 3 shows an exploded view of the cable management system of FIG. 2 that is constructed in accordance to the illustrated preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 shows an ultrasound imaging system 5 including a cable array 7 that is constructed in accordance to the first illustrated preferred embodiment of the present invention. The cable array 7 includes transducer cables 9 and a cable management system. Retaining clips 11 and a mounting rod 12 which are parts of the cable management system, are shown. The cable management system prevents the transducer cables 9 from becoming entangled with each other and entangled with wheels or castors 4, used to transport the ultrasound imaging system 5. The retaining clips 11 with their corresponding transducer cables 9 slide from side to side, as necessary, to better maneuver transducer probes 3 attached to the transducer cables 9. While a peripheral component 2 such as a disk drive, tape deck or video printer is used to record ultrasound images by the physician or technician operating the ultrasound imaging system 5, the sliding action of the retaining clips 11 also provides access to the peripheral component 2. Transducer cables 9 provide electrical connections between the transducer probes 3 and the ultrasound imaging system 5. A terminal 15 at the end of each transducer cable 9 joins the transducer cable to the ultrasound imaging system 5. To use the ultrasound imaging system 5, a transducer probe 3 is held by a physician or technician and is placed against a patient's skin. The transducer probe 3 uses ultrasound signals to ultrasonically interrogate the patient's body by transmitting an ultrasound signal and receiving the ultrasound signal after it is reflected by the patient's body. An ultrasound image of a patient's organs and tissues is viewed on a display 17 while adjustments to the ultrasound image are made using switches and knobs on a control panel 18. While transducer probes 3 are not used, they are held in place by a cable rack 19. A service tray 14 provides storage space for gels that are applied to the patient's skin, swabs used to wipe the gel from the patient, or other items. FIG. 2 shows a detailed view of the cable array 7 including a cable management system that is constructed in accordance to the illustrated preferred embodiment of the present invention. The cable array 7 includes a series of individual transducer cables 9 and a cable management system. The cable management system comprises a slot assembly 10, retaining clips 11 and an optional mounting rod 12. The retaining clips are held in place in the slot assembly 10 using retaining rings, not shown. The slot assembly 10 is shown mounted on the underside 34 of a service tray 14 attached to the ultrasound imaging system 5. In ultrasound imaging systems that do not have a service tray 14, the slot assembly 10 may be mounted on a surface of the ultrasound imaging system 5, such as the side or front. If the ultrasound system 5 lacks castors 4 and is instead mounted on a cart (not shown), the cart may then be considered to be part of the ultrasound system. The slot assembly 10 may also be attached to a part of the cart. The retaining clips 11 secure the transducer cables 9 in a removable fashion to the slot assembly 10. If a transducer probe 3 replacement or transducer cable 9 replacement is needed, the transducer cable 9 is unfastened from the retaining clip 11. The retaining clips 11 hold the transducer cables 9 by pinching or encircling the transducer cable or by other suitable means. The retaining clips 11 are designed to slide within the slot assembly 10 in the lateral direction, indicated by arrows X, to provide maneuverability to transducer probes 3 attached to the transducer cables 9. The sliding action also provides access to peripheral components 2 behind the cable array 7. Depending on the surrounding environment in which the ultrasound imaging system is used, the transducer cable 9 may be re-positioned within the retaining clip 11 so as to secure the transducer cable 9 at a different point. The number of retaining clips 11 within the cable management system may be increased or decreased to correspond to the number of transducer cables 9, or a number of retaining clips 11 sufficient to accommodate the anticipated number of transducer cables 9 may be selected in advance. A mounting rod 12 which is an optional element of the cable management system is shown secured to the bottom surface 34 of the service tray 14. In an alternative embodiment, the mounting rod 12 is attached to a surface of the imaging system 5. The mounting rod 12 is secured by screws, glue or other suitable attachment methods. The mounting rod 12 provides further convenience to the physician or technician operating the ultrasound imaging system by allowing a transducer cable 9 to be draped over the mounting rod 12. The mounting rod 12 enables a particular transducer cable 9 of the cable array 7 to remain separated from other transducer cables 9. The mounting rod 12 is either hook shaped or "J" shaped, or even a straight rod positioned in an upward direction, as to accommodate a transducer cable 9 draped over it. FIG. 3 shows an exploded view of the cable management system 20 that is constructed in accordance to the illustrated preferred embodiment of the present invention. A slot assembly 10 is formed of metal, plastic or other material. The slot assembly 10 is attached to a surface of the ultrasound imaging system with screws or other fasteners (not shown) positioned in cut-outs 24 formed in side flanges 25 of the slot assembly 10. Alternatively, the slot assembly 10 is integrated into a part of the ultrasound imaging system, such as a service tray 14. The slot assembly 10 accommodates multiple retaining clips 11 within a slotted aperture 23 cut in a trough 26. The retaining clips 11 such as those available from ITW Corporation, part number 232-120207-20 are held in place by retaining rings 13. A barb 21 terminates a shaft 27 attached to a clasp 29 of each retaining clip 11. The barb 21 penetrates the annular shaped retaining ring 13 and is captively held within the retaining ring 13 by the barb 21 and a flange 22 located along the shaft 27. The shape of the retaining ring 13 allows pivotal rotation of the retaining clip 11. The clasp 29 and the fastener, which includes the retaining ring 13, barb 21, shaft 27 and flange 22, are slidably held within the slotted aperture 23 of the slot assembly 10. Other fasteners for slidably holding the retaining clips 11 in the slotted aperture 23 are also feasible. For example, the retaining clip 11 may not have the barb 21 and the flange 22. A screw threaded into the shaft 27 and a washer positioned below the slotted aperture 23 in place of the flange 22, would also hold the retaining clip 11 in a slidably mounted fashion within the slotted aperture 23. The screw would replace the function of the barb 21 and retaining ring 13, while the washer would replace the function of the flange 22. Other embodiments of the invention will be apparent to the skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.
A cable management system organizes transducer cables connecting multiple transducer probes to a mobile ultrasound imaging system. The transducer cables and the cable management system form a cable array. Each transducer cable within the cable array is held by a retaining clip and rides in a common slot assembly. The retaining clips are suspended in the slot assembly by retaining rings. The cable management system slidably mounts multiple transducer cables on the mobile ultrasound imaging system, avoiding entanglement with casters of the mobile ultrasound imaging system and with other transducer cables in the cable array.
7
BACKGROUND In the hydrocarbon exploration and recovery industry, it is often necessary to anchor equipment within a tubular structure such as a casing or tubing string. A common and long used apparatus for such duty is a set of slips with attendant support structure. In some embodiments, slips are utilized with conical structures that impart radially outwardly directed impetus on each slip as the slip is axially moved along the cone, usually under a compressive load. While such configurations have been extensively used, it is also known that this type of configuration can become stuck in the tubular structure in which it has been set, thereby rendering retrieval thereof difficult. In another embodiment of a slip configuration, the slips are tangentially loaded to avoid the need for the conical portion. Depending upon the configuration of these tangentially loaded systems, there has been difficulty in retrieval or difficulty in creating acceptable holding strength. As the art to which this disclosure pertains is always interested in improved technology, the disclosure hereof is likely to be well received. SUMMARY A slip system includes a set of drive slips having wickers thereon, substantially all of which being truncated in cross-section; a set of gripping slips operatively interengagable with the set of drive slips; a drive slip end ring in operable communication with the set of drive slips; and a gripping slip end ring in operable communication with the set of gripping slips, the end rings capable of transmitting a load applied in an axial direction of the system to the set of gripping slips and the set of drive slips to tangentially load the set-of drive slips and the set of gripping slips against each other thereby increasing a radial dimension of the system and distributing stresses created in a target tubular. A method for distributing stress in a target tubular imparted by a slip system includes embedding a plurality of sharp wickers of the slip system into the target tubular; and contacting an inside dimension of the target tubular with a plurality of truncated wickers. BRIEF DESCRIPTION OF THE DRAWINGS Referring now to the drawings wherein like elements are numbered alike in the several Figures: FIG. 1 is a perspective view of one embodiment of the slip system disclosed herein in a set position; FIG. 2 is a perspective view of one embodiment of the slip system disclosed herein in a retracted position; FIG. 3 is a perspective view of one of the slips from the illustration of FIG. 1 ; FIG. 4 is a perspective view of another of the slips illustrated in FIG. 1 having a distinct wicker configuration; and FIG. 5 is an illustration of an alternate slip ring configured to unset the slip system. DETAILED DESCRIPTION Referring to FIG. 1 , the slip system 10 is illustrated in perspective view. Apparent in FIG. 1 is the configuration of a set of drive slips 12 and a set of grip slips 14 that together cooperate in a way that promotes tangential loading of the slips against one another to radially expand. Radial expansion is necessary to set the system 10 by driving certain portions of the wicker threads (numerically introduced and discussed hereunder) into a receiving tubular structure (not shown). System 10 further includes a drive slip ring 16 and a grip slip ring 18 . Ring 16 is endowed with interengagement (for example, T-shaped) slots 20 about a perimeter thereof, each of the slots 20 being substantially the same shape and set of dimensions as each other. Ring 18 on the other hand, in one embodiment, includes a plurality of interengagement (for example, T-shaped) slots 22 disposed about a periphery thereof having a first set of dimensions and a plurality of interengagement (for example, T-shaped) slots 24 having another set of dimensions. In the illustrated embodiment of FIG. 1 , slots 22 and 24 alternate (single alternating) around the perimeter of ring 18 . It is to be understood, however, that more of slot 22 or slot 24 could be grouped together in alternate embodiments such as, for example, two slot 22 's next to one another and two slot 24 's next to one another alternating with the 22 's (double alternating). Further, there is no requirement that there be any particular number of a certain type of slot 22 or 24 , for example, there may only be one slot 24 or two slots 24 , etc. or each slot could be unique as desired (random alternating). In each of the rings 16 and 18 , the position of slots 20 , 22 or 24 are such, relative to each other, that slips 12 and 14 are alternately positioned when engaged with adjacent T-shaped slots in each ring. The alternate positioning of slips 12 and 14 is easily seen in FIGS. 1 and 2 . Finally, of note in FIGS. 1 and 2 is the trapezoidal shape of each of the slips 12 and 14 . The trapezoidal shape is important because it facilitates radial expansion of the slip system 10 upon axial compression of the system 10 into a shorter axial dimension. Growth in the radial direction is of course important to a slip system because it is such radial growth that allows the system itself to become anchored into the receiving tubular structure. Because of the trapezoidal shape and positioning of that shape, each slip acts as a wedge (perimetrically) against its two neighboring slips. When the axial length of system 10 is increased, the radial dimension of the system 10 will necessarily and naturally decrease. It is to be noted that the radial expansion of system 10 is affected entirely by tangential application of force through the slips 12 and 14 ; this means that the ID of the slip system can remain completely open and that conical structures previously used to radially displace slips are not necessary. Referring now to FIG. 3 , one of the drive slips 12 is illustrated in perspective view and enlarged from the FIGS. 1 and 2 views. In the FIG. 3 view there is visible interlocking members provided in each of the slips in order to keep them engaged as a single unit while simultaneously allowing them to slide relative to each other. Each one of the slips includes a keyed flange 26 , which in the embodiment illustrated, is of L-shape but may be of any shape that allows sliding motion while inhibiting disassociation of each slip from its neighboring slip. On an opposite side of slip 12 is a complementary flange keyhole 28 , one end of which is visible. It will be understood that the flange keyhole 28 extends the length of slip 12 as does keyed flange 26 . If one were to obtain an opposing slip (i.e. slip 14 ) one would notice that the keyed flange 26 and the flange keyhole 28 can be engaged as the slips 12 and 14 slid axially relative to one another. Sliding movement is thus enabled while lateral disassociation is prevented or at least inhibited. It should also be noted in passing that an angle of the mating surfaces 30 , on each slip 12 and 14 , is dictated by a radius extending from the axis of system 10 . This angle ensures smooth and distributed contact along each face 30 to improve overall efficiency and strength of system 10 . Still referring to FIG. 3 , drive slips 12 of the current disclosure possess a number of wickers 32 , a substantial number of which are truncated. In the illustrated embodiment, all of the wickers 32 are truncated, but it is to be appreciated that merely a substantial number of the wickers must be truncated to achieve the benefit of distribution of stresses in the receiving tubular structure. It is possible to add pointed wickers without departing from the scope of the invention. Truncation 34 removes what would otherwise be a sharper point of a slip gripping wicker. In one embodiment the truncation amount is of a dimension that is about the same as the amount of a sharp wicker that would be embedded in the material of the receiving tubular structure. Slips 12 are so configured to enhance retrieveability of the slip system 10 as well as assist in the distribution of stresses in the receiving tubular structure. Each one of the wickers 32 that is truncated, is so truncated to an extent about equal to the amount of penetration into the receiving tubular structure that is anticipated for pointed wickers on the gripping slips 14 . The reason for this is so that when the pointed wickers are maximally embedded in the receiving tubular structure, the wickers 32 will be radially loaded against the receiving tubular structure without penetrating it into. This distributes the stresses of the receiving tubular structure more evenly about the tubular structure consistent with contact around the entirety of the slip system 10 . One further benefit of the configuration of slips 12 is realized in the case of paraffin or other debris lining the inside dimension of the receiving tubular structure. Because wickers 32 are still above the surface of slips 12 , those wickers are able to penetrate debris at the inside dimension of the receiving tubular structure and still ensure contact of truncation 34 with the inside dimension surface of the receiving tubular structure forming a frictional engagement therewith. Each wicker 32 , of course, possesses a pair of flanks 36 , which in one embodiment, are positioned at 45°. It is to be understood that other angles are possible. It is also noted that in the system 10 , it is not necessary to harden wickers 32 , as they are not intended to bite into the receiving tubular structure. This is not to say that it is undesirable to harden wickers 32 but merely that it is not necessary to do so. Referring to FIG. 4 , one of the gripping slips 14 is illustrated. It will be noted that there are two distinguishing features of gripping slip 14 over driving slip 12 as illustrated in FIG. 3 . These are a length 40 of a T-upright 42 , and a configuration of wickers 44 and 46 . Addressing the wickers first, it will be apparent that in the illustrated embodiment, every other wicker is sharp pointed (wicker 44 ) while the intervening wickers 46 are truncated (single alternating). In this embodiment, the degree of truncation of wickers 46 is roughly equal to the expected penetration of wickers 44 into the receiving tubular structure (not shown). Again the purpose for this construction, like that of the drive slip illustrated in FIG. 3 , is to distribute the load on the receiving tubular structure imparted by radial motion of slip system 10 . More specifically, upon full penetration of wickers 44 into the receiving tubular structure, wickers 46 come into contact with the inside diameter of the receiving tubular structure thereby distributing stress in that structure. It is to be appreciated that only one embodiment of the slip system contemplated is shown in FIG. 4 . It is also possible for numbers of wickers 44 and 46 to be grouped such as two wickers 44 alternating with two wickers 46 (double alternating) or three wickers 44 alternating with three wickers 46 (triple alternating) or even a number of sharp wickers 44 alternating with a different number of truncated wickers 46 (random alternating). The overall point of alternating sharp and truncated wickers is to distribute stress otherwise imparted in an undistributed way to the receiving tubular structure. It is further possible to retain all of the wickers on slips 14 in the 44 configuration in some embodiments of the invention, since the truncated wickers 32 on the drive slips 12 will still substantially balance stresses in the receiving tubular structure. It will also be noted that pointed wickers 44 should be hardened such that they are sufficiently durable to penetrate the inside diameter of the receiving tubular structure. Addressing now the upright 42 of the key structure 48 , and referring to both FIGS. 3 and 4 , it is apparent that the length 40 of the upright section 22 is longer than that of the comparable portion of slip 12 . The reason for the length of this portion of slip 14 is to delay a tensile force being applied to this slip 14 when retraction of the slip system 10 is desired. Referring back to FIGS. 1 and 2 and reiterating that the T-shaped slots 22 and 24 are distinct, a review of the drawing will make clear that T-shaped slots 24 , upon an axial tensile load on ring 18 , will cause an immediate transfer of the tensile load to the associated slip 14 . This is distinct from the T-shaped slots 22 wherein the same tensile load applied to ring 18 , is not immediately transferred to the associated slip 14 but rather the ring 18 must axially move relative to the associated slip 14 until surface 50 contacts surface 52 . Upon this contact, the tensile load will be transmitted to the associated slip 14 . In such configuration it will be appreciated that every other slip 14 , in the illustrated embodiment, will be pulled in a direct commensurate with retracting the slip system 10 prior to the other slips 14 being so pulled. This reduces the force necessary to retract the slip system 10 . In the illustrated embodiment, the force is roughly halved while in other embodiments with differing numbers of alternating T-shaped slots 22 and 24 , the reduction in tensile force required will be describable as a percentage of the whole proportional to the number of earlier pulled slips relative to the total number of slips associated with the subject ring. It will be noted by the astute reader that ring 16 contains only T-shaped slot 20 . The reason that the staggered T-shaped slots are not required on ring 16 is that all of the associated slips 12 substantially lack gripping wickers and therefore, the tensile force required to unseat them is substantially less than that of the slips 14 . Therefore, there is no need to stagger the T-shaped slots in ring 16 . This is by no means to say that it is inappropriate to stagger T-shaped slots 20 , as it certainly is not only possible and functional, but rather merely to state that it is unnecessary. Referring to FIG. 5 , an alternate embodiment of ring 18 is illustrated which allows for the T-shaped structures on each of the slips 14 to be identical. In this embodiment, the T-shaped structure 48 is not required to be long, as it is illustrated in the FIG. 1 and FIG. 2 embodiments. It will be appreciated that the reason that the elongated section 42 is not needed, is that surface 50 of slots 22 is positioned closer to an end 60 of ring 18 than it is in the FIG. 1 embodiment. One will also note that the clearances between the T-shaped structure 48 and the slots 22 has also been increased to account for potential axial movement of the system. This additional clearance alleviates unnecessary load on the structure 48 when the system is set. While the figures in this application may suggest to one of ordinary skill in the art the existence of a clear uphole end and downhole end of slip system 10 , based upon conventional illustration methods, it is to be understood that slip system 10 is usable with either end uphole. Generally, it will be desirable to impart a compressive setting force against ring 16 and the drive slips 12 while maintaining ring 18 and gripping slips 14 stationary. This is, however, not a requirement and the slip system 10 is to be understood to be actuable and retractable from either end. It is also to be understood that the system is actuable and retractable from a position downhole of the system of a position uphole of the system. While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
A slip system includes a set of drive slips having wickers thereon, substantially all of which being truncated in cross-section; a set of gripping slips operatively interengagable with the set of drive slips; a drive slip end ring in operable communication with the set of drive slips; and a gripping slip end ring in operable communication with the set of gripping slips, the end rings capable of transmitting a load applied in an axial direction of the system to the set of gripping slips and the set of drive slips to tangentially load the set of drive slips and the set of gripping slips against each other thereby increasing a radial dimension of the system and distributing stresses created in a target tubular and method.
4
CROSS REFERENCE TO RELATED APPLICATION This application is a Continuation of U.S. patent application Ser. No. 11/608,107 filed Dec. 7, 2006, and claims the benefit under 35 USC 119 of U.S. provisional patent application No. 60/754,272 filed Dec. 29, 2005, both incorporated herein by reference in their entirety. FIELD OF THE INVENTION This invention relates generally to shear panels that are applied to framing in residential and other types of light construction. More particularly, the invention relates to panels that are able to resist lateral forces imposed by high wind and earthquake loads in regions where they are required by building codes. Such panels, commonly known as shear walls or diaphragms, must demonstrate shear resistance as shown in recognized tests, such as ASTM E72. These panels may also be used for flooring or roofing or other locations where shear panels are used in residential or commercial construction. The shear panels include one or more reinforcement members bonded to a structural cementitious panel (SCP) to provide a completed panel that can breathe and has weather resistant characteristics to be capable of sustaining exposure to the elements during construction, without damage. The SCP material (continuous phase) of the SCP panel is made from a mixture of inorganic binder and lightweight fillers. BACKGROUND OF THE INVENTION Interior residential and light commercial wall and flooring systems commonly include plywood or oriented strand board (OSB) nailed to a wooden frame or mechanically fastened to a metal frame. OSB consists of pieces of wood glued together. Regardless of whether the frame of a building is constructed from wood and/or steel, such frame structures are commonly subjected to a variety of forces. Among the most significant of such forces are gravity, wind, and seismic forces. Gravity is a vertically acting force while wind and seismic forces are primarily laterally acting. Not all sheathing panels are capable of resisting such forces, nor are they very resilient, and some will fail, particularly at points where the panel is fastened to the framing. Where it is necessary to demonstrate shear resistance, the sheathing panels are measured to determine the load which the panel can resist within the allowed deflection without failure. The shear rating is generally based on testing of three identical 8×8 feet (2.44×2.44 m) assemblies, i.e., panels fastened to framing. One edge is fixed in place while a lateral force is applied to a free end of the assembly until the load is no longer carried and the assembly fails. The measured shear strength will vary, depending upon the thickness of the panel and the size and spacing of the nails or mechanical fasteners used in the assembly. The measured strength will vary as the nail or mechanical fastener size and spacing is changed, as the ASTM E72 test provides. This ultimate strength will be reduced by a safety factor, e.g., typically a factor of two to three, to set the design shear strength for the panel. As the thickness of the board affects its physical and mechanical properties, e.g., weight, load carrying capacity, racking strength and the like, the desired properties vary according to the thickness of the board. U.S. Pat. No. 6,620,487 to Tonyan et al., incorporated herein by reference in its entirety, discloses a reinforced, lightweight, dimensionally stable structural cement panel (SCP) capable of resisting shear loads when fastened to framing equal to or exceeding shear loads provided by plywood or oriented strand board panels. The panels employ a core of a continuous phase resulting from the curing of an aqueous mixture of calcium sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime, the continuous phase being reinforced with alkali-resistant glass fibers and containing ceramic microspheres, or a blend of ceramic and polymer microspheres, or being formed from an aqueous mixture having a weight ratio of water-to-reactive powder of 0.6/1 to 0.7/1 or a combination thereof. At least one outer surface of the panels may include a cured continuous phase reinforced with glass fibers and containing sufficient polymer spheres to improve nailability or made with a water-to-reactive powders ratio to provide an effect similar to polymer spheres, or a combination thereof. U.S. Pat. No. 6,241,815 to Bonen, incorporated herein by reference in its entirety, also discloses formulations useful for SCP panels. One form of wallboard structure purportedly for metal construction applications is disclosed in U.S. Pat. No. 5,768,841 to Swartz et al. That wallboard structure has a metal sheet attached to an entire side of a gypsum panel with an adhesive. Another wallboard panel is disclosed in U.S. Pat. No. 6,412,247 to Menchetti et al. The International Building Code in its “Steel” section also references the use of shear walls utilizing panel type members, i.e., drywall, steel plates and plywood, etc. US patent application publication no. 2005/0086905 A1 to Ralph et al. discloses shear wall panels and methods of manufacturing shear wall panels. Various embodiments comprise wallboard material employed with a sheet stiffener in the form of a plate to form a wall panel that may be used in applications wherein shear panels are desired. SUMMARY OF THE INVENTION The present invention relates to one or more reinforcement members bonded to an SCP panel to provide a completed panel that can breathe and has weather resistant characteristics to be capable of sustaining exposure to the elements during construction, without damage. The SCP material (continuous phase) of the SCP panel is made from a mixture of inorganic binder and lightweight fillers. In particular, the present invention relates to a panel for resisting shear loads when fastened to framing, comprising: a panel of a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight % lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers); and at least one reinforcing member selected from the group consisting of plate and a mesh sheet attached to a first surface of the continuous phase panel, wherein the at least one reinforcing member covers 5 to 90%, typically 10 to 80%, of the first surface of the continuous phase panel. Typically, a high strength adhesive such as an epoxy or urethane is applied to a reinforcement member or to indentations on the embossed side of a weather durable SCP panel such sheet of mesh or metal. The reinforcement member is then placed into the indentations on the embossed side of a weather durable SCP panel and then held in a press until the adhesive has cured sufficiently to permit handling the panel without debonding. The finished panel can then be placed on steel or wood framing and attached with either screws or nails. Shear capacity will be determined by the gage of the laminated sheet, size spacing of the fasteners, and the gage and size of the framing members. Typically about 5 to 90%, typically about 10 to 80%, or about 20 to 50% of the embossed side is covered with one or more reinforcement members. If desired the embossing can be omitted such that the reinforcement members protrude from the surface of the SCP panel. In a first embodiment, a fiber reinforced SCP panel is reinforced with horizontal metal strips 8-12 inches wide laminated along the length of the panel at the edges and mid point of the panel. This reduces the weight of the panel compared to a panel covered with a full sheet of metal. At 12 inches wide the panel typically has about half the steel of a fully laminated panel. The strips allow the panel to breathe and the spacing allows the panel to be adequately supported between the strips. The shear capacity is a function of the gage of metal and width of the strips. In a second embodiment, the edges of the SCP panel are stiffened by placing metal along the SCP panel edges and bending the metal, e.g., ⅜ inch of metal edge, approximately 90 degrees to form a shallow tray to protect the edges of the SCP panel and add to the lateral fastener pullout strength to resist tear out along edges when the panel is loaded in shear. The term “tear out” means where the fastener tears out a portion of the SCP panel as the panel is racked. In another embodiment, a reinforced SCP panel is reinforced with diagonal metal plates at the corners to carry the shear and rectangular plates in the field to laterally support the panel against bending out of plane when attached to framing. This embodiment also allows the panel to breathe and reduces the weight of the steel. This embodiment typically has about ⅓ the amount of steel as a fully laminated sheet. The reinforcement members are typically metal, polymer or mesh. Typical metal sheets are about 0.02 to about 0.07 inches (about 0.05 to about 0.2 cm) thick. The metal is typically steel or aluminum. For example, steel sheets about 25 to 14 gauge, e.g., 22 gauge. The metal can be replaced by one or more about 1/32 to ¼ inch (about 0.08 to about 0.6 cm) thick sheets of polymer, e.g., thermoplastic polymer or thermosetting polymer, or mesh, e.g. fiber glass mesh or carbon fiber mesh. The present invention also relates to floor or wall systems for residential and light commercial construction including a wooden or metal frame and the reinforced SCP shear panels. Employing a metal frame provides a fully non-combustible system in which all elements pass ASTM E-136. For example, the system may include the reinforced SCP panels employed with a metal framing system employing any standard light-gauge steel C-channels, U-channels, I-beams, square tubing, corrugated metal sheet, and light-gauge prefabricated building sections, such as floor trusses or open web bar joists. The composite SCP panel may be fastened to framing members with either pneumatically driven nails or conventional self-drilling screws. A wall of reinforced SCP shear panel may have a higher specific racking strength in a shear wall compared to a reinforced concrete masonry shear wall. Specific racking strength is the ultimate racking strength (in pounds per lineal foot) divided by the weight of the wall assembly (in pounds per lineal foot) for a constant wall height. For a given racking strength the present inventive wall is lighter within a practical range of racking strengths than the respective masonry wall of the same racking strength. The present system having a shear diaphragm on light gauge cold rolled metal frame also is typically water durable. Preferably when testing the system with the SCP panels laid oriented horizontally, the horizontal shear diaphragm load carrying capacity of a system of the present invention will not be lessened by more than 25% (more preferably will not be lessened by more than 20%) when exposed to water in a test wherein a 2 inch head of water is maintained over ¾ inch thick reinforced SCP panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. In this test, the 2 inch head is maintained by checking, and replenishing water, at 15 minute intervals. Preferably the system of the present invention will not absorb more than 0.7 pounds per square foot of water when exposed to water in a test wherein a 2 inch head of water is maintained over ¾ inch thick reinforced SCP panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. In this test, the 2 inch head is maintained by checking, and replenishing water, at 15 minute intervals. Also, the system of the present invention resists swelling due to moisture. Preferably, in the system of the present invention a system of a oriented horizontally 10 foot wide by 20 foot long by ¾ inch thick diaphragm of the reinforced SCP panels attached to a 10 foot by 20 foot metal frame will not swell more than 5% when exposed to a 2 inch head of water maintained over the SCP panels fastened on the metal frame for a period of 24 hours. In this test, the 2 inch head is maintained by checking, and replenishing water, at 15 minute intervals. Also, the system of the present invention leads to a mold and mildew resistant floor, wall or roof system. Preferably every component of the system of the present invention meets ASTM G-21 in which the system achieves approximately a rating of 1 and meets ASTM D-3273 in which the system achieves approximately a rating of 10. Preferably the system of the present invention supports substantially zero bacteria growth when clean. A potential advantage of the present system is that, due to its high strength it is better able to provide an earthquake resistant structure. As the thickness of the board affects its physical and mechanical properties, e.g., weight, load carrying capacity, racking strength and the like, the desired properties vary according to the thickness of the board. Thus, for example, the desired properties which a shear rated panel with a nominal thickness of 0.75 inches (19.1 mm) should meet include the following. A 4×8 ft, ¾ inch thick panel (1.22×2.44 m, 19.1 mm thick) typically weighs no more than 156 lbs (71 kg) and preferably no more than 144 lbs (65.5 kg). Thinner panels are proportionally lighter. The present invention provides a method of making the reinforced SCP panel. The present invention provides a method of making systems comprising placing the reinforced SCP panel on one or both sides of metal framing members. The reinforced SCP panels may float on the framing members, for example, joists, or be connected to the framing members mechanically or by adhesive. Connecting the reinforced SCP panels directly or indirectly to the metal framing members may achieve a composite action such that the metal framing and panels work together to carry greater loads. The present invention also encompasses a non-combustible building system, such as a floor, wall or roof system, including a reinforced SCP panel of the present invention attached to one or both sides of a metal frame to increase the shear capacity of the framed wall. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top view of a first embodiment of a reinforced structural cementitious panel (SCP) panel of the present invention employing strips of reinforcing sheets inserted in indentations on the SCP material of the panel. FIG. 2 is a cross-sectional view along view II-II of the panel of FIG. 1 . FIG. 3 is a top view of a second embodiment of a reinforced SCP panel of the present invention employing strips of reinforcing sheets, including strips which wrap around opposed edges of the panel. FIG. 4 is a cross-sectional view along view IV-IV of the panel of FIG. 3 . FIG. 5 is a top view of a third embodiment of a reinforced SCP panel of the present invention wherein the reinforcement strips protrude from a surface of the panel. FIG. 6 is a cross-sectional view along view VI-VI of the panel of FIG. 5 . FIG. 7 is a top view of a fourth embodiment of a reinforced SCP panel of the present invention including reinforcing strips which wrap around opposed sidewalls of the panel. FIG. 8 is a cross-sectional view along view VIII-VIII of the panel of FIG. 7 . FIG. 9 is a perspective view of a fifth embodiment of a reinforced SCP panel of the present invention including reinforcing mesh which wrap around opposed walls of the panel. FIG. 10 is a top view of a sixth embodiment of a reinforced SCP panel of the present invention including reinforcing corner pieces and separate optional reinforcing strips. FIG. 11 is a cross-sectional view along view XI-XI of the panel of FIG. 10 . FIG. 12 is a cross-sectional view along view XII-XII of the panel of FIG. 10 . FIG. 13 is a top view of a seventh embodiment of a reinforced SCP panel of the present invention including reinforcing strips and separate reinforcing corner pieces. Optionally, two of the reinforcing strips contact the corner pieces. FIG. 14 is a cross-sectional view along view XIV-XIV of the panel of FIG. 13 . FIG. 15 is a cross-sectional view along view XV-XV of the panel of FIG. 13 . FIG. 16 is a top view of an eighth embodiment of a reinforced SCP panel of the present invention employing a one piece reinforced border on one of its surfaces. FIG. 17 is a cross-sectional view along view XVII-XVII of the panel of FIG. 16 . FIG. 18 is a top view of a ninth embodiment of a reinforced SCP panel of the present invention employing a multi-piece reinforced border on one of its surfaces. FIG. 19 is a top view of a tenth embodiment of a reinforced SCP panel of the present invention employing a perforated panel. FIG. 20 is a cross-sectional view along view XX-XX of the panel of FIG. 19 . FIG. 21 is a perspective view of the panel of FIG. 19 . FIG. 22 is a perspective view of a portion of an eleventh embodiment of a reinforced SCP panel of the present invention employing a panel with small perforations. FIG. 23 is a top view of a portion of a twelfth embodiment of a reinforced SCP panel of the present invention employing a panel with small perforations. FIG. 24 is a cross-sectional view along view XXIV-XXIV of the panel of FIG. 23 . FIG. 25 is a top view of a portion of a thirteenth embodiment of a reinforced SCP panel of the present invention. FIG. 26 is a cross-sectional view along view XXVI-XXVI of the panel of FIG. 25 . FIG. 27 is a top view of a portion of a fourteenth embodiment of a reinforced SCP panel of the present invention. FIG. 28 is a cross-sectional view along view XXVIII-XXVIII of the panel of FIG. 27 . FIG. 29 is a side view of a multi-layer SCP panel of the present invention with the reinforcement omitted for clarity. FIG. 30 is a schematic side view of a metal frame wall suitable for employing with a reinforced structural cementitious panel (SCP) panel of the present invention. FIG. 31 is an elevation view of an apparatus which is suitable for making the SCP panel of the present invention, except for a downstream embossing station and reinforcement attaching station. FIG. 32 is a perspective view of a slurry feed station of the type used in the present process. FIG. 33 is a fragmentary overhead plan view of an embedment device suitable for use with the present process to embed lightweight filler. FIG. 34 shows ASTM E72 Racking data of five 8 foot×8 foot (2.16×2.16 mm) samples with SCP installed horizontally on 16 gauge 3.624 steel studs at 16 inches on center with fastener layout of 6″ (15.2 cm) on center on the perimeter and 12″ (30.4 cm) in the field. FIG. 35 is a perspective view of a typical metal floor frame 160 suitable for use with the reinforced SCP panels of the present invention. FIG. 36 is a fragmentary schematic vertical section of a single-layer SCP panel 162 supported on metal frame of FIG. 35 in a system of the present invention. FIG. 37 is a perspective view of SCP panels of FIG. 36 supported on a corrugated sheet in the non-combustible flooring system of the present invention. FIG. 38 shows a perspective view of a portion of the embodiment of FIG. 37 wherein SCP panel is attached to corrugated sheet with metal screws. FIG. 39 shows an embodiment of a roofing system using the reinforced SCP panels of the present invention. FIG. 40 shows another embodiment of a roofing system using the reinforced SCP panels of the present invention. DETAILED DESCRIPTION OF THE INVENTION The present invention may employ single layer or multi-layer SCP panels reinforced with reinforcement members such as sheets of metal, polymer or mesh placed on the panel surface. The reinforcement members are typically metal, polymer or mesh, e.g. fiber glass mesh or carbon fiber mesh. Typical SCP panel material (discussed in more detail elsewhere in this specification) is made from a mixture of water and inorganic binder (examples—gypsum-cement, Portland cement or other hydraulic cements) with the selected lightweight fillers (examples glass fibers, hollow glass microspheres, hollow ceramic microspheres and/or perlite uniformly), and superplasticizer/high-range water reducing admixtures (examples—polynapthalene sulfonates, poly acrylates, etc.) distributed throughout the mixture. Other additives such as accelerating and retarding admixtures, viscosity control additives may optionally be added to the mixture to meet the demands of the manufacturing process involved. The glass fibers can be used alone or in combination with other types of non-combustible fibers such as steel fibers. This results in panels of the present invention which comprise inorganic binder having the selected lightweight fillers distributed throughout the full thickness of the panel. In the multi-layer SCP panel the layers may be the same or different. For example, the SCP panel may have an inner layer of a continuous phase and at least one outer layer of a continuous phase on each opposed side of the inner layer, wherein at least one outer layer on each opposed side of the inner layer has a higher percentage of glass fibers than the inner layer. This has the ability to stiffen, strengthen and toughen the panel. In another embodiment, a multi-layer panel structure may be created to contain at least one outer layer having improved nailability and cutability by using a higher water-to-reactive powder (defined below) ratio in making the outer layer(s) relative to the core of the panel. A small thickness of the skin coupled with a small dosage of polymer content may improve the nailability without necessarily failing the non-combustibility test. Of course, high dosages of polymer content would lead to failure of the product in the non-combustibility test. Calcium Sulfate Hemihydrate Calcium sulfate hemihydrate, which may be used in panels of the invention, is made from gypsum ore, a naturally occurring mineral, (calcium sulfate dihydrate CaSO 4 .2H 2 O). Unless otherwise indicated, “gypsum” will refer to the dihydrate form of calcium sulfate. After being mined, the raw gypsum is thermally processed to form a settable calcium sulfate, which may be anhydrous, but more typically is the hemihydrate, CaSO 4 .½H 2 O. For the familiar end uses, the settable calcium sulfate reacts with water to solidify by forming the dihydrate (gypsum). The hemihydrate has two recognized morphologies, termed alpha hemihydrate and beta hemihydrate. These are selected for various applications based on their physical properties and cost. Both forms react with water to form the dihydrate of calcium sulfate. Upon hydration, alpha hemihydrate is characterized by giving rise to rectangular-sided crystals of gypsum, while beta hemihydrate is characterized by hydrating to produce needle-shaped crystals of gypsum, typically with large aspect ratio. In the present invention either or both of the alpha or beta forms may be used depending on the mechanical performance desired. The beta hemihydrate forms less dense microstructures and is preferred for low density products. The alpha hemihydrate forms more dense microstructures having higher strength and density than those formed by the beta hemihydrate. Thus, the alpha hemihydrate could be substituted for beta hemihydrate to increase strength and density or they could be combined to adjust the properties. A typical embodiment for the inorganic binder used to make panels of the present invention comprises hydraulic cement such as Portland cement, high alumina cement, pozzolan-blended Portland cement, or mixtures thereof. Another typical embodiment for the inorganic binder used to make panels of the present invention comprises a blend containing calcium sulfate alpha hemihydrate, hydraulic cement, pozzolan, and lime. Hydraulic Cement ASTM defines “hydraulic cement” as follows: a cement that sets and hardens by chemical interaction with water and is capable of doing so under water. There are several types of hydraulic cements that are used in the construction and building industries. Examples of hydraulic cements include Portland cement, slag cements such as blast-furnace slag cement and super-sulfated cements, calcium sulfoaluminate cement, high-alumina cement, expansive cements, white cement, and rapid setting and hardening cements. While calcium sulfate hemihydrate does set and harden by chemical interaction with water, it is not included within the broad definition of hydraulic cements in the context of this invention. All of the aforementioned hydraulic cements can be used to make the panels of the invention. The most popular and widely used family of closely related hydraulic cements is known as Portland cement. ASTM defines “Portland cement” as a hydraulic cement produced by pulverizing clinker consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an interground addition. To manufacture Portland cement, an intimate mixture of limestone, argillaceous rocks and clay is ignited in a kiln to produce the clinker, which is then further processed. As a result, the following four main phases of Portland cement are produced: tricalcium silicate (3CaO.SiO 2 , also referred to as C 3 S), dicalcium silicate (2CaO.SiO 2 , called C 2 S), tricalcium aluminate (3CaO.Al 2 O 3 or C 3 A), and tetracalcium aluminoferrite (4CaO.Al 2 O 3 .Fe 2 O 3 or C 4 AF). Other compounds present in minor amounts in Portland cement include calcium sulfate and other double salts of alkaline sulfates, calcium oxide, and magnesium oxide. Of the various recognized classes of Portland cement, Type III Portland cement (ASTM classification) is preferred for making the panels of the invention, because of its fineness it has been found to provide greater strength. The other recognized classes of hydraulic cements including slag cements such as blast-furnace slag cement and super-sulfated cements, calcium sulfoaluminate cement, high-alumina cement, expansive cements, white cement, rapidly setting and hardening cements such as regulated set cement and VHE cement, and the other Portland cement types can also be successfully used to make the panels of the present invention. The slag cements and the calcium sulfoaluminate cement have low alkalinity and are also suitable to make the panels of the present invention. Fibers Glass fibers are commonly used as insulating material, but they have also been used as reinforcing materials with various matrices. The fibers themselves provide tensile strength to materials that may otherwise be subject to brittle failure. The fibers may break when loaded, but the usual mode of failure of composites containing glass fibers occurs from degradation and failure of the bond between the fibers and the continuous phase material. Thus, such bonds are important if the reinforcing fibers are to retain the ability to increase ductility and strengthen the composite over time. It has been found that glass fiber reinforced cements do lose strength as time passes, which has been attributed to attack on the glass by the lime which is produced when cement is cured. One possible way to overcome such attack is to cover the glass fibers with a protective layer, such as a polymer layer. In general, such protective layers may resist attack by lime, but it has been found that the strength is reduced in panels of the invention and, thus, protective layers are not preferred. A more expensive way to limit lime attack is to use special alkali-resistant glass fibers (AR glass fibers), such as Nippon Electric Glass (NEG) 350Y. Such fibers have been found to provide superior bonding strength to the matrix and are, thus, preferred for panels of the invention. The glass fibers are monofilaments that have a diameter from about 5 to 25 microns (micrometers) and typically about 10 to 15 microns (micrometers). The filaments generally are combined into 100 filament strands, which may be bundled into rovings containing about 50 strands. The strands or rovings will generally be chopped into suitable filaments and bundles of filaments, for example, about 0.25 to 3 inches (6.3 to 76 mm) long, typically 1 to 2 inches (25 to 50 mm). It is also possible to include other non-combustible fibers in the panels of the invention, for example, steel fibers are also potential additives. Pozzolanic Materials As has been mentioned, most Portland and other hydraulic cements produce lime during hydration (curing). It is desirable to react the lime to reduce attack on glass fibers. It is also known that when calcium sulfate hemihydrate is present, it reacts with tricalcium aluminate in the cement to form ettringite, which can result in undesirable cracking of the cured product. This is often referred to in the art as “sulfate attack.” Such reactions may be prevented by adding “pozzolanic” materials, which are defined in ASTM C618-97 as “ . . . siliceous or siliceous and aluminous materials which in themselves possess little or no cementitious value, but will, in finely divided form and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties.” One often used pozzolanic material is silica fume, a finely divided amorphous silica which is the product of silicon metal and ferro-silicon alloy manufacture. Characteristically, it has a high silica content and a low alumina content. Various natural and man-made materials have been referred to as having pozzolanic properties, including pumice, perlite, diatomaceous earth, tuff, trass, metakaolin, microsilica, ground granulated blast furnace slag, and fly ash. While silica fume is a particularly convenient pozzolan for use in the panels of the invention, other pozzolanic materials may be used. In contrast to silica fume, metakaolin, ground granulated blast furnace slag, and pulverized fly ash have a much lower silica content and large amounts of alumina, but can be effective pozzolanic materials. When silica fume is used, it will constitute about 5 to 20 wt. %, preferably 10 to 15 wt. %, of the reactive powders (i.e., hydraulic cement, calcium sulfate alpha hemihydrate, silica fume, and lime). If other pozzolans are substituted, the amounts used will be chosen to provide chemical performance similar to silica fume. Lightweight Fillers/Microspheres The lightweight panels employed in systems of the present invention typically have a density of 65 to 90 pounds per cubic foot, preferably 65 to 85 pounds per cubic foot, more preferably 72 to 80 pounds per cubic foot. In contrast, typical Portland cement based panels without wood fiber will have densities in the 95 to 110 pcf range, while the Portland Cement based panels with wood fibers will be about the same as SCP (about 65 to 85 pcf). To assist in achieving these low densities the panels are provided with lightweight filler particles. Such particles typically have an average diameter (average particle size) of about 10 to 500 microns (micrometers). More typically they have a mean particle diameter (mean particle size) from 50 to 250 microns (micrometers) and/or fall within a particle diameter (size) range of 10 to 500 microns. They also typically have a particle density (specific gravity) in the range from 0.02 to 1.00. Microspheres or other lightweight filler particles serve an important purpose in the panels of the invention, which would otherwise be heavier than is desirable for building panels. Used as lightweight fillers, the microspheres help to lower the average density of the product. When the microspheres are hollow, they are sometimes referred to as microballoons. When the microspheres are hollow, they are sometimes referred to as microballoons. The microspheres are either non-combustible themselves or, if combustible, added in sufficiently small amounts to not make the SCP panel combustible. Typical lightweight fillers for including in mixtures employed to make panels of the present invention are selected from the group consisting of ceramic microspheres, polymer microspheres, perlite, glass microspheres, and/or fly ash cenospheres. Ceramic microspheres can be manufactured from a variety of materials and using different manufacturing processes. Although a variety of ceramic microspheres can be utilized as a filler component in the panels of the invention, the preferred ceramic microspheres of the invention are produced as a coal combustion by-product and are a component of the fly ash found at coal fired utilities, for example, EXTENDOSPHERES-SG made by Kish Company Inc., Mentor, Ohio or FILLITE® Brand ceramic microspheres made by Trelleborg Fillite Inc., Norcross, Ga. USA. The chemistry of the preferred ceramic microspheres of the invention is predominantly silica (SiO 2 ) in the range of about 50 to 75 wt. % and alumina (Al 2 O 3 ) in the range of about 15 to 40 wt. %, with up to 35 wt. % of other materials. The preferred ceramic microspheres of the invention are hollow spherical particles with diameters in the range of 10 to 500 microns (micrometers), a shell thickness typically about 10% of the sphere diameter, and a particle density preferably about 0.50 to 0.80 g/mL. The crushing strength of the preferred ceramic microspheres of the invention is greater than 1500 psi (10.3 MPa) and is preferably greater than 2500 psi (17.2 MPa). Preference for ceramic microspheres in the panels of the invention primarily stems from the fact that they are about three to ten times stronger than most synthetic glass microspheres. In addition, the preferred ceramic microspheres of invention are thermally stable and provide enhanced dimensional stability to the panel of invention. Ceramic microspheres find use in an array of other applications such as adhesives, sealants, caulks, roofing compounds, PVC flooring, paints, industrial coatings, and high temperature-resistant plastic composites. Although they are preferred, it should be understood that it is not essential that the microspheres be hollow and spherical, since it is the particle density and compressive strength which provide the panel of the invention with its low weight and important physical properties. Alternatively, porous irregular particles may be substituted, provided that the resulting panels meet the desired performance. The polymer microspheres, if present, are typically hollow spheres with a shell made of polymeric materials such as polyacrylonitrile, polymethacrylonitrile, polyvinyl chloride or polyvinylidine chloride, or mixtures thereof. The shell may enclose a gas used to expand the polymeric shell during manufacture. The outer surface of the polymer microspheres may have some type of an inert coating such as calcium carbonate, titanium oxides, mica, silica, and talc. The polymer microspheres have a particle density preferably about 0.02 to 0.15 g/mL and have diameters in the range 10 to 350 microns (micrometers). The presence of polymer microspheres may facilitate simultaneous attainment of low panel density and enhanced cutability and nailability. Other lightweight fillers, for example glass microspheres, perlite or hollow alumino-silicate cenospheres or microspheres derived from fly ash, are also suitable for including in mixtures in combination with or in place of ceramic microspheres employed to make panels of the present invention. The glass microspheres typically are made of alkali resistant glass materials and may be hollow. Typical glass microspheres are available from GYPTEK INC., Suite 135, 16 Midlake Blvd SE, Calgary, AB, T2X 2X7, CANADA. In a first embodiment of the invention, only ceramic microspheres are used throughout the full thickness of the panel. The panel typically contains about 35 to 42 weight % of ceramic microspheres uniformly distributed throughout the thickness of the panel. In a second embodiment of the invention, a blend of lightweight ceramic and glass microspheres is used throughout the full thickness of the panel. The volume fraction of the glass microspheres in the panel of the second embodiment of the invention will typically be in the range of 0 to 15% of the total volume of the dry ingredients, where the dry ingredients of the composition are the reactive powders (examples of reactive powders: hydraulic cement only; blend of hydraulic cement and pozzolan; or blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), ceramic microspheres, polymer microspheres, and alkali-resistant glass fibers. A typical aqueous mixture has a ratio of water-to-reactive powders from greater than 0.3/1 to 0.7/1. As mentioned above, if desired the panel may have a single layer or multiple layers of SCP material. Typically, the panel is made by a process which applies multiple layers which, depending upon how the layers are applied and cured as well as whether the layers have the same or different compositions, may or may not in the final panel product retain distinct layers. FIG. 29 shows a multi-layer structure of a panel 101 having layers 102 , 104 , 106 and 108 . In the multi-layer structure the composition of the layers may be the same or different. The typical thickness of the layer(s) ranges between about 1/32 to 1.0 inches (about 0.75 to 25.4 mm). Where only one outer layer is used, it typically will be less than ⅜ of the total panel thickness. Typical Configurations of Reinforced SCP Panels of the Present Invention FIG. 1 is a top view of a first embodiment of a metal reinforced structural cementitious panel (SCP) panel 10 of the present invention employing strips 14 of reinforcing sheets attached to the SCP material 12 of the panel 10 . The strips 14 are implanted in cavities on the surface of the panel such that the upper surface of the strips 14 is flush with the uppermost surface of the SCP material 12 . The reinforcing strips 14 are typically metal, polymer or mesh having a thickness “A”. Typical metal reinforcing strips 14 have a thickness “A” of about 0.02 to about 0.07 inches (about 0.05 to about 0.2 cm) thick. The metal is typically steel or aluminum. For example, steel sheets about 25 to 14 gauge, e.g., 22 gauge. The metal can be replaced by one or more sheets of polymer, e.g., thermoplastic polymer or thermosetting polymer, or mesh, e.g. fiber glass mesh or carbon fiber mesh having a thickness “A” of about 1/32 to ¼ inch (about 0.08 to about 0.6 cm). FIG. 2 is a cross-sectional view along view II-II of the panel 10 of FIG. 1 . FIG. 3 is a top view of a second embodiment of a metal reinforced SCP panel 11 of the present invention employing strips 15 , 17 of reinforcing sheets embedded in the SCP material 13 of the panel 10 . The strips include strips 15 which wrap around opposed edges of the panel. In a second embodiment, the edges of the SCP panel are stiffened by placing metal along the SCP panel edges and bending the metal, e.g., ⅜ inch of metal edge, approximately 90 degrees to form a shallow tray to protect the edges of the SCP panel and add to the lateral fastener tear out along edges when the panel is loaded in shear. FIG. 4 is a cross-sectional view along view IV-IV of the panel 11 of FIG. 3 . FIG. 5 is a top view of a third embodiment of a reinforced SCP panel 20 of the present invention having reinforcement strips 24 which protrude from a surface of the SCP material 22 of the panel 20 . FIG. 6 is a cross-sectional view along view VI-VI of the panel 20 of FIG. 5 . FIG. 7 is a top view of a fourth embodiment of a reinforced SCP panel 30 of the present invention including reinforcing strips 34 which wrap around opposed sidewalls of the SCP material 32 of the panel 30 . Optionally, a reinforcing strip 36 is also attached to the SCP material 32 . FIG. 8 is a cross-sectional view along view VIII-VIII of the panel 30 of FIG. 7 . FIG. 9 is a perspective view of a fifth embodiment of a reinforced SCP panel 40 of the present invention including reinforcing mesh 44 which wraps around opposed walls of the SCP material 46 of the panel 40 . FIG. 10 is a top view of a sixth embodiment of a reinforced SCP panel 50 of the present invention including separate reinforcing corner pieces 54 and optional reinforcing strips 56 attached to the SCP material 52 of the panel 50 . FIG. 11 is a cross-sectional view along view XI-XI of the panel 50 of FIG. 10 . FIG. 12 is a cross-sectional view along view XII-XII of the panel 50 of FIG. 10 . FIG. 13 is a top view of a seventh embodiment of a reinforced SCP panel 60 of the present invention including a central reinforcing strip 68 and separate reinforcing corner pieces 64 . Optionally, the panel 60 is further provided with two reinforcing strips 66 which contact the corner pieces 64 . FIG. 14 is a cross-sectional view along view XIV-XIV of the panel 60 of FIG. 13 . FIG. 15 is a cross-sectional view along view XV-XV of the panel 60 of FIG. 13 . FIG. 16 is a top view of a eighth embodiment of a reinforced SCP panel 70 of the present invention employing an one piece reinforced border 74 placed into a notched area along the perimeter of one of the surfaces of the SCP material 72 . The outer perimeter of the border 74 overlaps the outer perimeter of the surface of the SCP material 72 to which the border 74 is attached. FIG. 17 is a cross-sectional view along view XVII-XVII of the panel 70 of FIG. 16 . FIG. 18 is a top view of a ninth embodiment of a reinforced SCP panel 80 of the present invention which is the same as the embodiment of FIG. 16 , but for employing a multi-piece reinforced border on one of the surfaces of the SCP material 82 . The border including corner pieces 84 , longitudinal side pieces 86 and transverse side pieces 88 . FIG. 19 is a top view of a tenth embodiment of a reinforced SCP panel 90 of the present invention employing a panel 94 , having perforations 96 , attached to SCP material 92 . FIG. 20 is a cross-sectional view along view XX-XX of the panel 90 of FIG. 19 . FIG. 21 is a perspective view of the panel 90 of FIG. 19 . FIG. 21 shows the panel 90 has a tongue 91 and a groove 93 . The other embodiments of the present invention also optionally have a tongue and groove on opposed sidewalls. FIG. 22 is a perspective view of a portion of an eleventh embodiment of a reinforced SCP panel 95 of the present invention employing a panel 99 , with small perforations, attached to the SCP material 97 . Typical ranges for holes/perforations of FIGS. 19 and 22 are as follows: Range of hole size: 1/32″ diameter to 12″ diameter Range of Hole density per square foot: 0.5 to 20,000 Surface area of reinforcement coverage range: 5% to 90% (this is different than the 10-80% reinforcement coverage range for the other reinforcement members). FIG. 23 is a top view of a portion of a twelfth embodiment of a reinforced SCP panel 130 of the present invention employing a crossed pair of reinforcing members 134 , 136 , attached to SCP material 132 . The crossed pair of reinforcing members 134 , 136 overlap where they cross. FIG. 24 is a cross-sectional view along view XXIV-XXIV of the reinforced SCP panel 130 of FIG. 23 . FIG. 25 is a top view of a portion of a thirteenth embodiment of a reinforced SCP panel 140 of the present invention employing three reinforcing members 144 , 146 , 148 attached to SCP material 142 to form a cross-shaped pattern. FIG. 26 is a cross-sectional view along view XXVI-XXVI of the panel 140 of FIG. 25 . FIG. 27 is a top view of a portion of a fourteenth embodiment of a reinforced SCP panel of the present invention a crossed pair of reinforcing members 154 , 155 attached to SCP material 152 to form a cross-shaped pattern and framed by a multi-piece reinforced border on one of the surfaces of the SCP material 152 . The border including corner pieces 153 , longitudinal side pieces 156 and transverse side pieces 151 . FIG. 28 is a cross-sectional view along view XXVIII-XXVIII of the panel 150 of FIG. 27 . FIG. 29 is a side view of a multi-layer SCP panel 101 of the present invention having layers 102 , 104 , 106 , 108 , with the reinforcement omitted for clarity. Use of the Panels on Framing FIG. 30 is a perspective view of a typical metal wall frame suitable for use with the reinforced SCP panels of the present invention. As shown in FIG. 30 , a frame 110 for supporting the walls of the foundation 2 includes a lower track 112 , a plurality of metal studs 120 , and an optional spacer member 140 . SCP panels 101 ( FIG. 29 ) may be secured in any known manner to the outer side, and if desired the inner side, of the metal wall frame 110 to close the wall and form the exterior surface or surfaces of the wall. U.S. Pat. No. 6,694,695 to Collins et al., incorporated herein by reference, more fully describes the arrangement of this metal wall frame. The studs 120 are generally C-shaped. More particularly, the studs 120 have a web 122 and a pair of L-shaped flanges 124 perpendicular to the web 122 . There are also one or more openings 126 in the web 122 . The openings 126 permit electrical conduit and plumbing to be run within the stud wall. The metal studs 120 are secured at one end 121 to lower track 112 by conventional fasteners 123 such as, for example, screws, rivets, etc. The lower track 112 is also C-shaped with a central web portion 114 and two legs 116 protruding from web 114 . In the present foundation system, the web 114 of the bottom track 112 is typically affixed to a floor (not shown) with conventional fasteners such as screws, bolts, rivets, etc. An optional V-shaped stud spacer member 140 having a crease 149 is inserted through the aligned openings 126 provided through the webs 122 of the respective studs 120 such that notches 142 in the stud spacer member 140 engage the stud openings 126 of the web 122 of respective studs 120 . FIG. 35 is a perspective view of a typical metal floor frame 460 suitable for use with the reinforced SCP panels of the present invention. The metal frame 460 has C-joist framing 450 supported on a header or longitudinal rim track 452 . In practice, the reinforced SCP panels may be mechanically or adhesively attached to the C-joists 450 or be not attached to the C-joists (i.e., be floating). The joists were attached to the rim track 452 using screws into the side of the joist through a pre-bent tab and screws through the top of rim track into the joist 450 , at each end. Steel angles 451 were also fastened with screws to the respective joist 450 and to the rim track 452 . KATZ blocking 458 was fastened to the bottom of the joists 450 across the center line of the floor. The blocking 458 was attached using a screw through the end of each Katz blocking member 458 . In particular, the Katz blocking 458 is located between transverse joints 450 by being positioned staggered on either side of the midpoint and attached by screws. Additional horizontal blocking may be added to the rim track 452 on the load side to strengthen the rim track 452 for point loading purposes. Namely, blocking 457 for load support is provided along the longitudinal rim track between a number of transverse joists 450 . 20 inch long blocking 459 is fixed between each transverse end joist and the respective penultimate transverse end 452 joist generally along the longitudinal axis of the frame with screws. Typically a reinforced SCP panel could be attached to the frame by screws or adhesive. Afterwards, at the butt-joints and tongue and groove locations of the panels, an adhesive, for example ENERFOAM SF polyurethane foam adhesive manufactured by Flexible Products Company of Canada, Inc., could be applied in the joint. U.S. Pat. No. 6,691,478 B2 to Daudet et al. discloses another example of a suitable metal flooring system. FIG. 36 is a fragmentary schematic vertical section of a single-layer SCP panel 462 supported on metal frame 460 of FIG. 35 in a system of the present invention. If desired a fastener (not shown) may attach the SCP panel to a C-joist of the metal frame 460 . In practice the floor may be mechanically or adhesively attached to the C-joist or be not attached to the C-joist (i.e., be floating). The frames may be wood or any metal, e.g., steel or galvanized steel, framing systems suitable for supporting flooring. Typical metal frames include C-joists having openings therein for passing plumbing and electrical lines there through and headers for supporting the C-joists about the floor perimeter. Preferably the frames are metal to result in a non-combustible system. FIG. 37 is a perspective view of SCP panels 416 of FIG. 36 supported on a corrugated sheet 403 in the non-combustible flooring system of the present invention. In FIG. 38 the numeral 401 generally designates a composite flooring deck assembly comprising a corrugated sheet 403 supported from below by a joist (not shown, but which could for example be a C-joist or I-beam beam or any other suitable joist) and secured from above by mechanical fasteners 405 to a diaphragm 407 of SCP panels 416 . Corrugated sheet 403 typically has flat portions 408 and 410 of substantially equal length joined by connector portions 412 providing straight, parallel, regular, and equally curved ridges and hollows. This configuration has a substantially equal distribution of surface area of the corrugated sheet above and below a neutral axis 414 (as seen in FIG. 38 ). Optionally the panels 416 have a tongue 418 and groove 420 formed on opposite edges thereof to provide for continuous interlocking of flooring substrate panels 416 to minimize joint movement under moving and concentrated loads. The embodiment of FIG. 37 involves a design using a system of corrugated steel decking, designed using steel properties provided by the Steel Deck Institute (SDI) applied over steel joists and girders. A ceiling (not shown), such as gypsum drywall mounted on DIETRICH RC DELUXE channels may be attached to the bottoms of the joists or ceiling tiles and grid may be hung from the joists. An alternate is for the bottom surfaces of the steel to be covered with spray fiber or fireproofing materials. The steel joists which support the steel decking are any which can support the system. Typical steel joists may include those outlined by the SSMA (Steel Stud Manufacturer's Association) for use in corrugated steel deck systems, or proprietary systems, such as those sold by Dietrich as TRADE READY Brand joists. Joist spacing of 24 inches (61 cm) is common. However, spans between joists may be greater or less than this. C-joists and open web joists are typical. In the particular embodiment of the invention illustrated in FIG. 37 , SCP panels 416 have sufficient strength to create a structural bridge over the wide rib openings 422 . FIG. 38 shows the SCP panels 416 attached to the corrugated sheet 403 by screws 405 . As illustrated in FIG. 39 , for a roof deck, spaced screws 405 , having screw heads 442 are oriented to form a series of generally triangular shaped horizontally disposed trusses (for example, truss T h shown as the horizontal line between two of the screws 405 ) and a series of vertically disposed trusses T v throughout the length and width of spans between spaced joists P (such as that shown in the embodiment of FIG. 40 ) to increase the resistance to horizontal and vertical planar deflection of the roof deck. SCP panel 416 is described in more detail below. In the form of the invention illustrated in FIG. 39 the diaphragm 407 comprises an SCP panel 416 positioned over a sheet of insulation material 430 . FIG. 40 is a cross-sectional view of the SCP panel of FIG. 36 supported on a corrugated sheet of a roofing system wherein the SCP panel 416 is secured over a sheet of insulation material 430 in the non-combustible building system of the present invention. In the form of the invention of FIG. 40 the diaphragm 407 is secured to upper ridge portions 208 of the corrugated sheet 403 by threaded screws 405 having enlarged heads 442 . The form of the system illustrated in FIG. 40 is similar to that of FIG. 39 except that a layer or sheet 430 of thermal insulation material is positioned over the SCP panels 416 to form the diaphragm 407 . Sheet 430 of insulation material typically comprises incombustible foamed polystyrene or other suitable insulation material. For example, other insulation material such as polyurethane, fiberglass, cork and the like may be employed in combination with or in lieu of the polystyrene. Formulation of SCP Panels The components used to make the shear resistant panels of the invention include hydraulic cement, calcium sulfate alpha hemihydrate, an active pozzolan such as silica fume, lime, ceramic microspheres, alkali-resistant glass fibers, superplasticizer (e.g., sodium salt of polynapthalene sulfonate), and water. Typically, both hydraulic cement and calcium sulfate alpha hemihydrate are present. Long term durability of the composite is compromised if calcium sulfate alpha hemihydrate is not present along with silica fume. Water/moisture durability is compromised when Portland cement is not present. Small amounts of accelerators and/or retarders may be added to the composition to control the setting characteristics of the green (i.e., uncured) material. Typical non-limiting additives include accelerators for hydraulic cement such as calcium chloride, accelerators for calcium sulfate alpha hemihydrate such as gypsum, retarders such as DTPA (diethylene triamine pentacetic acid), tartaric acid or an alkali salt of tartaric acid (e.g., potassium tartrate), shrinkage reducing agents such as glycols, and entrained air. Panels of the invention will include a continuous phase in which alkali-resistant glass fibers and light weight filler, e.g., microspheres, are uniformly distributed. The continuous phase results from the curing of an aqueous mixture of the reactive powders, i.e., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), preferably including superplasticizer and/or other additives. Typical weight proportions of embodiments of the reactive powders (inorganic binder), e.g., hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan and lime, in the invention, based on dry weight of the reactive powders, are shown in TABLE 1. TABLE 1A lists typical ranges of reactive powders, lightweight filler, and glass fibers in compositions of the present invention. TABLE 1 Weight Percent Typical Weight Reactive Powder (%) Percent (%) Hydraulic Cement 20-55 25-40 Calcium Sulfate Alpha Hemihydrate 35-75 45-65 Pozzolan  5-25 10-15 Lime up to 3.5 or 0.75-1.25 from 0.2 to 3.5 TABLE 1A Typical Weight SCP Composition (dry basis) Weight Percent (%) Percent (%) Reactive Powder 35-70 35-68 Lightweight Filler 20-50 23-49 Glass Fibers  5-20  5-17 Lime is not required in all formulations of the invention, but it has been found that adding lime provides superior panels and it usually will be added in amounts greater than about 0.2 wt. %. Thus, in most cases, the amount of lime in the reactive powders will be about 0.2 to 3.5 wt. %. In the first embodiment of an SCP material for use in the invention, the dry ingredients of the composition will be the reactive powders (i.e., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), ceramic microspheres and alkali-resistant glass fibers, and the wet ingredients of the composition will be water and superplasticizer. The dry ingredients and the wet ingredients are combined to produce the panel of the invention. The ceramic microspheres are uniformly distributed in the matrix throughout the full thickness of the panel. Of the total weight of dry ingredients, the panel of the invention is formed from about 49 to 56 wt. % reactive powders, 35 to 42 wt. % ceramic microspheres and 7 to 12 wt. % alkali-resistant glass fibers. In a broad range, the panel of the invention is formed from 35 to 58 wt. % reactive powders, 34 to 49 wt. % lightweight filler, e.g., ceramic microspheres, and 6 to 17 wt. % alkali-resistant glass fibers of the total dry ingredients. The amounts of water and superplasticizer added to the dry ingredients will be sufficient to provide the desired slurry fluidity needed to satisfy processing considerations for any particular manufacturing process. The typical addition rates for water range between 35 to 60% of the weight of reactive powders and those for superplasticizer range between 1 to 8% of the weight of reactive powders. The glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers), preferably about 10 to 15 microns (micrometers). The monofilaments typically are combined in 100 filament strands, which may be bundled into rovings of about 50 strands. The length of the glass fibers will typically be about 0.25 to 1 or 2 inches (6.3 to 25 or 50 mm) or about 1 to 2 inches (25 to 50 mm) and broadly about 0.25 to 3 inches (6.3 to 76 mm). The fibers have random orientation, providing isotropic mechanical behavior in the plane of the panel. A second embodiment of an SCP material suitable for use in the invention contains a blend of ceramic and glass microspheres uniformly distributed throughout the full thickness of the panel. Accordingly, the dry ingredients of the composition will be the reactive powders (hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), ceramic microspheres, glass microspheres, and alkali-resistant glass fibers, and the wet ingredients of the composition will be water and superplasticizer. The dry ingredients and the wet ingredients will be combined to produce the panel of the invention. The volume fraction of the glass microspheres in the panel will typically be in the range of 7 to 15% of the total volume of dry ingredients. Of the total weight of dry ingredients, the panel of the invention is formed from about 54 to 65 wt. % reactive powders, 25 to 35 wt. % ceramic microspheres, 0.5 to 0.8 wt. % glass microspheres, and 6 to 10 wt. % alkali-resistant glass fibers. In the broad range, the panel of the invention is formed from 42 to 68 wt. % reactive powders, 23 to 43 wt. % lightweight fillers, e.g., ceramic microspheres, 0.2 to 1.0 wt. % glass microspheres, and 5 to 15 wt. % alkali-resistant glass fibers, based on the total dry ingredients. The amounts of water and superplasticizer added to the dry ingredients will be adjusted to provide the desired slurry fluidity needed to satisfy the processing considerations for any particular manufacturing process. The typical addition rates for water range between 35 to 70% of the weight of reactive powders, but could be greater than 60% up to 70% (weight ratio of water to reactive powder of 0.6/1 to 0.7/1), preferably 65% to 75%, when it is desired to use the ratio of water-to-reactive powder to reduce panel density and improve cutability. The amount of superplasticizer will range between 1 to 8% of the weight of reactive powders. The glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers), preferably about 10 to 15 microns (micrometers). They typically are bundled into strands and rovings as discussed above. The length of the glass fibers typically is about 1 to 2 inches (25 to 50 mm) and broadly about 0.25 to 3 inches (6.3 to 76 mm). The fibers will have random orientation providing isotropic mechanical behavior in the plane of the panel. A third embodiment of SCP material suitable for use in the invention, contains a multi-layer structure in the panel created where the outer layer(s) have improved nailability (fastening ability)/cutability. This is achieved by increasing the water-to-cement ratio in the outer layer(s), and/or changing the amount of filler, and/or adding an amount of polymer microspheres sufficiently small such that the panel remains noncombustible. The core of the panel will typically contain ceramic microspheres uniformly distributed throughout the layer thickness or alternatively, a blend of one or more of ceramic microspheres, glass microspheres and fly ash cenospheres. The dry ingredients of the core layer of this third embodiment are the reactive powders (typically hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), lightweight filler particles (typically microspheres such as ceramic microspheres alone or one or more of ceramic microspheres, glass microspheres and fly ash cenospheres), and alkali-resistant glass fibers, and the wet ingredients of the core layer are water and superplasticizer. The dry ingredients and the wet ingredients will be combined to produce the core layer of the panel of the invention. Of the total weight of dry ingredients, the core of the panel of the invention preferably is formed from about 49 to 56 wt. % reactive powders, 35 to 42 wt. % hollow ceramic microspheres and 7 to 12 wt. % alkali-resistant glass fibers, or alternatively, about 54 to 65 wt. % reactive powders, 25 to 35 wt. % ceramic microspheres, 0.5 to 0.8 wt. % glass microspheres or fly ash cenospheres, and 6 to 10 wt. % alkali-resistant glass fibers. In the broad range, the core layer of the panel of this embodiment of the present invention is typically formed by about 35 to 58 wt. % reactive powders, 34 to 49 wt. % lightweight fillers, e.g., ceramic microspheres, and 6 to 17 wt. % alkali-resistant glass fibers, based on the total dry ingredients, or alternatively, about 42 to 68 wt. % of reactive powders, 23 to 43 wt. % ceramic microspheres, up to 1.0 wt. %, preferably 0.2 to 1.0 wt. %, other lightweight filler, e.g., glass microspheres or fly ash cenospheres, and 5 to 15 wt. % alkali-resistant glass fibers. The amounts of water and superplasticizer added to the dry ingredients will be adjusted to provide the desired slurry fluidity needed to satisfy the processing considerations for any particular manufacturing process. The typical addition rates for water will range between 35 to 70% of the weight of reactive powders but will be greater than 60% up to 70% when it is desired to use the ratio of water-to-reactive powders to reduce panel density and improve nailability and those for superplasticizer will range between 1 to 8% of the weight of reactive powders. When the ratio of water-to-reactive powder is adjusted, the slurry composition will be adjusted to provide the panel of the invention with the desired properties. There is generally an absence of polymer microspheres and an absence of polymer fibers that would cause the SCP panel to become combustible. The dry ingredients of the outer layer(s) of this third embodiment will be the reactive powders (typically hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), lightweight filler particles (typically microspheres such as ceramic microspheres alone or one or more of ceramic microspheres, glass microspheres and fly ash cenospheres), and alkali-resistant glass fibers, and the wet ingredients of the outer layer(s) will be water and superplasticizer. The dry ingredients and the wet ingredients are combined to produce the outer layers of the panel of the invention. In the outer layer(s) of the panel of this embodiment of the present invention, the amount of water is selected to furnish good fastening and cutting ability to the panel. Of the total weight of dry ingredients, the outer layer(s) of the panel of the invention preferably are formed from about 54 to 65 wt. % reactive powders, 25 to 35 wt. % ceramic microspheres, 0 to 0.8 wt. % glass microspheres, and 6 to 10 wt. % alkali-resistant glass fibers. In the broad range, the outer layers of the panel of the invention are formed from about 42 to 68 wt. % reactive powders, 23 to 43 wt. % ceramic microspheres, up to 1.0 wt. % glass microspheres (and/or fly ash cenospheres), and 5 to 15 wt. % alkali-resistant glass fibers, based on the total dry ingredients. The amounts of water and superplasticizer added to the dry ingredients are adjusted to provide the desired slurry fluidity needed to satisfy the processing considerations for any particular manufacturing process. The typical addition rates for water range between 35 to 70% of the weight of reactive powders and particularly greater than 60% up to 70% when the ratio of water-to-reactive powders is adjusted to reduce panel density and improve nailability, and typical addition rates for superplasticizer will range between 1 to 8% of the weight of reactive powders. The preferable thickness of the outer layer(s) ranges between 1/32 to 4/32 inches (0.8 to 3.2 mm) and the thickness of the outer layer when only one is used will be less than ⅜ of the total thickness of the panel. In both the core and outer layer(s) of this embodiment of the present invention, the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers), preferably 10 to 15 microns (micrometers). The monofilaments typically are bundled into strands and rovings as discussed above. The length typically is about 1 to 2 inches (25 to 50 mm) and broadly about 0.25 to 3 inches (6.3 to 76 mm). The fiber orientation will be random, providing isotropic mechanical behavior in the plane of the panel. A fourth embodiment of SCP material for use in the present invention provides a multi-layer panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing and comprising a core layer of a continuous phase resulting from the curing of an aqueous mixture, a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight percent lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers); and at least one outer layer of respectively another continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight percent lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers) on each opposed side of the inner layer, wherein the at least one outer layer has a higher percentage of glass fibers than the inner layer. Making a Panel of the Invention The reactive powders, e.g., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), and lightweight filler, e.g., microspheres, are blended in the dry state in a suitable mixer. Then, water, a superplasticizer (e.g., the sodium salt of polynapthalene sulfonate), and the pozzolan (e.g., silica fume or metakaolin) are mixed in another mixer for 1 to 5 minutes. If desired, a retarder (e.g., potassium tartrate) is added at this stage to control the setting characteristics of the slurry. The dry ingredients are added to the mixer containing the wet ingredients and mixed for 2 to 10 minutes to form smooth homogeneous slurry. The slurry is then combined with glass fibers, in any of several ways, with the objective of obtaining a uniform slurry mixture. The cementitious panels are then formed by pouring the slurry containing fibers into an appropriate mold of desired shape and size. If necessary, vibration is provided to the mold to obtain good compaction of material in the mold. The panel is given required surface finishing characteristics using an appropriate screed bar or trowel. The panel may then be embossed to provide indentations and the reinforcement members are inserted into the indentations and attached to the panel. If desired, rather than placing the reinforcement members into indentations, they may be placed on the non-indented surface to protrude from the panel. One of a number of methods to make multi-layer SCP panels is as follows. The reactive powders, e.g., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), and lightweight filler, e.g., microspheres, are blended in the dry state in a suitable mixer. Then, water, a superplasticizer (e.g., the sodium salt of polynapthalene sulfonate), and the pozzolan (e.g., silica fume or metakaolin) are mixed in another mixer for 1 to 5 minutes. If desired, a retarder (e.g., potassium tartrate) is added at this stage to control the setting characteristics of the slurry. The dry ingredients are added to the mixer containing the wet ingredients and mixed for 2 to 10 minutes to form a smooth homogeneous slurry. The slurry may be combined with the glass fibers in several ways, with the objective of obtaining a uniform mixture. The glass fibers typically will be in the form of rovings that are chopped into short lengths. In a preferred embodiment, the slurry and the chopped glass fibers are concurrently sprayed into a panel mold. Preferably, spraying is done in a number of passes to produce thin layers, preferably up to about 0.25 inches (6.3 mm) thick, which are built up into a uniform panel having no particular pattern and with a thickness of ¼ to 1 inch (6.3 to 25.4 mm). For example, in one application, a 3×5 ft (0.91×1.52 m) panel was made with six passes of the spray in the length and width directions. As each layer is deposited, a roller may be used to assure that the slurry and the glass fibers achieve intimate contact. The layers may be leveled with a screed bar or other suitable means after the rolling step. Typically, compressed air will be used to atomize the slurry. As it emerges from the spray nozzle, the slurry mixes with glass fibers that have been cut from a roving by a chopper mechanism mounted on the spray gun. The uniform mixture of slurry and glass fibers is deposited in the panel mold as described above. If desired the outer surface layers of the panel may contain polymer spheres, or be otherwise constituted, in order that the fasteners used to attach the panel to framing can be driven easily. The preferable thickness of such layers will be about 1/32 inches to 4/32 inches (0.8 to 3.2 mm). The same procedure described above by which the core of the panel is made may be used to apply the outer layers of the panel. Other methods of depositing a mixture of the slurry and glass fibers will occur to those familiar with the panel-making art. For example, rather than using a batch process to make each panel, a continuous sheet may be prepared in a similar manner, which after the material has sufficiently set, can be cut into panels of the desired size. The percentage of fibers relative to the volume of slurry typically constitutes approximately in the range of 0.5% to 3%, for example 1.5%. Typical panels have a thickness of about ¼ to 1½ inches (6.3 to 38.1 mm). The SCP panels are typically embossed with a pattern sufficiently deep such that the reinforcement when inserted into the pattern has an outer surface flush with the outer surface of the panel. Although, if desired, the embossing may be omitted such that the reinforcement upper surface will protrude from the surface of the SCP panel. The reinforcement members are preferably at least temporarily affixed to the SCP panel by an adhesive applied to one of the mating major surfaces. Other attachment means of affixing reinforcement members to SCP panel, such as double sided tape, may be employed also. The adhesive may be epoxy or glue, and may be applied by various means such as brushing or spraying, for example. Further, the adhesive may be applied to a portion or portions of one or both of the major surfaces. However, adhesive is preferably spread over the extent of one of the major surfaces of one of either wallboard panel or reinforcement piece and is a water soluble latex based glue. The amount of adhesive applied to adhere the SCP panel and reinforcement piece together is an amount at least sufficient to hold these two members together such that the composite wallboard structure can be handled and constructed into a building wall structure. Thus, the adhesive applied between the SCP panel and reinforcement piece is of sufficient quantity to hold these two members together while the composite structure is being handled, shipped and attached to building wall framing studs or floor framing joists, in typical building construction processes. The reinforced SCP panel could be made by automated processes. For example, an SCP panel could be manufactured and provided by automated machinery well known in the industry. The SCP panel could continue its processing by spraying one of its surfaces with an adhesive utilizing a spraying device stationed over SCP panel. A reinforcement piece such as a metal strip can thereafter be laid on the adhesive by a robotics mechanism. Another method of making panels of the present invention is by using the process steps disclosed in U.S. patent application Ser. No. 10/666,294 incorporated herein by reference. U.S. patent application Ser. No. 10/666,294, incorporated herein by reference, discloses after one of an initial deposition of loosely distributed, chopped fibers or a layer of slurry upon a moving web, fibers are deposited upon the slurry layer. An embedment device compacts the recently deposited fibers into the slurry, after which additional layers of slurry, then chopped fibers are added, followed by more embedment. The process is repeated for each layer of the board, as desired. Then the board is typically embossed to have a pattern of indentations and the reinforcement members are inserted into the indentations and attached to the board. More specifically, U.S. patent application Ser. No. 10/666,294 discloses a multi-layer process for producing structural cementitious panels, including: (a.) providing a moving web; (b.) one of depositing a first layer of loose fibers and (c.) depositing a layer of settable slurry upon the web; (d.) depositing a second layer of loose fibers upon the slurry; (e.) embedding the second layer of fibers into the slurry; and (f.) repeating the slurry deposition of step (c.) through step (d.) until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. FIG. 31 is a diagrammatic elevational view of an apparatus which is suitable for performing the process of U.S. patent application Ser. No. 10/666,294, but for adding embossing capability to the forming device 394 and adding a reinforcement member attaching station 400 . Referring now to FIG. 31 , a structural panel production line is diagrammatically shown and is generally designated 310 . The production line 310 includes a support frame or forming table 312 having a plurality of legs 313 or other supports. Included on the support frame 312 is a moving carrier 314 , such as an endless rubber-like conveyor belt with a smooth, water-impervious surface, however porous surfaces are contemplated. As is well known in the art, the support frame 312 may be made of at least one table-like segment, which may include designated legs 313 . The support frame 312 also includes a main drive roll 316 at a distal end 318 of the frame, and an idler roll 320 at a proximal end 322 of the frame. Also, at least one belt tracking and/or tensioning device 324 is preferably provided for maintaining a desired tension and positioning of the carrier 314 upon the rolls 316 , 320 . Also, in the preferred embodiment, a web 326 of Kraft paper, release paper, and/or other webs of support material designed for supporting slurry prior to setting, as is well known in the art, may be provided and laid upon the carrier 314 to protect it and/or keep it clean. However, it is also contemplated that the panels produced by the present line 310 are formed directly upon the carrier 314 . In the latter situation, at least one belt washing unit 328 is provided. The carrier 314 is moved along the support frame 312 by a combination of motors, pulleys, belts or chains which drive the main drive roll 316 as is known in the art. It is contemplated that the speed of the carrier 314 may vary to suit the application. In the apparatus of FIG. 31 , structural cementitious panel production is initiated by one of depositing a layer of loose, chopped fibers 330 or a layer of slurry upon the web 326 . An advantage of depositing the fibers 330 before the first deposition of slurry is that fibers will be embedded near the outer surface of the resulting panel. A variety of fiber depositing and chopping devices are contemplated by the present line 310 , however the preferred system employs at least one rack 331 holding several spools 332 of fiberglass cord, from each of which a cord 334 of fiber is fed to a chopping station or apparatus, also referred to as a chopper 336 . The chopper 336 includes a rotating bladed roll 338 from which project radially extending blades 340 extending transversely across the width of the carrier 314 , and which is disposed in close, contacting, rotating relationship with an anvil roll 342 . In the preferred embodiment, the bladed roll 338 and the anvil roll 342 are disposed in relatively close relationship such that the rotation of the bladed roll 338 also rotates the anvil roll 342 , however the reverse is also contemplated. Also, the anvil roll 342 is preferably covered with a resilient support material against which the blades 340 chop the cords 334 into segments. The spacing of the blades 340 on the roll 338 determines the length of the chopped fibers. As is seen in FIG. 31 , the chopper 336 is disposed above the carrier 314 near the proximal end 322 to maximize the productive use of the length of the production line 310 . As the fiber cords 334 are chopped, the fibers 330 fall loosely upon the carrier web 326 . Next, a slurry feed station, or a slurry feeder 344 receives a supply of slurry 346 from a remote mixing location 347 such as a hopper, bin or the like. It is also contemplated that the process may begin with the initial deposition of slurry upon the carrier 314 . The slurry is preferably comprised of varying amounts of Portland cement, gypsum, aggregate, water, accelerators, plasticizers, foaming agents, fillers and/or other ingredients, and described above and in the patents listed above which have been incorporated by reference for producing SCP panels. The relative amounts of these ingredients, including the elimination of some of the above or the addition of others, may vary to suit the use. While various configurations of slurry feeders 344 are contemplated which evenly deposit a thin layer of slurry 346 upon the moving carrier 314 , the preferred slurry feeder 344 includes a main metering roll 348 disposed transversely to the direction of travel of the carrier 314 . A companion or back up roll 350 is disposed in close parallel, rotational relationship to the metering roll 348 to form a nip 352 there between. A pair of sidewalls 354 , preferably of non-stick material such as Teflon® brand material or the like, prevents slurry 346 poured into the nip 352 from escaping out the sides of the feeder 344 . The feeder 344 deposits an even, relatively thin layer of the slurry 346 upon the moving carrier 314 or the carrier web 326 . Suitable layer thicknesses range from about 0.05 inch to 0.20 inch. However, with four layers preferred in the preferred structural panel produced by the present process, and a suitable building panel being approximately 0.5 inch, an especially preferred slurry layer thickness is approximately 0.125 inch. Referring now to FIGS. 31 and 32 , to achieve a slurry layer thickness as described above, several features are provided to the slurry feeder 344 . First, to ensure a uniform disposition of the slurry 346 across the entire web 326 , the slurry is delivered to the feeder 344 through a hose 356 located in a laterally reciprocating, cable driven, fluid powered dispenser 358 of the type well known in the art. Slurry flowing from the hose 356 is thus poured into the feeder 344 in a laterally reciprocating motion to fill a reservoir 359 defined by the rolls 348 , 350 and the sidewalls 354 . Rotation of the metering roll 348 thus draws a layer of the slurry 346 from the reservoir. Next, a thickness monitoring or thickness control roll 360 is disposed slightly above and/or slightly downstream of a vertical centerline of the main metering roll 348 to regulate the thickness of the slurry 346 drawn from the feeder reservoir 357 upon an outer surface 362 of the main metering roll 348 . Also, the thickness control roll 360 allows handling of slurries with different and constantly changing viscosities. The main metering roll 348 is driven in the same direction of travel “T” as the direction of movement of the carrier 314 and the carrier web 326 , and the main metering roll 348 , the backup roll 350 and the thickness monitoring roll 360 are all rotatably driven in the same direction, which minimizes the opportunities for premature setting of slurry on the respective moving outer surfaces. As the slurry 346 on the outer surface 362 moves toward the carrier web 326 , a transverse stripping wire 364 located between the main metering roll 348 and the carrier web 326 ensures that the slurry 346 is completely deposited upon the carrier web and does not proceed back up toward the nip 352 and the feeder reservoir 359 . The stripping wire 364 also helps keep the main metering roll 348 free of prematurely setting slurry and maintains a relatively uniform curtain of slurry. A second chopper station or apparatus 366 , preferably identical to the chopper 336 , is disposed downstream of the feeder 344 to deposit a second layer of fibers 368 upon the slurry 346 . In the preferred embodiment, the chopper apparatus 366 is fed cords 334 from the same rack 331 that feeds the chopper 336 . However, it is contemplated that separate racks 331 could be supplied to each individual chopper, depending on the application. Referring now to FIGS. 31 and 33 , next, an embedment device, generally designated 370 is disposed in operational relationship to the slurry 346 and the moving carrier 314 of the production line 310 to embed the fibers 368 into the slurry 346 . While a variety of embedment devices are contemplated, including, but not limited to vibrators, sheep's foot rollers and the like, in the preferred embodiment, the embedment device 370 includes at least a pair of generally parallel shafts 372 mounted transversely to the direction of travel “T” of the carrier web 326 on the frame 312 . Each shaft 372 is provided with a plurality of relatively large diameter disks 374 which are axially separated from each other on the shaft by small diameter disks 376 . During SCP panel production, the shafts 372 and the disks 374 , 376 rotate together about the longitudinal axis of the shaft. As is well known in the art, either one or both of the shafts 372 may be powered, and if only one is powered, the other may be driven by belts, chains, gear drives or other known power transmission technologies to maintain a corresponding direction and speed to the driving roll. The respective disks 374 , 376 of the adjacent, preferably parallel shafts 372 are intermeshed with each other for creating a “kneading” or “massaging” action in the slurry, which embeds the fibers 368 previously deposited thereon. In addition, the close, intermeshed and rotating relationship of the disks 372 , 374 prevents the buildup of slurry 346 on the disks, and in effect creates a “self-cleaning” action which significantly reduces production line downtime due to premature setting of clumps of slurry. The intermeshed relationship of the disks 374 , 376 on the shafts 372 includes a closely adjacent disposition of opposing peripheries of the small diameter spacer disks 376 and the relatively large diameter main disks 374 , which also facilitates the self-cleaning action. As the disks 374 , 376 rotate relative to each other in close proximity (but preferably in the same direction), it is difficult for particles of slurry to become caught in the apparatus and prematurely set. By providing two sets of disks 374 which are laterally offset relative to each other, the slurry 346 is subjected to multiple acts of disruption, creating a “kneading” action which further embeds the fibers 368 in the slurry 346 . Once the fibers 368 have been embedded, or in other words, as the moving carrier web 326 passes the embedment device 370 , a first layer 377 of the SCP panel is complete. In the preferred embodiment, the height or thickness of the first layer 377 is in the approximate range of 0.05-0.20 inches. This range has been found to provide the desired strength and rigidity when combined with like layers in a SCP panel. However, other thicknesses are contemplated depending on the application. To build a structural cementitious panel of desired thickness, additional layers are needed. To that end, a second slurry feeder 378 , which is substantially identical to the feeder 344 , is provided in operational relationship to the moving carrier 314 , and is disposed for deposition of an additional layer 380 of the slurry 346 upon the existing layer 377 . Next, an additional chopper 382 , substantially identical to the choppers 336 and 366 , is provided in operational relationship to the frame 312 to deposit a third layer of fibers 384 provided from a rack (not shown) constructed and disposed relative to the frame 312 in similar fashion to the rack 331 . The fibers 384 are deposited upon the slurry layer 380 and are embedded using a second embedment device 386 . Similar in construction and arrangement to the embedment device 370 , the second embedment device 386 is mounted slightly higher relative to the moving carrier web 314 so that the first layer 377 is not disturbed. In this manner, the second layer 380 of slurry and embedded fibers is created. Referring now to FIG. 31 , with each successive layer of settable slurry and fibers, an additional slurry feeder station 344 , 378 , 402 followed by a fiber chopper 336 , 366 , 382 , 404 and an embedment device 370 , 386 , 406 is provided on the production line 310 . In the preferred embodiment, four total layers (see for example, the panel 101 of FIG. 29 ) are provided to form the SCP panel. Upon the disposition of the four layers of fiber-embedded settable slurry as described above, a forming device 394 is preferably provided to the frame 312 to shape an upper surface 396 of the panel. Such forming devices 394 are known in the settable slurry/board production art, and typically are spring-loaded or vibrating plates which conform the height and shape of the multi-layered panel to suit the desired dimensional characteristics. The panel which is made has multiple layers (see for example layers 22 , 24 , 26 , 28 of panel 101 of FIG. 29 ) which upon setting form an integral, fiber-reinforced mass. Provided that the presence and placement of fibers in each layer are controlled by and maintained within certain desired parameters as is disclosed and described below, it will be virtually impossible to delaminate the panel. At this point, the layers of slurry have begun to set, and the respective panels are separated from each other by a cutting device 398 , which in the preferred embodiment is a water jet cutter. Other cutting devices, including moving blades, are considered suitable for this operation, provided that they can create suitably sharp edges in the present panel composition. The cutting device 398 is disposed relative to the line 310 and the frame 312 so that panels are produced having a desired length, which may be different from the representation shown in FIG. 31 . Since the speed of the carrier web 314 is relatively slow, the cutting device 398 may be mounted to cut perpendicularly to the direction of travel of the web 314 . With faster production speeds, such cutting devices are known to be mounted to the production line 310 on an angle to the direction of web travel. Upon cutting, the separated panels 321 are stacked for further handling, packaging, storage and/or shipment as is well known in the art. Then the reinforcement members are inserted into the pattern downstream of the forming device 394 and adhered with glue or other means to the SCP panel in an insertion and attaching station 400 . If desired, the forming device 394 embosses the SCP panel to make indentations in the SCP panels and the reinforcement members are placed into the indentations in the insertion and attaching station 400 . In quantitative terms, the influence of the number of fiber and slurry layers, the volume fraction of fibers in the panel, and the thickness of each slurry layer, and fiber strand diameter on fiber embedment efficiency has been investigated. In the analysis, the following parameters were identified: v T =Total composite volume v s =Total panel slurry volume v f =Total panel fiber volume v f,l =Total fiber volume/layer v T,l =Total composite volume/layer v s,l =Total slurry volume/layer N l =Total number of slurry layers; Total number of fiber layers V f =Total panel fiber volume fraction d f =Equivalent diameter of individual fiber strand l f =Length of individual fiber strand t=Panel thickness t l =Total thickness of individual layer including slurry and fibers t s,l =Thickness of individual slurry layer n f,l , n f1,l , n f2,l =Total number of fibers in a fiber layer s f,l P , s f,l P , s f2,l P =Total projected surface area of fibers contained in a fiber layer S f,l P , S f1,l P , S f2,l P =Projected fiber surface area fraction for a fiber layer. Projected Fiber Surface Area Fraction, S f,l P Assume a panel composed of equal number of slurry and fiber layers. Let the number of these layers be equal to N l and the fiber volume fraction in the panel be equal to V f . In summary, the projected fiber surface area fraction, S f,l P of a layer of fiber network being deposited over a distinct slurry layer is given by the following mathematical relationship: S f , l P = 4 ⁢ ⁢ V f ⁢ t π ⁢ ⁢ N l ⁢ d f = 4 ⁢ ⁢ V f * t s , l π ⁢ ⁢ d f ⁡ ( 1 - V f ) where, V f is the total panel fiber volume fraction, t is the total panel thickness, d f is the diameter of the fiber strand, N l is the total number of fiber layers and t s,l is the thickness of the distinct slurry layer being used. Accordingly, to achieve good fiber embedment efficiency, the objective function becomes keeping the fiber surface area fraction below a certain critical value. It is noteworthy that by varying one or more variables appearing in the Equations 8 and 10, the projected fiber surface area fraction can be tailored to achieve good fiber embedment efficiency. Different variables that affect the magnitude of projected fiber surface area fraction are identified and approaches have been suggested to tailor the magnitude of “projected fiber surface area fraction” to achieve good fiber embedment efficiency. These approaches involve varying one or more of the following variables to keep projected fiber surface area fraction below a critical threshold value: number of distinct fiber and slurry layers, thickness of distinct slurry layers and diameter of fiber strand. Based on this fundamental work, the typical magnitudes of the projected fiber surface area fraction, S f,l P have been discovered to be as follows: Typical projected fiber surface area fraction, S f,l P <0.65 Another range of typical projected fiber surface area fraction, S f,l P <0.45 For a design panel fiber volume fraction, V f , achievement of the aforementioned preferred magnitudes of projected fiber surface area fraction can be made possible by tailoring one or more of the following variables—total number of distinct fiber layers, thickness of distinct slurry layers and fiber strand diameter. In particular, the desirable ranges for these variables that lead to the typical magnitudes of projected fiber surface area fraction are as follows: Thickness of Distinct Slurry Layers in Multiple Layer SCP Panels, t s,l Preferred thickness of distinct slurry layers, t s,l ≦0.20 inches More Preferred thickness of distinct slurry layers, t s,l ≦0.12 inches Most preferred thickness of distinct slurry layers, t s,l ≦0.08 inches Number of Distinct Fiber Layers in Multiple Layer SCP Panels, N l Preferred number of distinct fiber layers, N l ≧4 Most preferred number of distinct fiber layers, N l ≧6 Fiber Strand Diameter, d f Preferred fiber strand diameter, d f ≧30 tex Most preferred fiber strand diameter, d f ≧70 tex In using the panels as structural subflooring or flooring underlayment, they preferably will be made with a tongue and groove construction, which may be made by shaping the edges of the panel during casting or before use by cutting the tongue and groove with a router. Preferably, the tongue and groove will be tapered, as shown in FIGS. 3 and 4 A-C, the taper providing easy installation of the panels of the invention. Additional details of variations on the process and the amounts of fibers embedded in typical SCP panels for use in the present invention are provided by the following patents and patent applications: U.S. Pat. No. 6,986,812, to Dubey et al. entitled SLURRY FEED APPARATUS FOR FIBER-REINFORCED STRUCTURAL CEMENTITIOUS PANEL PRODUCTION, herein incorporated by reference in its entirety; and the following co-pending, commonly assigned, United States patent applications, all herein incorporated by reference in their entirety: United States Patent Application Publication No. 2005/0064164 A1 to Dubey et al., application Ser. No. 10/666,294, entitled, MULTI-LAYER PROCESS AND APPARATUS FOR PRODUCING HIGH STRENGTH FIBER-REINFORCED STRUCTURAL CEMENTITIOUS PANELS; United States Patent Application Publication No. 2005/0064055 A1 to Porter, application Ser. No. 10/665,541, entitled EMBEDMENT DEVICE FOR FIBER-ENHANCED SLURRY; U.S. patent application Ser. No. 11/555,647, entitled PROCESS AND APPARATUS FOR FEEDING CEMENTITIOUS SLURRY FOR FIBER-REINFORCED STRUCTURAL CEMENT PANELS, filed Nov. 1, 2006; U.S. patent application Ser. No. 11/555,655, entitled METHOD FOR WET MIXING CEMENTITIOUS SLURRY FOR FIBER-REINFORCED STRUCTURAL CEMENT PANELS, filed Nov. 1, 2006; U.S. patent application Ser. No. 11/555,658, entitled APPARATUS AND METHOD FOR WET MIXING CEMENTITIOUS SLURRY FOR FIBER-REINFORCED STRUCTURAL CEMENT PANELS, filed Nov. 1, 2006; U.S. patent application Ser. No. 11/555,661, entitled PANEL SMOOTHING PROCESS AND APPARATUS FOR FORMING A SMOOTH CONTINUOUS SURFACE ON FIBER-REINFORCED STRUCTURAL CEMENT PANELS, filed Nov. 1, 2006; U.S. patent application Ser. No. 11/555,665, entitled WET SLURRY THICKNESS GAUGE AND METHOD FOR USE OF SAME, filed Nov. 1, 2006; U.S. patent application Ser. No. 11/591,793, entitled MULTI-LAYER PROCESS AND APPARATUS FOR PRODUCING HIGH STRENGTH FIBER-REINFORCED STRUCTURAL CEMENTITIOUS PANELS WITH ENHANCED FIBER CONTENT, filed Nov. 1, 2006; U.S. patent application Ser. No. 11/591,957, entitled EMBEDMENT ROLL DEVICE, filed Nov. 1, 2006. Properties The SCP panel and frame systems employing such SCP panels (prior to including reinforcement) preferably have one or more of the properties listed in TABLES 2A-2D. A number of these properties will be improved by reinforcement while others, for example, mold and bacterial resistance are expected to remain substantially the same. TABLE 2A ASTM Preferred Physical Test Target Characteristics Method Unit Value Typical Range Notes Non-Combustibility E-136 Weight ≦50% ≦50% From Sec. 8, E-136 Loss Temp ≦54° F. ≦54° From Sec. 8, E-136 Rise 30 No No From Sec. 8, E-136 seconds flaming flaming Water Durability Flex. Strength of Sheathing Dry C-947 psi ≧1800 1400-3500 Wet C-947 psi ≧1650 1300-3000 AMOE of Sheathing Dry ksi ≧700  600-1000 Wet ksi ≧600 550-950 Screw Withdrawal (screw size: #8 wire 1⅝ inch screw with 0.25 inch diameter head minimum) ½″ Panel-Dry D-1761 pounds 352 250-450 Equiv. to American Plywood Assoc. (APA) S-4 ½″ Panel-Wet D-1761 pounds 293 200-400 % of force for SCP relative to OSB 82%; % of force for SCP relative to Plywood 80% ¾″ Panel-Dry D-1761 pounds 522 450-600 Equiv. to American Plywood Assoc. (APA) S-4 ¾″ Panel-Wet D-1761 pounds 478 450-550 % of force for SCP relative to OSB 82%; % of force for SCP relative to Plywood 80% TABLE 2B ASTM Preferred Physical Test Target Characteristics Method Unit Value Typical Range Notes Lateral Screw Screw size: #8 wire 1⅝ Resistance inch screw with 0.25 inch diameter head minimum ½″ Panel-Dry D-1761 pounds 445 350-550 Equiv. to APA S-4 ½″ Panel-Wet D-1761 pounds 558 400-650 % of force for SCP relative to OSB 73; % of force for SCP relative to Plywood 82% ¾″ Panel-Dry D-1761 pounds 414 400-500 Equiv. to APA S-4 ¾″ Panel-Wet D-1761 pounds 481 400-500 % of force for SCP relative to OSB 73; % of force for SCP relative to Plywood 82% Static & Impact Test (¾ inch thick SCP) Ultimate Static E-661 pounds 1286 1000-1500 APA S-1; 16 inch o.c. Span Rating ≧ 550 lbs. Following E-661 pounds 2206 1500-3000 APA S-1; 16 inch o.c. Impact Span Rating ≧ 400 lbs Deflection under 200 lb. Load Static E-661 inches 0.014 0.010-0.060 APA S-1; 16 inch o.c. Span Rating ≦ 0.078″ Following E-661 inches 0.038 0.020-0.070 APA S-1; 16 inch o.c. Impact Span Rating ≦ 0.078″ Uniform Load ¾″ Panel-Dry psf 330 300-450 16 inch o.c. Span Rating ≧ 330 psf Linear Expansion ½″ to ¾″ APA P-1 % ≦0.1 ≦0.1 APA P-1 requires ≦ 0.5% Panel TABLE 2C ASTM Preferred Physical Test Target Characteristics Method Unit Value Typical Range Notes Water Absorption ½″ Panel APA % 11.8  7 to 15 % water absorption of PRP-108 SCP relative to ½ inch thick OSB: 51.5%, % water absorption of SCP relative to ½ inch thick Plywood: 46.2% ¾″ Panel APA % 10.8  7 to 15 % water absorption of PRP-108 SCP relative to OSB: 51.3%, % water absorption of SCP relative to Plywood: 48.1% Thickness Swell ½″ Panel APA % 2.3 1 to 5 % water absorption of PRP-108 SCP relative to ½ inch thick OSB: 22.2%, % water absorption of SCP relative to ½ inch thick Plywood: 7.8% ¾″ Panel APA % 2.4 1 to 5 % water absorption of PRP-108 SCP relative to OSB: 22.2%, % water absorption of SCP relative to Plywood: 7.8% Mold & Bacteria Resistance ½ to ¾″ Panel G-21 1 0 to 1 OSB & Plywood have food source ½ to ¾″ Panel D-3273 10 10 OSB & Plywood have food source Termite Resistance ½ to ¾″ Panel No food No food source source TABLE 2D ASTM Preferred Physical Test Target Characteristics Method Unit Value Typical Range Notes Horizontal Design Shear Capacity of the Floor Diaphragm ¾″ Panel- E-455 pounds 487.2 300-1000 Performance relates to 10′ × 20′ per Typically 400-800 panel properties, Assembly linear joist depth & spacing and foot fastener type and spacing System Fire Resistance ⅝ to ¾″ SCP E-119 Time 1 hr and 1 to 1.5 hr. Nominal 4″ deep stud, Panel on one side of 10 min. 24″ O.C., metal frame batt insulation, 1 layer ⅝″ FIRECODE Gypsum Board available from USG. ¾″ Panel SCP on E-119 Time 1.5 hr to 2 hr - 1 to 2.5 hr Nominal 10″ deep joist, one side of metal 9 min or 24″ O.C., frame 1 to 2.25 hr batt insulation, 1 layer ⅝″ FIRECODE Gypsum Board available from USG ¾″ Panel SCP on E-119 Time 1.5 hr to 2 hr - 1.5 to 2.5 hr Nominal 10″ deep joist, one side of metal 9 min or 24″ O.C., frame 1.5 to 2.25 hr batt insulation, 2 layers ⅝″ FIRECODE Gypsum Board available from USG Horizontal Design Shear Capacity in Table 2D provides for a safety factor of 3. A typical ¾ inch (19 mm) thick panel when tested according to ASTM 661 and APA S-1 test methods over a span of 16 inches (406.4 mm) on centers, has an ultimate load capacity greater than 550 lb (250 kg), under static loading, an ultimate load capacity greater than 400 lb (182 kg) under impact loading, and a deflection of less than 0.078 inches (1.98 mm) under both static and impact loading with a 200 lb (90.9 kg) load. Typically, the flexural strength of a panel having a dry density of 65 lb/ft 3 (1040 kg/m 3 ) to 90 lb/ft 3 (1440 kg/m 3 ) or 65 lb/ft 3 (1040 kg/m 3 ) to 95 lb/ft 3 (1522 kg/m 3 ) after being soaked in water for 48 hours is at least 1000 psi (7 MPa), e.g. 1300 psi (9 MPa), preferably at least 1650 psi (11.4 MPa) more preferably at least 1700 psi (11.7 MPa) as measured by the ASTM C 947 test. Typically the horizontal shear diaphragm load carrying capacity of the system will not be lessened by more than 25%, preferably not be lessened by more than 20%, when exposed to water in a test wherein a 2 (5.1 cm) inch head of water is maintained over ¾ inch (1.9 cm) thick SCP panels fastened on a 10 foot by 20 foot (305×610 cm) metal frame for a period of 24 hours. Typically the system will not absorb more than 0.7 pounds per square foot of water when exposed to water in a test wherein a 2 inch head of water is maintained over ¾ inch thick SCP panels fastened on a 10 foot by 20 foot (305×610 cm) metal frame for a period of 24 hours. Typically an embodiment of the present system having a 10 foot wide by 20 foot (305×610 cm) long by ¾ inch thick diaphragm of the SCP panels attached to a 10 foot by 20 foot (305×610 cm) metal frame will not swell more than 5% when exposed to a 2 inch (5.1 cm) head of water maintained over the SCP panels fastened on the metal frame for a period of 24 hours. Typically, the present reinforced SCP panel meets ASTM G-21 in which the panel achieves approximately a 1 and meets ASTM D-3273 in which the system achieves approximately a 10. Also, typically the present system supports substantially zero bacteria growth when clean. Also, typically the present system is inedible to termites. Typically a non-combustible system for construction comprising: a shear diaphragm supported on metal frame, the shear diaphragm comprising the panel of the present invention and the frame comprising metal framing members, wherein the panel has a thickness of ¾ inch and has a racking strength ultimate load measured according to ASTM E72 racking from about 4400 to 7400 lbs. (1996 to 3357 kgs.) for an 8 foot by 8 foot wall assembly. This translates to a nominal wall racking shear strength of about 550 lbs per linear foot to 925 pounds per linear foot. For example, the racking strength ultimate load may be in the range of from about 4600 to about 6000 lbs. (2086 to 2721 kgs.) for an 8 foot by 8 foot wall assembly. This translates to a nominal wall racking shear strength of about 575 lbs per linear foot to 750 pounds per linear foot. The assembly for this ASTM E72 racking measurement is single sided and has 16 gage 3⅝ inch studs, 16 inches on center with fasteners 6 inches on center in the perimeter and 12 inches on center in the field. The panels for this ASTM E72 racking measurement are installed horizontally with no blocking in the cavities. The fasteners were #8-18×1⅝ inch long winged DRILLER BUGEL HEAD screws. Values for wall racking strength can vary for different gauge studs, different stud spacing or different fastener spacing. Thus, a typical range for wall racking strength ranges from 500-7000 plf, nominal racking shear strength. Wall Racking Strength is expressed in pounds per lineal foot, the ultimate load for a test specimen can be expressed as the max load on the test specimen as an entire unit, or in an ultimate load expressed in pounds per lineal foot, e.g., the width of the specimen. Typically, the panel when fastened to wall framing has racking shear strength between 1.1 and 3.0 times the racking shear strength of a similar dimensioned (sized) SCP panel without reinforcing fastened to the same wall framing with the same fasteners. EXAMPLES Test Specimen Diaphragm Materials Prototype ¾″ SCP—Structural Cement Panel of the present invention reinforced with fiberglass strands. A “V”-groove and tongue is located along the 8′ dimension of the 4′×8′ (122×244 cm) sheets. The formulation used in the SCP panel examples of this floor diaphragm test is listed in TABLE 3. TABLE 3 Ingredient Weight Percent (%) Reactive Powder Blend Portland Cement 29 Calcium Sulfate Alpha Hemihydrate 58 Silica Fume 12 Lime 1 SCP Cementitious Composition Portland Cement 12.2 Calcium Sulfate Alpha Hemihydrate 24.4 Silica Fume 5.1 Lime 0.4 Ceramic Microspheres 27.4 Superplasticizer 1.9 Water 24.2 Alkali-Resistant Glass Fibers 1 4.4 1 Weight proportion corresponds to 1.8% volume fraction of Alkali Resistant Glass Fibers in the composite. Length of glass fibers used in the floor diaphragm test - 36 mm. A total of 5 panels were tested. Each panel consisted of the same framing detail (16 ga 3⅝″ (9.2 cm) studs manufactured by Dietrich located 16″ (40.6 cm) on center), fastener layout (6″ (15.2 cm) on center on the perimeter, 12″ (30.5 in the field) and ¾″ SCP panels were all installed horizontally with no blocking in the cavities. All of the assemblies were single sided. Panel 1 is the base case with no additional metal reinforcement added. Panel 2 had a full sheet (4′×8′) (122×244 cm) piece of 22 gauge steel bonded to the back side. Panel 3 had 8″ (20.3 cm) wide strips of 22 gauge steel bonded along the 8′ dimension of the panel (similar to the embodiment of FIG. 5 ). The reinforcements of Panels 3 - 5 are glued to the surface of the panel to protrude from the panel surface. Panel 4 had 18″×18″ (46×46 cm) gussets bonded to all four corners of each SCP panel (similar to the embodiment of FIG. 10 , but the reinforcements protrude and there are no reinforcing members 56 ). Panel 5 had 18″×18″ (46×46 cm) gussets with folded over edges bonded to all 4 corners of each SCP panel (similar to Panel 4 but the gussets having folded over edges). The ultimate loads measured according to ASTM E72 racking were as follows (number in square brackets are the correlating indices): Panel 1 —4147 lb (1881 kg) [1] Panel 2 —7651 lb (3470 kg) [1.845] Panel 3 —5641 lb (2558 kg) [1.360] Panel 4 —4712 lb (2137 kg) [1.136] Panel 5 —3828 lb (1736 kg) [0.923] The failure modes for each panel were as follows: Panel 1 —fastener pull through around the perimeter Panel 2 —fastener pull through/shear around the perimeter. Metal unbonded and buckled on backside. Panel 3 —fastener pull through/shear around the perimeter. Metal unbonded and buckled on backside. Panel 4 —fastener pull through/shear around the perimeter. Metal unbonded and buckled on backside. Adhesive appeared not to be fully cured and still wet to the touch after test. Panel 5 —fastener shear around the perimeter initially then bending pull out of fasteners. Metal unbonded and buckled on backside. It should be noted here that due to the bent portion of the gusset that a 3/16″ space was present along the horizontal joint of the assembly. This will adversely affect the performance. FIG. 34 shows ASTM E72 Racking of these five 8 foot×8 foot samples with SCP installed horizontally on 16 gauge 3.624 steel studs at 16 inches on center with fastener layout of 6″ (15.2 cm) on center on the perimeter and 12″ (30.5 cm) in the field. While a particular embodiment of the system employing a horizontal diaphragm of fiber-reinforced structural cement panels on a metal frame has been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
This invention relates to a structural cementitious panel (SCP) panel able to resist lateral forces imposed by high wind and earthquake loads in regions where they are required by building codes. These panels may be used for shear walls, flooring or roofing or other locations where shear panels are used in residential or commercial construction. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of inorganic binder reinforced with glass fibers and containing lightweight filler particles. One or more reinforcement members, such as mesh or plate sheets, are bonded to at least one surface of the panel to provide a completed panel that can breathe and has weather resistant characteristics to be capable of sustaining exposure to the elements during construction, without damage.
8
CROSS REFERENCES TO RELATED APPLICATIONS The present application is a Continued Prosecution Application under 37 C.F.R. § 1.53(d) based upon parent application Ser. No. 08/683,818, now abandoned. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not Applicable REFERENCE TO A “MICROFICHE APPENDIX” Not Applicable BACKGROUND OF THE INVENTION This invention is directed generally to the fastener arts, but specifically to sealing fasteners having an undercut groove or channel in the underside of a fastener head for accommodating a sealing element, (specifically an o'ring type elastomer) to accomplish sealing engagement with a workpiece having a threaded or unthreaded aperture. In general sealing fasteners are well known in the art, spurred on by the space age when finding new ways to seal fasteners became a primary focus. Outdated methods such as copper washers, rtv sealant, etc. are still used to seal fasteners in some applications; however, as the sophistication our world increases, the need for reliable methods of sealing fasteners also becomes increasingly more crucial. That is why many of these inferior methods of sealing are gradually being phased out and replaced with more reliable sealing methods. One of the best ways to accomplish this task is to provide a formed groove or channel in a normally flat undersurface of the fastener head to accommodate a sealing element that is held captive in the fastener head, also achieving metal to metal contact with the workpiece and the outer rim of the fastener head. However, all previous designs have not properly calculated the groove in the fastener head. This causes sealing element failure. In static sealing threaded fastener designs, it is crucial that the groove be precisely calculated in depth, volume, angle, and configuration if one hopes to maintain a positive “seal line” between the sealed surfaces. Without a precisely calculated groove design, the sealing element will either compress too much or not compress enough. For example, by using too large a sealing element it will not have enough volumetric space to accommodate it and will, therefore, force the excess volume of the sealing element beyond the groove area, causing the sealing element to extrude and pinch between the screw and the workpiece in a process known as extruding “on the take down face”. Another problem associated with previous designs is a process known as compression set. A sealing element must maintain a continuous “seal line” between the sealed surfaces. The establishment of this “seal line” is a function of groove design and sealing element cross section which determines the proper amount of squeeze (compression) on the sealing element. When a sealing element volume is larger than the area sealed, it causes excessive squeeze on the sealing element. This excessive squeeze causes sealing element deformation and loss of seal integrity, therefore rendering the sealing element ineffective. A third problem with previous designs is a process known as installation damage. As the fastener is being assembled to the workpiece, the excessive compression of the sealing element causes it to stick between the end wall surface of the groove in the fastener head and the workpiece, thereby twisting and deforming the sealing element and/or causing sealing element extrusion as previously mentioned. When too small a sealing element is used, there is not enough compression on the sealing element to maintain a continuous “seal line” between the sealed surfaces rendering its sealing capabilities useless. As an additional matter, it is vital that fasteners of this type be cold formed without removal of material from the shank or head portion of the fastener since an alteration of this type weakens the grain flow structure of the fastener in a high stress area and greatly increases the chances of head separation either before or after the fastener is tightened to its proper torque specification. It is extremely important that these fasteners maintain the ability to withstand the stress involved when tightened to normal torque values. The main reason for a modification of this type is that during cold forming or roll forming threading operations there is generally an external screw thread of up to one and one half thread pitches of incomplete thread between the undersurface of the fastener head to where the thread begins on the fastener shank. This unthreaded portion would normally keep the mating surfaces from achieving adequate metal to metal contact thus preventing a positive seal. However, using a smaller diameter cold forming wire than is normally used when manufacturing similar products of the same diameter affords the flexibility necessary to maintain high quality while forming the fastener to the minimum pitch diameter. This in conjunction with limiting the unthreaded length from the head to a maximum of 1 incomplete thread assures a complete metal to metal engagement with a workpiece having a standard size threaded or unthreaded aperture. This eliminates the need for any alterations to the fastener as mentioned above and thereby maintains fastener integrity. BRIEF SUMMARY OF THE INVENTION It is the general object of this invention to provide a novel fastener having a formed groove or channel precisely calculated in depth, volume, angle and configuration to greatly improve reliability and substantially eliminate the problems associated with prior art design. A more specific object is to provide a fastener with a formed annular groove or channel having a sealing element completely captive in said groove and maintaining a continuous positive “seal line” between the fastener and the workpiece while maintaining a stable metal to metal contact between fastener head and the workpiece. Another object is to provide a fastener with a formed groove or channel in the shape of a trapezoid precisely calculated in depth, volume, and angle to achieve a predetermined percentage of compression on the sealing element preventing sealing element deformation and assuring sealing element reliability and reusability. It is another object to provide a fastener with a formed groove or channel in the shape of a parallelogram precisely calculated in depth, angle, and volume like the trapezoidal shaped groove to assures a continuous positive “seal line” in larger clearance hole applications. It is another object to manufacture a fastener with a formed groove or channel in such a way that assures complete mating of the fastener with the workpiece in metal to metal contact without materially altering the physical dimensions of the fastener, thereby retaining the shear and tension characteristics of the said fastener. This prevents head separation by maintaining the necessary strength to withstand the stress involved with using standard torque values. It is a related object to provide a fastener with a formed groove or channel of the highest quality, reliability of material, and performance. Our design has eliminated the guess work by precisely designing the fastener to assure confidence in aerospace applications, but at the same time, keeping the manufacturing costs down to make it affordable for all industries. It is another object to have a design method that is versatile enough to use in similar applications such as nuts & rivets and special product configurations. This allows the flexibility necessary to design new products quickly and easily without excessive cost to the customer and at the same time assuring fastener sealing reliability. A. An annular groove or channel formed in the undersurface of a threaded or unthreaded fastener head and combined there with a sealing element (o'ring). The fastener is comprised of a vertically disposed externally threaded elongate shank extending from an enlarged fastener head that contains an annular groove or channel substantially similar to the shape of a trapezoid formed in the essentially flat undersurface of the fastener head and combined there with a sealing element (specifically an o'ring type elastomer). The said fastener shank is designed to enter into complete engagement with a mating workpiece having an internally threaded or unthreaded aperture. When threaded the shank of the fastener has a screw thread profile that defines a minimum major or thread crest diameter, a minor diameter or thread root diameter, a pitch diameter, and flanks. The unthreaded portion of the fastener shank directly adjacent to the fastener head would have a maximum length of 1 incomplete thread. The said unthreaded diameter of the fastener shank is in accordance with the minimum pitch diameter as specified by IFI standards. The inner wall surface of the groove or channel begins from the periphery of the pitch diameter and is inclined up and outward concentric with the axis of the fastener shank to a predetermined depth, and there connects with a relatively flat annular end wall surface that extends radially outward concentric with the axis of the fastener shank and parallel to the undersurface of the fastener head. The outer wall of the groove having a decline down and outward concentric with the axis of the fastener shank that ends at the undersurface of the fastener head completing the trapezoidal shaped groove configuration. B. When used to seal a workpiece having an oversized threaded aperture the enlarged fastener head would be 1 to 5 times larger than the fastener head described above. This fastener head contains an annular groove or channel substantially similar to the shape of a parallelogram formed in the essentially flat undersurface of the fastener head and combined there with a sealing element (specifically an o'ring type elastomer).The shank of the fastener having a screw thread profile that defines a minimum major or thread crest diameter, a minor diameter or thread root diameter, a pitch diameter, and flanks. The said fastener shank is designed to enter into complete engagement with a workpiece having an oversized internally threaded aperture. The said groove has an inner wall surface that begins from the periphery of the theoretical pitch diameter (calculated as the pitch diameter of a fastener having a screw thread 1-2 sizes larger than the threaded aperture to be sealed) and is inclined up and inward frusta-conically concentric with the axis of the fastener shank and there connects with a relatively flat annular end wall surface that extends radially outward concentric with the axis of the fastener shank and parallel to the undersurface of the fastener head. The outer wall of said groove having a decline down and outward frusta-conically concentric with the axis of said fastener shank that ends at the point where the said outer wall meets the undersurface of the fastener head completing the parallelogram shaped groove configuration. C. The nut is comprised of a nut body that has an external wrenching portion normally of a conventional hexagonal configuration. The nut body has a nut face surface that is generally planar and normal to the axis of the said nut body. Incorporated through the nucleus of the nut body is a threaded bore. The said threaded bore having a screw thread profile that defines a minor diameter or thread crest diameter, a minimum major diameter or thread root diameter, and flanks. The nut body is designed to enter into complete engagement with a workpiece having an externally threaded stud or screw extruding from a threaded or unthreaded aperture. An annular groove substantially similar to the shape of a trapezoid is formed in the essentially flat nut face and is combined there with a sealing element (specifically an o'ring type elastomer). The said groove has an outer wall surface that begins at a precalculated outer groove dimension and is inclined up and inward frusta-conically concentric with the axis of the threaded bore, there it intersects with the relatively flat axially facing base surface or end wall surface that extends radially inward into the nucleus of the threaded bore concentric with the axis of the threaded bore and parallel to the nut face. As the sealing element is compressed between the end wall surface of the groove and the facing surface of the workpiece the sealing element has a controlled inward radial flow into the threaded bore to connect with the threads of the mating fastener shank. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS FIGS. 1A and 1B are an illustration of the basic concept of the threaded self-sealing fastener and self-sealing nut as employed in a through hole application. FIG. 2 is a threaded self-sealing fastener showing an enlarged view of the section that illustrates the sealing element in the trapezoid shaped groove prior to engagement with its mating surface. FIG. 3 is an enlarged view of a threaded self-sealing fastener that illustrates the sealing element in the trapezoid shaped groove and the sealing relationship with its mating surface at complete engagement. FIG. 4 is an enlarged view of a threaded self-sealing nut that illustrates the sealing element in the trapezoid shaped groove prior to engagement with its mating surface. FIG. 5 is an enlarged view of an oversized head threaded self-sealing fastener that illustrates the sealing element in the parallelogram shaped groove and the sealing relationship with its mating surface at complete engagement. FIG. 6 is an enlarged view of a threaded self-sealing nut that illustrates the sealing element and groove configuration similar to the trapezoidal shaped groove configuration as shown in FIGS. 2&3. Also illustrated is the sealing relationship with its mating part at complete engagement. FIG. 7 is an enlarged view of a prior art threaded sealing fastener that illustrates its inability to effectively seal and how its violation of fastener integrity effects the sealing relationship with its mating surface at complete engagement. FIG. 8 is an enlarged view of a non-threaded self-sealing solid rivet that illustrates the sealing element in the trapezoid shaped groove and the sealing relationship with its mating part at complete engagement. FIG. 9 is an enlarged view of a non-threaded structural self-sealing blind rivet that illustrates two separate sealing elements with trapezoidal shaped groove configurations similar to those as illustrated in FIGS. 2 , 3 & 6 . Also illustrated is the sealing relationship with their respective mating parts at complete engagement. DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings and initially to FIG. 7 . This undercut sealing threaded fastener in accordance with prior art construction will be described first. The fastener illustrated in FIG. 7 is substantially similar to the fastener construction shown in U.S. Pat. No. 4,701,088 by Crull, to which reference is also invited. It should be noted that the drawings of the Crull patent illustrates an ineffectual sealing fastener assembly. As shown in FIG. 7 removal of material from the fastener shank weakens the grain flow structure in a high stress area, thus when the fastener is tightened to standard torque specifications, head/shank separation is to be expected. The material removal also creates a significant gap between the fastener and workpiece. This in combination with groove angle and o'ring volume larger than the groove volume makes o'ring extrusion and/or o'ring compression set inevitable. However, Crull is considered to be the best prior art. As shown in FIG. 7 the prior art fastener 30 is in full engagement with the workpiece 42 . Metal has been removed at the area 56 of the fastener shank 32 . This was intended to allow the fastener shank 32 to freely advance in relation to the workpiece opening 60 . However, it should be noted that this removal of material from the area 56 of the fastener shank 32 disrupts the grain flow structure and weakens the fastener 30 in a high stress area 56 . This increases the likelihood of separation between the fastener head 34 and the fastener shank 32 at the unthreaded area 56 when the fastener 30 is tightened to normal torque standards. It should be further noted that in their method of sealing, Crull utilizes a sealing ring 48 preferably a torus in form and defines a volume greater than the volume defined by the undercut groove 44 . The material removal from the area 56 of the fastener shank 32 creates a significant gap at the workpiece opening 60 between the area 56 of the fastener shank 32 and the workpiece 42 . This material removal at the area 56 in conjunction with the oversized sealing ring 48 and the inner wall 64 angle of the groove 44 shown as 90 degrees from the unthreaded portion 56 into the fastener head 34 at the groove 44 causes the sealing ring 48 to extrude into the gap at the workpiece opening 60 as the fastener 30 is tightened to full engagement with the workpiece 42 . When this extrusion occurs it takes away from the volume of the sealing ring 48 in the groove 44 . This causes an inadequate “seal line” between the sealing ring 48 , the facing surface 42 A, and the end wall surface 66 . When external pressure is applied to the fastener head 34 the volume reduction increases allowing the fluid or pressure to pass around the sealing ring 48 causing the edges of the o'ring on the low pressure or downstream side of the groove to exhibit a chewed or chipped appearance as the “seal line” is corrupted. This fluid or pressure would follow a path traveling between the workpiece 42 and the fastener 30 more specifically at the point where the annular flat surface portion 70 of the workpiece 42 mates with the undersurface 46 of the fastener head 34 from there traveling up between the sealing ring 48 and the outer wall 68 of the groove 44 then between the sealing ring 48 and the end wall surface 66 and from there traveling down between the sealing ring 48 and the inner wall 64 of the groove 44 and through the workpiece opening 60 between the sealing ring 48 and the relieved area 56 of the fastener shank 32 into the component product that was to be sealed. This sealing ring is incorporated in a groove 44 with the inner wall 64 angle at substantially 90 degrees from the unthreaded portion 56 into the groove 44 and the outer wall 68 angle substantially 45 degrees relative to the axial direction of the fastener shank 32 . First it should be recognized that to have an inner wall 64 angle of 90 degrees from the unthreaded portion 56 into groove 44 is impractical and costly to manufacture. It should be further recognized that to have an inner wall 64 angle of 90 degrees from the unthreaded portion 56 into groove 44 and outer wall 68 angle substantially at 45 degrees will cause unequal distribution of the sealing ring volume 48 . This in conjunction with the oversized sealing ring 48 causes a problem known as installation damage that occurs when the fastener 30 is fastened to the workpiece 42 . The excess volume of the sealing ring 48 is forced out of the groove 44 . This in combination with the turning pressure applied to the sealing ring as it is compressed causes the sealing ring 48 to twist at 20 the same time it is pinched between the under surface 46 of the fastener head 34 and the annular flat surface portion 70 of the workpiece 42 . Not only does this cause the deformation of the sealing ring 48 compromising seal integrity, it also gives a spongy or false torque reading. This usually results in the fastener head 34 backing away from the workpiece 42 during the product operation. Again it should be noted that by incorporating a sealing ring 48 with a volume larger than the volume of the groove 44 that is to be filled will cause compression set and/or extrusion of the sealing ring 48 as previously described. Discussing now the effects of compression set which is a different variation of the same problem. As previously stated Crull utilizes a sealing ring 48 preferably a torus in form and defines a volume greater than the volume defined by the undercut groove 44 . This excess sealing ring 48 volume causes extreme compression (squeeze) on the sealing ring 48 as the sealing ring 48 is compressed between the end wall surface 66 of the groove 44 and the facing surface 42 A of the workpiece 42 . This extreme compression on the sealing ring 48 stresses the sealing ring 48 beyond its deflection endurance point causing the sealing ring 48 to lose seal integrity. The sealing ring 48 becomes permanently deformed into a flat sided oval shape, the flat sides of which were the original seal interface under compression before failure. This prevents the sealing ring 48 from exerting the necessary compression force to maintain a positive “seal line” between the end wall surface 66 of the groove 44 and the facing surface 42 A of the workpiece 42 . Turning now to FIGS. 1A-6. The obvious advantages of our novel threaded and unthreaded self-sealing fastener invention will be fully understood by the following detailed descriptions that demonstrate how the deficiencies of the prior art sealing fastener as illustrated in FIG. 7 have been avoided. FIGS. 1A and 1B are a full view of the basic concept of the threaded self-sealing fastener and self-sealing nut as employed in a through hole application. FIGS. 2-9 view only a partial section of the self-sealing fastener referenced as number 30 . It is to be understood that this fastener 30 may generally be considered as a bolt, screw, or rivet type fastener that is characterized by an elongated shank 32 that extends axially from an enlarged fastener head 34 of a generally cylindrical arrangement that contains an annular groove or channel 44 substantially similar to the shape of a trapezoid formed in the essentially flat undersurface 46 of the fastener head 34 and combined there with a sealing element 48 (specifically an o'ring type elastomer).or as in FIGS. 4&6 a self-sealing nut type fastener 12 that is characterized by a nut body 12 having a threaded center bore 13 through which the threads 28 of a mating fastener shank 75 contact axially, and having an annular groove 44 substantially similar to the shape of a trapezoid formed in the essentially flat nut face 22 that is combined there with a sealing element 48 (specifically an o'ring type elastomer). The head 34 or the nut body 12 may vary considerably in dimension, style, or configuration although the basic concept of the groove 44 design would remain the same. Referring first to the threaded self-sealing fastener 30 with a trapezoidal shaped groove 44 as illustrated in FIGS. 2&3, the fastener shank 32 of the fastener 30 has screw threads defined by reference number 33 . These threads 33 , define a minimum major or thread crest diameter 36 , a minor diameter or thread root diameter 31 , flanks 35 , a pitch diameter shown generally by reference number 43 , and the unthreaded diameter defined by reference number 40 . This unthreaded diameter 40 is substantially similar to the minimum pitch diameter as specified by IFI standards. This unthreaded diameter 40 has an unthreaded grip length 37 that begins at the periphery of the pitch diameter 41 directly adjacent to the fastener head 34 and extends axially outward from the fastener head 34 on the fastener shank 32 and ends at point 38 on the fastener shank 32 being a maximum of 1 incomplete thread from the fastener head 34 . The self-sealing fastener 30 as shown in FIGS. 2&3 has a fastener shank 32 that is formed with a cold forming wire that is substantially equal with the minimum pitch diameter of the screw. This diameter wire is smaller than the cold forming wire that is normally used when manufacturing similar products of the same diameter. This assures that the fastener 30 will maintain high quality while forming the fastener shank 32 to the minimum pitch diameter. This in conjunction with limiting the unthreaded grip length 37 of the unthreaded diameter 40 on the fastener shank 32 directly adjacent to the fastener head 34 to a maximum of 1 incomplete thread assures that the fastener 30 will achieve a complete metal to metal engagement between the outer rim 70 of the fastener head 34 and the facing surface 42 a of the workpiece 42 having an internally threaded aperture with the standard thread run out. This eliminates the need for material removal from the unthreaded diameter 40 of the fastener shank 32 as in the case of prior art design as illustrated in FIG. 7 . In addition to being practical and inexpensive to manufacture, our design significantly decreases the gap at the workpiece opening 60 allowing the fastener 30 to achieve a closer tolerance between the fastener shank 32 at the unthreaded diameter 40 of the fastener 30 . This in conjunction with precisely calculating the sealing element 48 maximum or uncompressed volume to be substantially similar to the minimum volume of the trapezoid shaped groove 44 allows the sealing element 48 to be held completely captive within the groove 44 and eliminates the possibility of o'ring extrusion between the unthreaded diameter 40 of the fastener shank 32 and the workpiece opening 60 of the workpiece 42 . As the fastener shank 32 is brought into engagement with the threads 27 of mating workpiece 42 the sealing element 48 is equally distributed within the groove 44 and the fastener head 34 of the fastener 30 is brought into complete metal to metal engagement between the outer rim 70 of the fastener head 34 and the facing surface 42 a of the workpiece 42 . Without the removal of material from the unthreaded diameter 40 of the fastener shank 32 the fastener 30 maintains an uninterrupted material grain flow structure. Thus the fastener 30 retains the tensile and tension characteristics necessary to maintain fastener integrity in this high stress area (unthreaded diameter 40 ) eliminating the danger of head separation when the fastener head 34 of the fastener 30 is tightened into full engagement with the workpiece 42 using standard torque values. From the periphery of the pitch diameter 41 the inner wall 92 of the groove 44 is inclined up and outward into the fastener head 34 frusta-conically concentric with the axis of the fastener shank 32 substantially in the order of 10 degrees forming the inner wall 92 of the groove 44 , at this juncture the inner wall 92 intersects with the relatively flat end wall surface 66 . This end wall surface 66 extends radially outward concentric with the axis of the fastener shank 32 and intersects with the outer wall 93 which declines down and outward fiusta-conically concentric with the axis of the fastener shank 32 substantially in the order of 10 degrees ending at the undersurface of the fastener head 34 , and creating a groove configuration that is substantially similar to the shape of a trapezoid. This trapezoidal shaped groove 44 configuration is incorporated with a sealing element 48 the material of which is generally composed of but not limited to a rubber or rubber based composition and is ideally a torus in cross sectional configuration. The inner wall 92 and the outer wall 93 of the groove 44 enter into the fastener head 34 to connect with the end wall surface 66 substantially equal in wall depth and degree of angle, the wall angles being substantially in the order of 10 degrees. This is vital to assure a proper seating of the sealing element 48 within the groove 44 . The maximum sealing element 48 volume is substantially similar to the minimum volume of the trapezoidal shaped groove 44 . This in conjunction with the inner wall 92 and the outer wall 93 of the groove 44 being substantially equal in wall depth and degree of angle forces the sealing element 48 to be equally distributed within the groove 44 . As the sealing element 48 is compressed to its precalculated rate the sealing element 48 extends radially outward concentric with the axis of the fastener shank 32 being guided and held captive by the inner wall 92 of the groove 44 and the outer wall 93 of the groove 44 forcing the sealing element 48 into a perfect seat within the groove 44 and eliminating the possibility of installation damage as the fastener 30 is brought into complete engagement with the mating workpiece 42 . A positive metal to metal engagement is achieved between the outer rim 70 of the fastener head 34 and the facing surface 42 a of the workpiece 42 . This eliminates sealing element 48 extrusion in this area and prevents the fastener 30 from backing away from the workpiece 42 as the fastener 30 is tightened into full engagement with the relative workpiece 42 . Metal to metal contact is also necessary to achieve an accurate torque reading as the fastener 30 is tightened to normal torque specifications. The inside diameter of the sealing element 48 is slightly smaller than the inner wall 92 diameter of the groove 44 where the inner wall 92 intersects with the periphery of the pitch diameter 41 at the base of the groove 44 on the fastener shank 32 . This causes the retention of the sealing element 48 in the groove 44 prior to engagement with mating workpiece 42 . As previously stated the sealing element 48 is designed not to exceed the volume of the groove 44 by having a maximum or uncompressed sealing element 48 volume that would be substantially similar to the minimum volume of the trapezoidal shaped groove 44 , keeping in mind the outward radial flow of the sealing element 48 so that the groove 44 would receive and accommodate the full volume of the sealing element 48 . The sealing element 48 is compressed (squeezed) between the end wall surface 66 of the groove 44 and the facing surface 42 a of the workpiece 42 to a percentage that is precisely calculated to apply pressure on the sealing element 48 making the sealing element 48 compression a minimum of 25%; this is the minimum compression force necessary to assure a continuous positive “seal line” between all sealed surfaces. A maximum sealing element 48 compression of 40% is necessary to maintain seal integrity. Keeping the sealing element 48 compression below the deflection endurance point of approximately 42% prevents sealing element 48 deformation and also retains the proper seal interface under compression assuring a continuous positive “seal line” between all sealed surfaces, and eliminating the possibility of compression set, as is common with excessive sealing element 48 compression (squeeze) such as is illustrated with the prior art fastener design of FIG. 7 . Our design is created to maximize the optimum sealing performance of the sealing element 48 , and to maintain seal integrity providing a completely reliable and reusable product. Referring now to the threaded self-sealing fastener with a parallelogram shaped groove as illustrated in FIG. 5 . This fastener 30 is similar the fastener 30 with the trapezoidal shaped groove 44 as illustrated in FIGS. 2&3. However, the differences and purpose of this fastener will be fully understood by the following description of FIG. 5 . This fastener 30 contains a fastener head 34 that may vary considerably in dimension, style, or configuration. This fastener 30 may generally be considered as a bolt, screw, or rivet type fastener that is characterized by an elongated shank 32 that extends axially from an enlarged fastener head 34 of a generally cylindrical arrangement that contains an annular groove or channel 44 substantially similar to the shape of a parallelogram formed in the essentially flat undersurface 46 of the fastener head 34 and combined there with a sealing element 48 (specifically an o'ring type elastomer). The fastener shank 32 of the fastener 30 has screw threads defined by reference number 33 . These threads 33 , define a minimum major or thread crest diameter 36 , a minor diameter or thread root diameter 31 , and flanks 35 . No reference is made to a pitch diameter since the pitch diameter is not crucial to this design. However, instead of the standard pitch diameter a theoretical pitch diameter is shown and is generally referenced by number 47 . This fastener 30 is used primarily in applications where the threaded aperture 60 of the workpiece 42 is oversized to the extent that it would not allow the sealing element 48 in the trapezoidal groove configuration 44 , as illustrated in FIGS. 2&3, to achieve a proper seal engagement with the workpiece 42 and therefore a positive “seal line” could not be achieved between the groove 44 in the fastener head 34 and the workpiece 42 . To accommodate the parallelogram shaped groove 44 the head 34 size is one to five times larger than the head 34 size of the fastener 30 with the trapezoidal shaped groove 44 as illustrated in FIGS. 2&3 that would normally be used to seal a threaded aperture of this diameter. The inner wall 92 of the groove 44 has an outside diameter that is larger than the outside diameter of the threaded aperture 60 . This section is referred to as the theoretical pitch diameter 47 . From the periphery of this theoretical pitch diameter 47 , the inner wall 92 of the groove 44 inclines up and inward into the fastener head 34 frusta-conically concentric with the axis of the fastener shank 32 substantially in the order of 20 degrees into the groove 44 , and there intersects with the relatively flat end wall surface 66 . This end wall surface 66 extends radially outward concentric with the axis of the fastener shank 32 and parallel with the relatively flat undersurface 46 of fastener head 34 and at this juncture intersects with the outer wall 93 of the groove 44 which declines down and outward frusta-conically concentric with the axis of the fastener shank 32 at an angle substantially in the order of 20 degrees ending at the undersurface 46 of the fastener head 34 creating a groove 44 configuration substantially similar to the shape of a parallelogram. The inner wall 92 and the outer wall 93 enter into the fastener head 34 to intersect with the end wall surface 66 substantially equal in wall depth and degree of angle. The inside diameter of the sealing element 48 is smaller than the theoretical pitch diameter 47 . The sealing element 48 is designed to stretch up to 5% upon assembly into the fastener head 34 and snaps securely in place being held captive within the groove 44 . This causes the retention of the sealing element 48 in the groove 44 even prior to assembly with the mating workpiece 42 . This parallelogram shaped groove 44 configuration is incorporated with a sealing element 48 , the material of which is generally composed of but not limited to a rubber or rubber based composition, which is ideally a torus in cross sectional configuration. The inner wall 92 and the outer wall 93 of the groove 44 enter into the fastener head 34 to connect with the end wall surface 66 substantially equal in wall depth and degree of angle, the wall angles being substantially in the order of 20 degrees. This is vital to assure a proper seating of the sealing element 48 within the groove 44 . The maximum sealing element 48 volume is substantially similar to the minimum volume of the parallelogram shaped groove 44 . This in conjunction with the inner wall 92 and the outer wall 93 of the groove 44 being substantially equal in wall depth and degree of angle forces the sealing element 48 to be equally distributed within the groove 44 . As the sealing element 48 is compressed to its precalculated rate the sealing element 48 extends radially outward concentric with the axis of the fastener shank 32 being guided and held captive by the inner wall 92 of the groove 44 and the outer wall 93 of the groove 44 forcing the sealing element 48 into a perfect seat within the groove 44 and eliminating the possibility of installation damage as the fastener 30 is brought into complete engagement with the mating workpiece 42 . A positive metal to metal engagement is achieved between the outer rim 70 of the fastener head 34 and the facing surface 42 a of the workpiece 42 . This eliminates sealing element 48 extrusion in this area and prevents the fastener 30 from backing away from the workpiece 42 as the fastener 30 is tightened into fill engagement with the relative workpiece 42 . Metal to metal contact is also necessary to achieve an accurate torque reading as the fastener 30 is tightened to normal torque specifications. As previously stated the sealing element 48 is designed not to exceed the volume of the groove 44 by having a maximum sealing element 48 volume that would be substantially similar to the minimum volume of the parallelogram shaped groove 44 , keeping in mind the outward radial flow of the sealing element 48 so that the groove 44 would receive and accommodate the f u ill volume of the sealing element 48 . The sealing element 48 is compressed (squeezed) between the end wall surface 66 of the groove 44 and the facing surface 42 a of the workpiece 42 to a percentage that is precisely calculated to apply pressure on the sealing element 48 making the sealing element 48 compression a minimum of 25%; this is the minimum compression force necessary to assure a continuous positive “seal line” between all sealed surfaces. A maximum sealing element 48 compression of 40% is necessary to maintain seal integrity. Keeping the sealing element 48 compression below the deflection endurance point of approximately 42% prevents sealing element 48 deformation and also retains the proper seal interface under compression assuring a continuous positive “seal line” between all sealed surfaces, and eliminating the possibility of compression set, as is common with excessive sealing element 48 compression. Our design is created to maximize the optimum sealing performance of the sealing element 48 , and to maintain seal integrity providing a completely reliable and reusable product. Referring now to the threaded self-sealing nut as illustrated in FIGS. 4&6 of our drawings. This nut 12 has a groove 44 design similar to that of the trapezoidal shaped groove 44 as illustrated in FIGS. 2&3 previously described. The nut body 12 generally has an external wrenching portion 15 and is normally of a conventional hexagonal configuration. The nut body 12 has a nut face surface 22 that is generally planar and normal to the axis of the nut body 12 and having a threaded bore 13 through the nucleus of the nut body 12 . This threaded bore 13 having a screw thread profile that defines a minor diameter or thread crest diameter 17 , a minimum major diameter or thread root diameter 19 , and flanks 20 . The said nut body 12 is designed to enter into complete engagement with a workpiece having an externally threaded shank 75 extruding from the aperture 60 of the workpiece 42 . An annular groove 44 is formed in the nut face 22 defined by a frusta-conical radial inward annular wall surface 16 and an axially facing base surface or end wall surface 66 . Beginning at the point where the nut face 22 intersects with the outer wall 16 of the groove 44 , this outer wall 16 is inclined up and inward substantially in the order of 10 degrees frusta-conically concentric with the axis of the threaded bore 13 penetrating into the nut body 12 forming the outer wall 16 of the groove 44 . There it intersects with a relatively flat end wall surface 66 . This end wall surface 66 extends radially inward into the nucleus of the threaded bore 13 concentric with the axis of the threaded bore 13 and parallel with the nut face 22 . This assures that the entrance of the outward radial flow of the sealing element 48 will completely engage with the threads 28 of the mating fastener shank 75 . The inner wall being the threads 28 of the mating fastener shank 75 in conjunction with the outer wall 16 of the groove 44 creates a groove 44 configuration that is substantially similar to the shape of a trapezoid. This trapezoidal shaped groove 44 configuration is incorporated with a sealing element 48 that is bonded to the end wall surface 66 of the groove 44 . The sealing element 48 material is composed of but not limited to a rubber or rubber based composition and is ideally a torus in cross sectional configuration. The sealing element 48 volume in this design differs from that of the groove 44 design in FIGS. 2 , 3 & 5 previously illustrated in that the threads 28 of the mating fastener shank 75 act as the inner wall of the groove 44 as illustrated in FIGS. 4&6 of our drawings. Therefore, this design not only accounts for the volume of the actual groove 44 but also for the volume of the outward radial flow of the sealing element 48 into the threads 28 of the mating fastener shank 75 . As the nut body 12 is tightened into full engagement with the mating workpiece 42 , the sealing element 48 is guided by the outer wall 16 of the groove 44 . As the sealing element 48 is compressed between the end wall surface 66 of the groove 44 and the face surface 42 a of the workpiece 42 . The sealing element 48 being held captive by the outer wall 16 of the groove 44 forces the sealing element 48 to extend radially inward concentric with the axis of the threaded bore 13 , this forces the sealing element 48 into a perfect seal within the groove 44 . At the same time the sealing element 48 having a controlled inward radial flow into the threaded bore 13 achieves a positive seal engagement with the threads 28 of the mating fastener shank 75 and the nut 12 is brought into complete engagement with the mating workpiece 42 . A positive metal to metal engagement is achieved between the outer rim 24 of the nut 12 and the facing surface 42 a of the workpiece 42 . This eliminates sealing element 48 extrusion in this area and prevents the nut 12 from backing away from the workpiece 42 as the nut 12 is tightened to full engagement with the relative workpiece 42 . Metal to metal contact is also necessary to achieve an accurate torque reading as the nut 12 is tightened to normal torque specifications. As previously stated this groove design as illustrated in FIGS. 4&6 differs from the groove 44 design in FIGS. 2 , 3 & 5 previously illustrated in that the threads 28 of the mating fastener shank 75 act as the inner wall of the groove 44 by accounting for the inward radial flow of the sealing element 48 the groove 44 would receive and accommodate the full volume of the sealing element 48 . This assures a positive engagement between the sealing element 48 and the threads 28 of the mating fastener shank 75 . As this occurs the sealing element 48 is compressed (squeezed) between the end wall surface 66 of the groove 44 and the facing surface 42 a of the workpiece 42 to a percentage that is precisely calculated to apply pressure on the sealing element 48 making the sealing element 48 compression a minimum of 25%. This is the minimum compression force necessary to assure a continuous positive “seal line” between all sealed surfaces. A maximum sealing element 48 compression of 40% is necessary to maintain seal integrity. Keeping the sealing element 48 compression below the deflection endurance point of approximately 42% prevents sealing element 48 deformation and also retains the proper seal interface under compression assuring a continuous positive “seal line” between all sealed surfaces, and eliminating the possibility of compression set, as is common with excessive sealing element 48 compression. Our design is created to maximize the optimum sealing performance of the sealing element 48 , and to maintain seal integrity providing a completely reliable and reusable product. Referring now to the unthreaded self-sealing fastener 20 as illustrated in FIG. 8 of our drawings. This unthreaded fastener 20 contains a fastener head 34 that may vary considerably in dimension, style, or configuration. This fastener 20 may generally be considered as a solid rivet type self-sealing fastener 20 that is characterized by a vertically disposed unthreaded elongated shank 32 that extends axially from an enlarged fastener head 34 that contains an annular groove or channel 44 substantially similar to the shape of a trapezoid formed in the essentially flat undersurface 46 of the fastener head 34 and is combined there with a sealing element 48 (specifically an o'ring type elastomer). With the exception of the unthreaded fastener shank 32 , this fastener 20 is substantially similar to the fastener 30 with the trapezoidal shaped groove 44 configuration as shown in FIGS. 2&3 of our drawings. Since the only difference between this fastener 20 and the fastener 30 , as shown in FIGS. 2&3, is the way in which the fastener 20 is secured to the workpiece 42 instead of reiterating that which has already been described in detail, namely the groove 44 information as shown in FIGS. 2&3, we will instead focus on how this fastener 20 differs from the fastener 30 of FIGS. 2&3. This fastener 20 is designed to be inserted into a standard size unthreaded aperture 60 of a workpiece 42 in order to join the workpiece 42 with the workpiece 40 to make one component by forcing the workpiece 42 into full metal to metal engagement with the workpiece 40 . The unheaded portion 62 of the fastener shank 32 extends beyond the unthreaded aperture 60 of the workpiece 42 . This extended portion 62 of the fastener shank 32 would by the use of a solid rivet tool have pressure applied to both the extended portion 62 of the fastener shank 32 and the rivet head 34 simultaneously. This pressure causes the rivet shank 32 at the extended portion 62 to collapse up and outward against the workpiece 42 in the direction of the rivet head 34 securing the workpiece 40 with the workpiece 42 , as the compressed material 49 forms the head 81 from the previously extended portion 62 of the rivet shank 32 . At the same time the rivet head 34 is moved into complete metal to metal engagement with the workpiece 40 , the head 81 is formed from the previously extended material 62 and moved into complete metal to metal engagement with the workpiece 42 , thus securing the two workpieces and the rivet in place, while assuring a positive “seal line” with all sealed surfaces. Now referring to the blind rivet of FIG. 9 . This unthreaded blind rivet 20 contains a fastener head 34 that may vary considerably in dimension, style, or configuration. This blind rivet 20 is generally considered as a structural flush break mechanically locked pull mandrel type self-sealing blind rivet 20 that is characterized by an unthreaded elongate shank 32 that extends axially from an enlarged fastener head 34 of a generally cylindrical arrangement. This blind rivet 20 assembly has an unthreaded aperture 65 through the nucleus of the blind rivet body 20 . This unthreaded aperture extends vertically from the top of the rivet head 34 to the end of the rivet shank 32 . This rivet 20 incorporates a mandrel 67 through the center of the aperture 65 in the blind rivet body 20 . This mandrel 67 mates with a self-sealing locking collar 45 at the trapezoidal shaped indention 49 in the enlarged fastener head 34 . A more detailed description is as follows; the mandrel 67 has a pre-formed head 25 having a semi-rounded cylindrical top surface 12 and a relatively flat under-surface 86 . This mandrel 67 also has mating collar locking teeth 85 on the mandrel shank 69 . These mating collar locking teeth 85 are angled down and out in the direction of the mandrel head 25 substantially in the order of 72 degrees. This mandrel shank 69 also has a threaded portion 78 at the end of the mandrel shank 69 opposite the mandrel head 25 . This threaded portion 78 mates with a mandrel pull tool to apply pulling pressure to the rivet body 20 . This pulling pressure draws the mandrel 67 away from the rivet head 34 causing the rivet shank 32 to be pulled through the aperture 65 forcing the rivet head 34 into complete engagement with the workpiece 42 . The collar 45 is a generally cylindrical arrangement. The outer wall 82 of the collar 45 is inclined up and outward from the collar face 72 frusta-conically concentric with the axis of the unthreaded aperture 65 substantially in the order of 25 degrees. The inner wall 50 angle is substantially in the order of 90 degrees through the nucleus of the collar 45 and the locking teeth 84 are angled up and inward substantially in the order of 72 degrees in the direction of the nucleus of the unthreaded aperture 65 opposite the direction of the collar face 72 . This collar face 72 has a groove or channel 54 . This groove 54 is substantially similar to the nut groove 44 design as illustrated in FIG. 6 . As the blind rivet 20 is mated with the workpiece 42 , the mandrel 67 has a pulling pressure applied at the threaded portion 78 of the mandrel 67 . This pressure pulls the mandrel 67 through the aperture 65 at the nucleus of the rivet body 20 . At the same time the pressure is applied to the threaded portion 78 , it is also applied to the collar 45 at the pull tool face 38 and at the mandrel undersurface 86 of the mandrel head 25 . As this pressure is applied to the collar 45 , it causes the collar 45 to engage with the mating locking teeth 85 of the mandrel 67 and pressure is also applied to the mandrel head 25 . This causes the rivet shank 32 to collapse at a pre-calculated rate moving the material next to the workpiece 42 to form a head 92 at the workpiece 42 opposite the rivet head 34 and securing the rivet 20 to the workpiece 42 . When this pressure is applied to the collar 45 , it forces the collar 45 into complete engagement with the trapezoidal shaped indention 49 in the fastener head 34 and metal to metal contact between the mating wall surface 47 and the angled wall surface 82 of the collar 45 is achieved. As the collar 45 engages with the trapezoidal shaped indention 49 in the fastener head 34 , the sealing element 46 (which is generally composed of but not limited to a rubber based composition and is ideally a torus in cross sectional configuration) is guided by the outer wall 17 of the groove 54 causing the sealing element to be compressed between the end wall surface 16 of the groove 54 and the collar face surface 72 in the rivet head 34 . This groove 54 design in FIG. 9 is substantially similar to the groove 44 design as illustrated in FIGS. 4&6. The sealing element 46 volume in this design differs from that of the groove 44 design in FIGS. 2 , 3 & 5 as illustrated in that the mating collar locking teeth 85 of the mandrel 67 act as the inner wall of the groove 54 as illustrated in FIG. 9 of our drawings. Therefore, this design not only accounts for the volume of the actual groove 54 but also for the volume of the outward radial flow of the sealing element 46 into the mating collar locking teeth 85 of the mandrel 67 . This assures that the sealing element 46 while being held captive in the groove 54 has a controlled inward radial flow into the nucleus of the rivet body 20 to connect into complete engagement with the mating collar locking teeth 85 of the mandrel 67 creating a positive seal. The distance between the end wall surface 16 of the groove 54 and the facing collar mating surface 72 is precisely calculated to apply pressure on the sealing element 46 and accounting for the inward radial flow of the sealing element 46 and the engagement of the sealing element 46 , with the mating collar locking teeth 85 of the mandrel 67 , the sealing element 46 squeeze would be a minimum of 25% assuring a continuous “seal line” between the sealed surfaces and a maximum squeeze of 40% to prevent sealing element 46 compression set thus maintaining a reliable seal. As pressure is applied to the mandrel 67 , the tensile stress required for separation of the mandrel 67 is achieved at the precalculated mandrel breaking area 36 and the mandrel 67 breaks off flush with the top of the rivet head 34 . As the mandrel 67 breaks off flush with the rivet head 34 , the locking teeth 84 of the collar 45 snap back and lock tight with the mating collar locking teeth 85 on the mandrel 67 into full metal to metal engagement. This in turn brings the rivet head 34 into fill engagement with the workpiece 42 . As previously stated this enlarged fastener head 34 contains a formed groove or channel 44 in the undersurface 41 of the said head 34 that incorporates a sealing element 48 that is held captive in the groove 44 . Now describing the groove 44 as shown in FIG. 9 . This groove 44 is substantially similar to that of the trapezoidal shaped groove 44 configuration as illustrated in FIGS. 2&3 of our drawings. From the periphery of the pitch diameter 41 the inner wall 92 of the groove 44 is inclined up and outward into the rivet head 34 frusta-conically concentric with the axis of the fastener shank 32 substantially in the order of 10 degrees forming the inner wall 92 of the groove 44 , at this juncture the inner wall 92 intersects with the relatively flat end wall surface 66 . This end wall surface 66 extends radially outward concentric with the axis of the fastener shank 32 and intersects with the outer wall 93 which declines down and outward frusta-conically concentric with the axis of the fastener shank 32 substantially in the order of 10 degrees ending at the undersurface of the rivet head 34 , creating a groove 44 configuration that is substantially similar to the shape of a trapezoid. This trapezoidal shaped groove 44 configuration is incorporated with a sealing element 48 the material of which is generally composed of but not limited to a rubber or rubber based composition and is ideally a torus in cross sectional configuration. The inner wall 92 and the outer wall 93 of the groove 44 enter into the rivet head 34 to connect with the end wall surface 66 substantially equal in wall depth and degree of angle, the wall angles being substantially in the order of 10 degrees. This is vital to assure a proper seating of the sealing element 48 within the groove 44 . The maximum sealing element 48 volume is substantially similar to the minimum volume of the trapezoidal shaped groove 44 . This in conjunction with the inner wall 92 and the outer wall 93 of the groove 44 being substantially equal in wall depth and degree of angle forces the sealing element 48 to be equally distributed within the groove 44 . As the sealing element 48 is compressed to its precalculated rate the sealing element 48 extends radially outward concentric with the axis of the fastener shank 32 being guided and held captive by the inner wall 92 of the groove 44 and the outer wall 93 of the groove 44 forcing the sealing element 48 into a perfect seat within the groove 44 and eliminating the possibility of installation damage as the rivet 20 is brought into complete engagement with the mating workpiece 42 . A positive metal to metal engagement is achieved between the outer rim 70 of the rivet head 34 and the facing surface 42 a of the workpiece 42 . This eliminates sealing element 48 extrusion in this area and prevents the rivet 20 from backing away from the workpiece 42 as the rivet 20 is tightened into full engagement with the relative workpiece 42 . The inside diameter of the sealing element 48 is slightly smaller than the inner wall 92 diameter of the groove 44 where the inner wall 92 intersects with the periphery of the pitch diameter 41 at the base of the groove 44 on the rivet shank 32 . This causes the retention of the sealing element 48 in the groove 44 prior to engagement with mating workpiece 42 . As previously stated the sealing element 48 is designed not to exceed the volume of the groove 44 by having a maximum sealing element 48 volume that would be substantially similar to the minimum volume of the trapezoidal shaped groove 44 , keeping in mind the outward radial flow of the sealing element 48 so that the groove 44 would receive and accommodate the full volume of the sealing element 48 . The sealing element 48 is compressed (squeezed) between the end wall surface 66 of the groove 44 and the facing surface 42 a of the workpiece 42 to a percentage that is precisely calculated to apply pressure on the sealing element 48 making the sealing element 48 compression a minimum of 25%, this is the minimum compression force necessary to assure a continuous positive “seal line” between all sealed surfaces. A maximum sealing element 48 compression of 40% is necessary to maintain seal integrity. Keeping the sealing element 48 compression below the deflection endurance point of approximately 42% prevents sealing element 48 deformation and also retains the proper seal interface under compression assuring a continuous positive “seal line” between all sealed surfaces, and eliminating the possibility of compression set, as is common with excessive sealing element 48 compression (squeeze). Our design is created to maximize the optimum sealing performance of the sealing element 48 , and to maintain seal integrity providing a completely reliable product. We have described only the preferred form and application of our invention. It is intended that this present invention not be limited or restricted to the specific details as described herein, but that we reserve the right to any variations or modifications that may appear to those skilled in the art without departing from the spirit or scope of our invention as defined in the appended claims.
A fastener is disclosed for sealed engagement with a workpiece. The fastener has a head having a lower face, and a shank extends from the lower surface of the head. A groove is formed in the lower surface, the groove having an inner wall and an outer wall. The inner wall has a proximal end which is adjacent the lower surface of the head and which is disposed radially remotely from the shank. A sealing element, such as an O-ring, is disposed at least partially within the groove. The groove may be configured so that a distal end of the inner wall is near to the axis of the shank than is the proximal end of the inner wall.
8
[0001] Method and apparatus for renting, customizing, manufacturing intermediating, and delivering risk and/or volatility products. RELATED APPLICATIONS [0002] U.S. Patent Documents 6,842,604 January 2005 Cook, et al. 6,405,245 June 2002 Burson, et al. 6,606,596 August 2003 Zirngibl, et al. 6,850,603 February 2005 Eberle, et al. 5,918,213 June 1999 Bernard, et al. 5,664,110 September 1997 Green, et al. 6,594,642 July 2003 Lemchen 6,584,450 June 2003 Hastings 6,839,686 August 2003 Galant, et al. 6,772,146 August 2003 Khemlani, et al. 6,349,290 February 2002 Hastings 6,681,211 January 2004 Gatto, et al. 6,211,880 April 1998 Impink, Jr. 6,195,103 November 1997 Stewart 5,918,217 November 1997 Stewart 6,801,201 December 2002 Escher 6,298,334 October 2001 Burfield, et al. 6,453,303 September 2002 Li 6,546,375 April 2003 Pang, et al. 6,862,579 August 2003 Mathews, et al. 6,772,136 August 2004 Kant, et al. 6,061,662 May 2000 Makivic 6,829,590 December 2004 Greener, et al. 5,991,743 November 1999 Irving, et al. 5,696,907 December 1997 Tom 6,119,103 September 2000 Basch, et al., 5,732,397 March 1998 DeTore, et al. 6,708,155 March 2004 Honarvar, et al. 6,611,807 August 2003) Bernheim, et al. 5,991,744 November 1999 DiCresce 6,292,787 September 2001 Scott, et al. 6,484,152 August 2001 Robinson 5,361,201 November 1994 Jost, et al. 6,058,369 May 2000 Rothstein 6,235,176 May 2001 Schoen, et al. 6,275,807 August 2001 Schirripa 6,611,815 August 2003 Lewis, et al. 6,029,149 February 2000 Dykstra, et al. 5,262,941 November 1993 Saladin, et al. 6,385,594 May 2002 Lebda, et al. 6,850,643 February 2005 Smith, II, et al 6,018,721 January 2000 Aziz, et al. 6,195,647 February 2001 Martyn, et al. 4,376,978 March 1983 Musmanno, et al. 5,913,202 June 1999 Motoyama Foreign Patent Documents Other Documents Bates, David S. (1996). Jumps and stochastic volatility: exchange rate processes implicit in deutsche mark options, Review of Financial Studies, 9 (1) 69-107. Black, Fischer (1976). The pricing of commodity contracts, Journal of Financial Economics, 3, 167-179. Black, Fischer and Myron S. Scholes (1973). The pricing of options and corporate liabilities, Journal of Political Economy, 81, 637-654. Britten-Jones, M. and A. Neuberger (2000). Option prices, implied prices processes, and stochastic volatility, Journal of Finance, 55 (2), 839-866. Derman, Emanuel (1999). Regimes of volatility, Risk, 4, 55-59. Available in Lipton (2003). Dupire, Bruno (1996). A unified theory of volatility, working paper. Heston, Steven L. (1993). “A closed-form solution for options with stochastic volatility with applications to bond and currency options,” Review of Financial Studies, 6 (2), 327-43. Hull, John C. and Allen White (1988). “An analysis of the bias in option pricing caused by a stochastic volatility,” Advances in Futures and Options Research, 3, 29-61. Merton, R. (1976). Option pricing when underlying stock returns are discontinuous, Journal of Financial Economics, 3, 125-144. Available in Merton (1992). Manfredo, Mark Ronald (1994). “Volatility forecasting and value-at-risk: an application to cattle feeding, “American Journal of Agricultural Economics, August 2000, vol. 82, no. 3, pp. 785-791(3). Michael Y. Hu, Christine X. Jiang and Christos Tsoukalas. “The volatility impact of the European monetary system on member and non-member currencies,” Applied Financial Economics, 2004, vol. 14, issue 5 , pages 313-325 Litterman R., Scheinkman J. & Weiss L. (1991) “Volatility and the yield curve”, Journal of Fixed Income, Vol. 1, No. 1, June, pp. 49-53. Julia Litvinova. (2004) “Volatility asymmetry in high-frequency data”, downloaded from Website http://www.missouri.edu/˜econwww/MEG_Papers/Julia %20Litvinova.pd f, in Mar. of 205. Stulz, René, 1996, “Rethinking Risk Management,” Journal of Applied Corporate Finance, Vol. 9, No. 3 (Fall), pp. 8-24. Cumming, Christine, and Beverly Hirtle, 2001, “The Challenges of Risk Management in Diversified Financial Companies,” FRBNY Economic Policy Review (March), pp. 1-17. Andersen, Torben, Tim Bollerslev, Francis X. Diebold, and Peter Christoffersen, 2004, “Practical volatility and correlation modeling for financial market risk management,” in Mark Carey and Rene M. Stulz, The risks of financial firms, forthcoming. Artzner, Philippe, Freddy Delbaen, Jean-Marc Eber, and David Heath, 1999, “Coherent measures of risk,” Mathematical Finance 9, 208-223. Danielsson, Jon, and Casper de Vries, 1997, “Value-at-Risk and Extreme Returns,” Discussion Paper No. 273, pp. 1-33 (London: School of Economics and Political Science). Ju, Xiongwei, and Neil Pearson, 1998, “Using value-at-risk to control risk taking: how wrong can you be?,” The Journal of Risk 1, 5-36. Duffie, Darrell, and Jun Pan, 1997, “An overview of value at risk,” The Journal of Derivatives, Vol. 4, No. 3 (Spring) pp. 7-49. Litterman, Robert, 1996, “Hot Spot and Hedges,” Journal of Portfolio Management, Special Issues, 52-75. Committee on the Global Financial System, Basel, 2001, “A Survey of Stress Tests and Current Practice at Major Financial Institutions,” (Switzerland: Bank for International Settlements). Hull, John, and Alan White, 1998, “Value at Risk When Daily Changes in Market Variables are Not Normally Distributed,” The Journal of Derivatives, Vol 5, No 3 (Spring) pp. 9-19. Berkowitz, Jeremy and James O'Brien, “How Accurate are Value-at-Risk Models at Commercial Banks?”, Journal of Finance 57, No 3, 1093-1111. Jorion, Philippe, “Risk Management Lessons From Long-Term Capital Management,” European financial Management, Vol. 6, No.3, 2000, 277-300. J. R. Aragones, C. Blanco, and K. Dowd, 2001, “Incorporating Stress Tests into Market Risk Modeling,” Derivatives Quarterly, Spring, 44-49. Kiesel, Rudiger, William Perraudin, and Alex Taylor, 2000, “An extremes analysis of VaRs for emerging market benchmark bonds,” working paper, Birkbeck College, London, England. Bams, Dennis, Thorsten Lehnert, and Christian C. Wolff, 2003, “An evaluation framework for Alternative VaR models,” working paper, Masstricht University. Anil Bangia, Francis X. Diebold, Til Schurmann, and John Stroughair, 1999, Modeling liquidity risk, with implications for traditional market risk measurement and management, Financial Institutions Center, The Wharton School, University of Pennsylvania. Embrechts, Paul, 2000, “Extreme value theory: Potential and limitations as an integrated risk management tool,” working paper, ETH Zurich. Grammig, Joachim and Pierre Giot, 2002, “How Large is Liquidity Risk in an Automated Auction Market?” Discussion paper 2002-23, University of St. Gallen, Swiss Institute of Banking and Finance. Sadorsky, Perry, 2005, “Stochastic volatility forecasting and risk management” Applied Financial Economics, 2005, 15, 121-135 Ju, Xiongwei and Pearson, Neil, 1998, “Using value-at-risk to control risk taking: how wrong can you be?” Journal of Risk Volume 1/Number 2, Winter 1998/1999 Nain, Amrita, “The Strategic Motives for Corporate Risk Management” http://www-personal.umich.edu/˜anain/Research_files/NAIN_SEPT16.pdf Gibson, Michael S., 1998, “The Implications of Risk Management Information Systems for the Organization of Financial Firms,” International Finance Discussion Papers No. 632 (Washington: Board of Governors of the Federal Reserve System). Fehle, Frank and Tsyplako, Sergey, “Dynamic Risk Management: Theory and Evidence” http://dmsweb.moore.sc.edu/tsyplakov/papers/Fehle_Tsyplakov.pdf [0039] Geczy, Christopher, Bernadette Minton, and Catherine Schrand, “Why Firms Use Currency Derivatives,” Journal of Finance, September 1997, 1323-1348. http://fisher.osu.edu/˜fin/journal/archive_papers/isssept97/ms48 06.pdf Artzner, Philippe, Freddy Delbaen, Jean-Marc Eber, and David Heath, 1999, “Coherent measures of risk,” Mathematical Finance 9, 208-223. www.math.ethz.ch/˜delbaen/ftp/preprints/CoherentMF.pdf Duffie, Darrell, and Jun Pan, 1997, “An overview of value at risk,” The Journal of Derivatives, Vol. 4, No. 3 (Spring) pp. 7-49. *Berkowitz, Jeremy and James O'Brien, “How Accurate are Value-at-Risk Models at Commercial Banks?”, Journal of Finance 57 , No 3, 1093-1111. Estimating Value at Risks for Short and Long Trading Positions http://www.eco.fundp.ac.be/cerefim/varpaper/200200. %20(Sriananth akumar %20 and %20Silvapulle)-Estimating %20VaR %20for %20Long %20 and %20Short %20Trading %20Position s.pdf Granger, C. and S.-H. Poon (2002), Forecasting Volatility in Financial Markets: A Review, September. Allayannis, George, and James P. Weston, “The Use of Foreign Currency Derivatives and Firm Market Value,” The Review of Financial Studies, Spring 2001, 243-276. http://faculty.darden.virginia.edu/allayannisy/ATT148761.pdf “subscribe to risk” exact phrase search using the following Google URL: http://www.google.com/search?q=+%22subscribe+to+risk %22&num=100& hl=en&lr=&as_qdr=all&start=100&sa=N Security Futures OCC Operational Overview http://www.optionsclearing.com/initiatives/security_futures/secu rity_futures_overview.jsp Lexis Nexis® Risk Management Solutions http://www.lexisnexis.com/risksolutions/management/Default. asp EGAR Technology, Inc. http://www.egartech.com/company_sum.asp About Us http://www.riskdataflow.com BACKGROUND OF THE INVENTION [0052] 1. Field of the Invention [0053] The invention relates generally to processes for customizing, renting, purchasing, manufacturing, and intermediating risk and/or volatility products in particular but not limited (i.e. the invention also relates to gene sequencing and weather) to the following areas: [0054] a. Customizable Electronic Works, [0055] b. Remote Renting and/or Purchasing, [0056] c. Automated Manufacturing and Ordering over the Internet, [0057] d. Accessing Investment Information and Analysis, [0058] e. Displaying Investment Information and Analysis, [0059] f. Automated Analysis for Financial Assets, [0060] g. Automated Volatility Analysis for Financial Assets, [0061] h. Risk Management Systems, [0062] i. Strategic and Financial Planning Systems, [0063] j. Real Estate Systems, [0064] j. Insurance/Retirement Systems, and [0065] k. Credit Systems. [0066] l. Misc. [0067] m. Advantages of the present invention [0068] 2. Description of Related Art [0069] a. Customizable Electronic Works [0070] Customizing electronic works, is well known to the art. For example, by Cook, et al., “Personal digital content system,” U.S. Pat. No. 6,842,604 (Jan. 11, 2005), Burson, et al., “System and method for automated access to personal information,” U.S. Pat. No. 6,405,245 (Jun. 11, 2002), Zirngibl, et al., Zirngibl, et al., “System and method for the creation and automatic deployment of personalized, dynamic and interactive voice services, including deployment through digital sound files,” U.S. Pat. No. 6,606,596 (Aug. 12, 2003), and Eberle, et al., “System and method for the creation and automatic deployment of personalized dynamic and interactive voice services,” U.S. Pat. No. 6,850,603 (Feb. 1, 2005), each of which is herein incorporated by reference in its entirety, related to customizable electronic works. None of these references, however, provides for provide for electronic work customization, automatic electronic work manufacturing, and the data administration of the present invention. This prior art does not provide for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0071] b. Remote Renting and/or Purchasing [0072] Remote Renting and/or Purchasing, is well known to the art. For example, Bernard, et al., “System and method for automated remote previewing and purchasing of music, video, software, and other multimedia electronic works,” U.S. Pat. No. 5,918,213 (Jun. 29, 1999), Hastings, “Method and apparatus for renting items,” U.S. Pat. No. 6,584,450 (Jun. 24, 2003), Green, et al., “Remote ordering system,” U.S. Pat. No. 5,664,110 (Sep. 2, 1997), each of which is herein incorporated by reference in its entirety, related to automated remote and/or purchasing. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0073] c. Automated Manufacturing and Ordering over the Internet [0074] Providing an automated process and a system for ordering and manufacturing personalized electronic works over the Internet, is well known to the art, such as the one described by Lemchen, “Automated customized remote ordering and manufacturing process,” U.S. Pat. No. 6,594,642 (Jul. 15, 2003) incorporated herein by reference. This prior work does not provide for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0075] d. Accessing Investment Information and Analysis [0076] Several patents have been issued in accessing investment information and analysis. For example, by Galant, et al., “Method and system for providing financial information and evaluating securities of a financial debt instrument,” U.S. Pat. No. 6,839,686 (Aug. 19, 2003), and Hastings, “Automated system and method for customized and personalized presentation of products and services of a financial institution,” U.S. Pat. No. 6,349,290 (Feb. 19, 2002) each of which is herein incorporated by reference in its entirety, related to accessing investment information and analysis. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0077] e. Displaying Investment Information and Analysis [0078] Several patents have been issued in displaying investment information and analysis. For example, by Gatto, et al., “Security analyst estimates performance viewing system and method,” U.S. Pat. No. 6,681,211 (Jan. 20, 2004), Impink, Jr., “Display apparatus,” U.S. Pat. No. 6,211,880 (Apr. 13, 1998), Stewart, “Volatility plot and volatility alert for display of time series data,” U.S. Pat. No. 6,195,103 (Nov. 18, 1997), Stewart, “User interface for a financial advisory system,” U.S. Pat. No. 5,918,217 (Nov. 18, 1997), and Escher, “Method for chart markup and annotation in technical analysis,” U.S. Pat. No. 6,801,201 (Dec. 17, 2002), each of which is herein incorporated by reference in its entirety, related to displaying investment information and analysis. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0079] f. Automated Analysis for Financial Assets [0080] Several patents have been issued in automated analysis for financial assets. For example, by Burfield, et al., “Object-based numeric-analysis engine,” U.S. Pat. No. 6,298,334 (Oct. 2, 2001) and Li, “Automated analysis for financial assets,” U.S. Pat. No. 6,453,303 (Sep. 17, 2002), each of which is herein incorporated by reference in its entirety, related to automated analysis for financial assets. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0081] g. Automated Volatility Analysis for Financial Assets [0082] Several patents have been issued in automated volatility analysis for financial assets. For example, Pang, et al., “Apparatus and method of pricing financial derivatives,” U.S. Pat. No. 6,546,375 (Apr. 8, 2003), Mathews, et al., “Systems, methods and computer program products for performing a generalized contingent claim valuation,” U.S. Pat. No. 6,862,579 (Aug. 19, 2003), Bekaert, et al., Kant, et al., “System and method for financial instrument modeling and using Monte Carlo simulation,” U.S. Pat. No. 6,772,136 (Aug. 3, 2004), and Makivic, “Simulation method and system for the valuation of derivative financial instruments,” U.S. Pat. No. 6,061,662 (May 9, 2000), each of which is herein incorporated by reference in its entirety, related to automated volatility analysis for financial assets. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0083] h. Risk Management Systems [0084] Several patents have been issued in risk management systems. For example, Greener, et al., “Enhanced online sales risk management system,” U.S. Pat. No. 6,829,590 (Dec. 7, 2004), Irving, et al., “System and method for proactively monitoring risk exposure,” U.S. Pat. No. 5,991,743 (Nov. 23, 1999), Tom, “System and method for performing risk and credit analysis of financial service applications,” U.S. Pat. No. 5,696,907 (Dec. 9, 1997), Basch, et al., “Financial risk prediction systems and methods therefor,” U.S. Pat. No. 6,119,103 (Sep. 12, 2000), Smith, II, et al., “Methods and apparatus for collateral risk monitoring,” U.S. Pat. No. 6,850,643 (Feb. 1, 2005), each of which is herein incorporated by reference in its entirety, related to risk management systems. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0085] h. Strategic Planning, Financial Planning, and/or Portfolio Systems [0086] Several patents have been issued in strategic planning, financial planning, and/or portfolio systems. For example, DeTore, et al., “Automated decision-making arrangement,” U.S. Pat. No. 5,732,397 (Mar. 24, 1998), Honarvar, et al., “Decision management system with automated strategy optimization,” U.S. Pat. No. 6,708,155 (Mar. 16, 2004), Bernheim, et al., “Economic security planning method and system,” U.S. Pat. No. 6,611,807 (Aug. 26, 2003), DiCresce, “Method and apparatus that processes financial data relating to wealth accumulation plans,” U.S. Pat. No. 5,991,744 (Nov. 23, 1999), Scott, et al., “Enhancing utility and diversifying model risk in a portfolio optimization framework,” U.S. Pat. No. 6,292,787 (Sep. 18, 2001), Robinson, “Automated portfolio selection system,” U.S. Pat. No. 6,484,152 (Aug. 28, 2001), each of which is herein incorporated by reference in its entirety related to planning, financial planning, and/or portfolio systems. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0087] i. Real Estate Systems [0088] Several patents have been issued in real estate systems, and/or portfolio systems. For example, Jost, et al., “Real estate appraisal using predictive modeling,” U.S. Pat. No. 5,361,201 (Nov. 1, 1994) and Rothstein, “Real estate appraisal using predictive modeling,” U.S. Pat. No. 6,058,369 (May 2, 2000), each of which is herein incorporated by reference in its entirety, related to real estate systems. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0089] i. Insurance/Retirement Systems [0090] Several patents have been issued in insurance and/or retirement systems. For example, Schoen, et al., “Computer apparatus and method for defined contribution and profit sharing pension and disability plan,” U.S. Pat. No. 6,235,176 (May 22, 2001) Schirripa, “Computer system and methods for management, and control of annuities and distribution of annuity payments,” U.S. Pat. No. 6,275,807 (Aug. 14, 2001) Lewis, et al., “Method and system for providing account values in an annuity with life contingencies,” U.S. Pat. No. 6,611,815 (Aug. 26, 2003), each of which is herein incorporated by reference in its entirety, related to insurance and/or retirement systems. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0091] j. Credit Systems [0092] Several patents have been issued in credit systems. For example, Saladin, et al., “Expert credit recommendation method and system,” U.S. Pat. No. 5,262,941 (Nov. 16, 1993), Lebda, et al., “Method and computer network for co-ordinating a loan over the internet,” U.S. Pat. No. 6,385,594 (May 7, 2002), and Aziz, et al., “Method and system for improved collateral monitoring and control,” U.S. Pat. No. 6,018,721 (Jan. 25, 2000), each of which is herein incorporated by reference in its entirety, related to credit systems. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0093] j. Financial Information Intermediary System [0094] Financial information intermediary system, is well known to the art. For example, by Motoyama, “Financial information intermediary system,” U.S. Pat. No. 5,913,202 (Jun. 15, 1999), which is herein incorporated by reference in its entirety, related to credit systems, related to financial information intermediary system. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0095] Institutional Banking and Existing Online Risk Applications [0096] Several commercial applications have been disclosed. For example, Lexis Nexis Risk Management Solutions has disclosed a one-click access to a comprehensive range of investigation, due diligence, and fraud prevention solutions—all from a single Web page. EGAR's free and/or non-customized products FOCUS, EGAR ONE, EGAR ETS, EGAR Dispersion ASP and IVolatility data services, each of which is herein incorporated by reference in its entirety, related to existing commercial applications. None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. Several institutional applications have been disclosed. For example, Security Futures OCC Operation the Options Clearing Corporation (“OCC”) has disclosed a system modifications for the trading of Single Stock and Narrow Based Index Futures (security futures). Martyn, et al. “On-line transaction processing system for security trading,” U.S. Pat. No. 6,195,647 (Feb. 27, 2001) and Musmanno, et al. “Securities brokerage-cash management system,” U.S. Pat. No. 4,376,978 (Mar. 15, 1983). None of these references, however, provides for risk and/or volatility product customization, automatic risk and/or volatility product manufacturing, risk and/or volatility product purchasing and/or rental, risk and/or volatility product intermediating, risk and/or volatility product display and data administration/integration of the present invention. [0097] m. Advantages of the Present Invention [0098] This invention discloses a method and apparatus for renting, customizing, producing, intermediating, and delivering one or more element selected from a group comprising of as means for measuring, monitoring, and/or displaying “liquidity risk,” means for measuring, monitoring, and/or displaying “settlement risk,” means for measuring, monitoring, and/or displaying “operational risk,” means for measuring, monitoring, and/or displaying “credit risk,” and means for measuring, monitoring, and/or displaying “systematic risk,” means for measuring, monitoring, and/or displaying “historical volatility,” and/or means for measuring, monitoring, and/or displaying “implied volatility,” and/or means for measuring, monitoring, and/or displaying “FX” and means for measuring, monitoring, and/or displaying “FX options,” and means for measuring, monitoring, and/or displaying “Margin trading,” and means for measuring, monitoring, and/or displaying “Fixed Income,” and means for measuring, monitoring, and/or displaying “Interest rate derivatives,” and means for measuring, monitoring, and/or displaying “Energy derivatives,” and means for measuring, monitoring, and/or displaying “Commodity and Metals trading and derivatives and Equity trading,” SUMMARY OF THE INVENTION [0099] According to one aspect of the invention, a method is provided for renting, customizing, and delivering risk and/or volatility products to customers on a subscription basis. Up to a specified number of risk and/or volatility products are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0100] According to one aspect of the invention, a method is provided for renting, customizing, and delivering risk and/or volatility products to customers. Up to a specified number of risk and/or volatility products are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0101] According to another of the invention, a computer-implemented method is provided for renting, customizing, and delivering risk and/or volatility products to customers. According to the method, one or more risk and/or volatility product selection criteria are received that indicate one or more risk and/or volatility products that a customer desires to rent. Up to a specified number of the one or more risk and/or volatility products indicated by the one or more risk and/or volatility product selection criteria are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0102] According to another aspect of the invention, a computer-implemented method is provided for renting, customizing, and delivering risk and/or volatility products to customers. According to the method, one or more risk and/or volatility product selection criteria are received that indicate one or more risk and/or volatility products that a customer desires to rent. Up to a specified number of the one or more risk and/or volatility products indicated by the one or more risk and/or volatility product selection criteria are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0103] According to another aspect of the invention, a method is provided for renting, customizing, and delivering risk and/or volatility products to customers. Up to a specified number of risk and/or volatility products are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0104] According to another aspect of the invention, a method is provided for renting, customizing, and delivering one or more element selected from a group comprising of means for measuring, monitoring, and/or displaying “historical volatility,” and/or means for measuring, monitoring, and/or displaying “implied volatility” to customers. Up to a specified number of risk and/or volatility products are provided to the customer. In response to one or more said group product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0105] According to another aspect of the invention, a method is provided for renting, customizing, and delivering one or more element selected from a group comprising of means for measuring, monitoring, and/or displaying “liquidity risk,” means for measuring, monitoring, and/or displaying “settlement risk,” means for measuring, monitoring, and/or displaying “operational risk,” means for measuring, monitoring, and/or displaying “credit risk,” and means for measuring, monitoring, and/or displaying “systematic risk” to customers. Up to a specified number of risk and/or volatility products are provided to the customer. In response to one or more said group product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0106] According to another aspect of the invention, a method is provided for renting, customizing, and delivering one or more element selected from a group comprising of means for measuring, monitoring, and/or displaying “liquidity risk,” means for measuring, monitoring, and/or displaying “settlement risk,” means for measuring, monitoring, and/or displaying “operational risk,” means for measuring, monitoring, and/or displaying “credit risk,” and means for measuring, monitoring, and/or displaying “systematic risk” to customers. [0107] According to another aspect of the invention, a method is provided for renting, customizing, and delivering one or more element selected from a group comprising of means for measuring, monitoring, and/or displaying “FX” and means for measuring, monitoring, and/or displaying “FX options,” and means for measuring, monitoring, and/or displaying “Margin trading,” and means for measuring, monitoring, and/or displaying “Fixed Income,” and means for measuring, monitoring, and/or displaying “Interest rate derivatives,” and means for measuring, monitoring, and/or displaying “Energy derivatives,” and means for measuring, monitoring, and/or displaying “Commodity and Metals trading and derivatives and Equity trading.” [0108] Up to a specified number of risk and/or volatility products are provided to the customer. In response to one or more said group product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0109] According to another aspect of the invention, a computer-implemented method is provided for renting one or more element selected from a group comprising of means for measuring, monitoring, and/or displaying “historical volatility,” and/or means for measuring, monitoring, and/or displaying “implied volatility” to customers. According to the method, one or more said group selection criteria are received from a customer that indicates one or more risk and or volatility products that the customer desires to rent. Up to a specified number of the one or more said indicated by the one or more risk and/or volatility selection criteria are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0110] According to another aspect of the invention, a computer-implemented method is provided for renting one or more element selected from a group comprising of means for measuring, monitoring, and/or displaying “liquidity risk,” means for measuring, monitoring, and/or displaying “settlement risk,” means for measuring, monitoring, and/or displaying “operational risk,” means for measuring, monitoring, and/or displaying “credit risk,” and means for measuring, monitoring, and/or displaying “systematic risk” to customers. According to the method, one or more said group selection criteria are received from a customer that indicates one or more risk and or volatility products that the customer desires to rent. Up to a specified number of the one or more said indicated by the one or more risk and/or volatility product selection criteria are provided to the customer. In response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0111] According to another aspect of the invention, an apparatus for renting, customizing, and delivering risk and/or volatility products risk and/or volatility products to customers is provided. The apparatus comprises one or more processors and a memory communicatively coupled to the one or more processors. The memory includes one or more sequences of one or more instructions which, when executed by the one or more processors, cause the one or more processors to perform several steps. First, one or more risk and/or volatility product selection criteria are received that indicate one or more risk and/or volatility products that a customer desires to rent. Up to a specified number of the one or more risk and/or volatility products indicated by the one or more risk and/or volatility product selection criteria are provided to the customer. Finally, in response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0112] According to another aspect of the invention, an apparatus is provided for renting, customizing, and delivering risk and/or volatility products to customers. The apparatus comprises a risk and/or volatility product rental mechanism configured to receive one or more risk and/or volatility product selection criteria that indicate one or more risk and/or volatility products that a customer desires to rent. The risk and/or volatility product rental mechanism is also configured to provide to the customer up to a specified number of the one or more risk and/or volatility products indicated by the one or more risk and/or volatility product selection criteria. Finally, the risk and/or volatility product rental mechanism is configured to in response to one or more risk and/or volatility product delivery criteria being satisfied (such as the payment of a specified fee), one or more other risk and/or volatility products are provided to the customer, wherein a total current one or more risk and/or volatility products provided to the customer can only be used during a specified time. [0113] In the foregoing specification, the invention has been described with reference to specific embodiments thereof. However, various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense. [0114] Many modifications and alterations may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the embodiment illustrations has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in an obvious combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. [0115] The claims are thus to be taught to include what is specifically illustrated and described above, what is an equivalent concept, what can be obviously substituted and also what essentially incorporates the essential idea of the invention. BRIEF DESCRIPTION OF THE DRAWING [0116] Embodiments of the invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which: [0117] FIG. 1 is a diagram depicting an approach for renting risk and/or volatility products to customers according to an embodiment. [0118] FIG. 2 is a flow diagram depicting an approach for renting risk and/or volatility products to customers according to an embodiment. [0119] FIG. 3 is a flow diagram depicting a “Specific Time Limit” approach for renting risk and/or volatility products to customers according to an embodiment. [0120] FIG. 4 is a flow diagram depicting a “Negotiated Time Limit with Intermediate” approach for renting risk and/or volatility products to customers according to an embodiment. [0121] FIG. 5 is a diagram depicting an approach for renting risk and/or volatility products to customers over the Internet according to an embodiment. [0122] FIG. 6 is a flow diagram illustrating an approach for renting risk and/or volatility products to customers over the Internet using both “Specific Time Limit” and “Negotiated Time Limit with Intermediate” according to an embodiment; and [0123] FIG. 7 is a block diagram of a data processing system upon which embodiments of the invention may be implemented. [0124] FIG. 8 is a block diagram of a risk and/or volatility product producer system upon which embodiments of the invention may be implemented. DETAILED DESCRIPTION OF THE INVENTION [0125] In the following description, reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Well-known structures and devices are depicted in block diagram form in order to avoid unnecessarily obscuring the invention. Yet, it will be apparent that the invention may be practiced without these specific details. [0126] Various aspects and features of example embodiments of the invention are described in more detail hereinafter in the following sections: (1) utilitarian overview; (2) risk and/or volatility products selection criteria; (3) risk and/or volatility products delivery; (4) “Specific Time Limit”; (5) “Negotiated Time Limit with Intermediate”; (6) register management; (7) implementation equipment, and (8) provider services. [0127] 1. Utilitarian Overview [0128] FIG. 1 is a block diagram 100 that illustrates an approach for renting risk and/or volatility products to customers according to various embodiments described herein. As used herein, the term “risk and/or volatility product” refers to any commercial risk and/or volatility measurement and/or monitoring electronic work that can be rented to customers. Examples of risk and/or volatility products include means for measuring and/or monitoring credit risk, liquidity risk, settlement risk, operational risk, and systematic risk, and/or means for measuring and/or monitoring historical volatility and implied volatility stored on a non-volatile memory such as a tape, other magnetic medium, optical medium, read-only memory or the like, and the invention is not limited to any particular type of risk and/or volatility product. In general, the decision of what risk and/or volatility products to rent is separated from the decision of when to rent the risk and/or volatility products. Customers may specify what risk and/or volatility products to rent using one or more risk and/or volatility product selection criteria separate from deciding when to receive the specified risk and/or volatility products. Furthermore, customers are not constrained by conventional rental “shopping carts” and instead can have continuous, serialized rental of risk and/or volatility products. [0129] According to one embodiment, a customer 140 provides one or more risk and/or volatility product selection criteria to a provider 120 over a link 110 . Link 110 may be any medium for transferring data between customer 140 and provider 120 . [0130] The risk and/or volatility product selection criteria indicate risk and/or volatility products that customer 140 desires to rent from provider 120 . In response to receiving the risk and/or volatility product selection criteria from customer 140 , provider 120 provides the risk and/or volatility products indicated by the risk and/or volatility product selection criteria to customer 140 over a delivery channel 120 . Delivery channel 120 may be implemented by any mechanism or medium that provides for the transfer of risk and/or volatility products from provider 120 to customer 140 and the invention is not limited to any particular type of delivery channel. Examples of delivery channel 120 include delivery using the Internet. Provider 120 may be centralized or distributed depending upon the requirements of a particular application. [0131] According to an embodiment, a “Specific Time Limit” approach allows up to a specified number of risk and/or volatility products to be rented simultaneously to customer 140 by provider 120 . According to another embodiment, a “Negotiated Time Limit with Intermediate” approach allows up to a specified number of risk and/or volatility product exchanges to occur during a specified period of time. The “Specific Time Limit” and “Negotiated Time Limit with Intermediate” approaches may be used together or separately with a variety of subscription methodologies. [0132] The approach just described for renting risk and/or volatility products to customers is now described with reference to a flow diagram 200 of FIG. 2 . After starting in step 202 , in step 204 , customer 140 creates risk and/or volatility product selection criteria. In step 206 , customer 140 provides the risk and/or volatility product selection criteria to provider 120 . In step 208 , in response to provider 120 receiving the risk and/or volatility product selection criteria from customer 140 , provider 120 provides one or more risk and/or volatility products indicated by the risk and/or volatility product selection criteria to customer 140 . The process is complete in step 210 . [0133] 2. Risk and/or Volatility Product Selection Criteria [0134] The one or more risk and/or volatility product selection criteria provided by customer 140 to provider 120 indicate the particular risk and/or volatility products that customer 140 desires to rent from provider 120 . Thus, the risk and/or volatility product selection criteria define a customer-specific order queue that is fulfilled by provider 120 . According to one embodiment, the risk and/or volatility product selection criteria specify attributes of risk and/or volatility products to be provided by provider 120 to customer 140 . Risk and/or volatility product selection criteria may specify any type of risk and/or volatility product attributes and the invention is not limited to particular risk and/or volatility product attributes. Examples of risk and/or volatility product attributes include, without limitation, identifier attributes, type attributes and cost attributes. Risk and/or volatility product selection criteria may be changed at any time to reflect changes in risk and/or volatility products that customers desire to rent from a provider. [0135] 3. Risk and/or Volatility Product Delivery [0136] According to one embodiment, risk and/or volatility products are delivered by provider 120 to customer 140 over delivery channel 120 based upon risk and/or volatility product delivery criteria. More specifically, the delivery of risk and/or volatility products from provider 120 to customer 140 is triggered by risk and/or volatility product delivery criteria being satisfied. The risk and/or volatility product delivery criteria may include a wide range of Internet delivery criteria and the invention is not limited to any particular risk and/or volatility product delivery criteria. Examples of risk and/or volatility product delivery criteria include, without limitation, customer messaging, customer web services, customer remote method invocation, customer p2p, and customer email. [0137] The risk and/or volatility product delivery criteria may be specified by customer 140 to provider 120 or negotiated by customer 140 and provider 120 as part of a subscription service. For example, a particular subscription service may include risk and/or volatility product delivery criteria that specifies that a particular number of risk and/or volatility products are to be delivered monthly. As another example, risk and/or volatility product delivery criteria may specify that an initial set of risk and/or volatility products is to be delivered by provider 120 to customer 140 upon initiation of a subscription service and that additional risk and/or volatility products are to be delivered to customer 140 upon return of risk and/or volatility products to provider 120 . Risk and/or volatility product delivery criteria may be applied uniformly to all risk and/or volatility products to be delivered to a customer, or may be risk and/or volatility product specific. For example, risk and/or volatility product delivery criteria may specify a particular date, i.e., the third Wednesday of every month, for all risk and/or volatility product deliveries. Alternatively, separate risk and/or volatility product delivery dates may be assigned to each risk and/or volatility product. [0138] 4. “Specific Time Limit” [0139] According to one embodiment, a “Specific Time Limit” approach is used to manage the number of risk and/or volatility products that may be simultaneously rented to customers. According to the “Specific Time Limit” approach, up to a specified number of risk and/or volatility products may be rented simultaneously to a customer. Thus, the “Specific Time Limit” approach establishes the size of an register of risk and/or volatility products that may be maintained by customers. The specified number of risk and/or volatility products may be specific to each customer or may be common to one or more customers. In the present example, if the specified number of risk and/or volatility products is nine, then up to nine risk and/or volatility products may be rented simultaneously by provider 120 to customer 140 . If the specified number of risk and/or volatility products are currently rented to customer 140 and the specified risk and/or volatility product delivery criteria triggers the delivery of one or more additional risk and/or volatility products, then those risk and/or volatility products are not delivered until one or more risk and/or volatility products are returned by customer 140 to provider 120 . [0140] According to one embodiment, in situations where the specified number of risk and/or volatility products are currently rented to customer 140 and the specified risk and/or volatility product delivery criteria triggers the delivery of one or more additional risk and/or volatility products, then the one or more additional risk and/or volatility products are delivered to customer 140 and customer 140 and a surcharge is applied customer 140 . The specified number of risk and/or volatility products may then be increased thereafter to reflect the additional risk and/or volatility products delivered to customer 140 and increase the size of the register maintained by customer 140 . Alternatively, the specified number of risk and/or volatility products may remain the same and number of risk and/or volatility products maintained by customer 140 returned to the prior level after risk and/or volatility products are returned to provider 120 by customer 140 . When used in conjunction with the “Negotiated Time Limit with Intermediate” approach described hereinafter, the specified number of risk and/or volatility products may be unlimited. [0141] The “Specific Time Limit” approach for managing the number of risk and/or volatility products that may be simultaneously rented to customers is now described with reference to a flow diagram 300 of FIG. 3 . After starting in step 302 , in step 304 , one or more initial risk and/or volatility products are delivered to customer 140 to establish the register maintained by customer 140 . Note that an initial delivery of risk and/or volatility products is not required and according to one embodiment, the register of customer 140 is incrementally established over time. [0142] In step 306 , a determination is made whether the risk and/or volatility product delivery criteria have been satisfied. If not, then the determination continues to be made until the risk and/or volatility product delivery criteria are satisfied. As described previously herein, the delivery criteria may include customer notification generally, customer notification that an risk and/or volatility product is being returned, the actual return of an risk and/or volatility product, the occurrence of a specific date, or that a specified amount of time has elapsed. [0143] Once the risk and/or volatility product delivery criteria are satisfied, then in step 308 , a determination is made whether the specified number of risk and/or volatility products have been delivered. If not, then control returns to step 304 and one or more additional risk and/or volatility products are delivered by provider 120 to customer 140 . If however, in step 308 , the specified number of risk and/or volatility products have been delivered, then in step 310 , a determination is made whether the specified number of risk and/or volatility products, i.e., the “Specific Time Limit” limit, is to be overridden. As previously described, the specified number of risk and/or volatility products may be overridden by increasing the specified number of risk and/or volatility products, i.e., the “Specific Time Limit” limit, to allow additional risk and/or volatility products to be delivered to customer 140 and charging a fee to customer 140 . Alternatively, the specified number of risk and/or volatility products is not changed and a surcharge applied to customer 140 . This process continues for the duration of the subscription and is then complete in step 310 . [0144] 5. “Negotiated Time Limit with Intermediate” [0145] According to one embodiment, a “Negotiated Time Limit with Intermediate” approach is used to rent risk and/or volatility products to customers. According to the “Negotiated Time Limit with Intermediate” approach, up to a specified number of risk and/or volatility product exchanges may be performed during a specified period of time. For example, referring to FIG. 1 , suppose that provider 120 agrees to rent risk and/or volatility products to customer 140 with a “Negotiated Time Limit with Intermediate” limit of nine risk and/or volatility products per month. This means that customer 140 may make up to nine risk and/or volatility product exchanges per month. This approach may be implemented independent of the number of risk and/or volatility products that a customer may have rented at any given time under the “Specific Time Limit” approach. The approach is also independent of the particular risk and/or volatility product delivery criteria used. [0146] According to one embodiment, the “Negotiated Time Limit with Intermediate” approach is implemented in combination with the “Specific Time Limit” approach to rent risk and/or volatility products to customers. In this situation, up to a specified number of total risk and/or volatility products are simultaneously rented to customer 140 and up to a specified number of risk and/or volatility product exchanges may be made during a specified period of time. Thus, using the “Specific Time Limit” and the “Negotiated Time Limit with Intermediate” approaches together essentially establishes a personal risk and/or volatility product register for customer 140 based upon the “Specific Time Limit” limit that may be periodically refreshed based upon the “Negotiated Time Limit with Intermediate” limit selected. [0147] In some situations, customer 140 may wish to exchange more than the specified number of risk and/or volatility products during a specified period. According to one embodiment, in this situation, provider 120 agrees to rent additional risk and/or volatility products above the specified number to customer 140 and to charge customer 140 for the additional risk and/or volatility products. For example, suppose that provider 120 agrees to rent risk and/or volatility products to customer 140 with up to nine risk and/or volatility product turns (exchanges) per month. If, in a particular month, customer 140 requires two additional turns, then the two additional risk and/or volatility products are provided to customer 140 and a surcharge is applied to customer 140 for the additional two risk and/or volatility products. [0148] In other situations, customer 140 may not use all of its allotted turns during a specified period. According to one embodiment, customers lose unused turns during a subscription period. For example, if customer 140 has a “Negotiated Time Limit with Intermediate” limit of four risk and/or volatility product exchanges per month and only makes two risk and/or volatility product exchanges in a particular month, then the two unused exchanges are lost and cannot be used. At the start of the next month, customer 140 would be entitled to four new risk and/or volatility product exchanges. [0149] According to another embodiment, customers are allowed to carry over unused turns to subsequent subscription periods. For example, if customer 140 has a “Negotiated Time Limit with Intermediate” limit of four risk and/or volatility product exchanges per month and only makes two risk and/or volatility product exchanges in a particular month, then the two unused exchanges are lost and cannot be used. At the start of the next month, customer 140 would be entitled to six new risk and/or volatility product exchanges, two from the prior month and four for the current month. [0150] The “Negotiated Time Limit with Intermediate” approach for renting risk and/or volatility products to customers is now described with reference to a flow diagram 400 of FIG. 4 . After starting in step 401 , in step 404 , customer 140 and provider 120 agree upon the terms of the “Negotiated Time Limit with Intermediate” agreement. Specifically, customer 140 and provider 120 negotiate a time limit. [0151] In step 405 , in response to risk product being provided within terms of time limit, provider 120 provides one or more risk and/or volatility products to customer 140 over delivery channel 120 . Any type of risk and/or volatility product delivery criteria may be used with the “Negotiated Time Limit with Intermediate” approach and the invention is not limited to any particular delivery criteria. For example, the initial one or more risk and/or volatility products may be delivered to customer 140 in response to a subscription payment made by customer 140 to provider 120 , the initiation of a specified subscription period, or by request of customer 140 for the initial rental risk and/or volatility products. The availabilty of initial one or more risk and/or volatility products must not exceed the terms of the “Negotiated Time Limit with Intermediate” agreement. [0152] In step 408 , in response to one or more delivery criteria being satisfied, a determination is made whether additional risk and/or volatility products can be provided to customer 140 within the terms of the “Negotiated Time Limit with Intermediate” agreement. For example, if the number of risk and/or volatility products rented to customer in the current subscription period is less than the agreed-upon “Negotiated Time Limit with Intermediate,” then additional risk and/or volatility products can be rented to customer 140 within the terms of the “Negotiated Time Limit with Intermediate” agreement. In this situation, this determination may be made in response to customer 140 returning one or more risk and/or volatility products to provider 120 , or by customer 140 requesting additional risk and/or volatility products. [0153] If, in step 405 , a determination is made that additional risk and/or volatility products can be rented to customer 140 within the terms of the “Terms of a Time Limit” agreement, then control returns to step 406 where one or more additional risk and/or volatility products are delivered to customer 140 . If however, in step 404 , a determination is made that customer 140 AND provider 120 CANNOT NEGOTITATE A TIME LIMIT AGREEMENT, then in step 403 , a determination is made whether to override the current agreement terms. If so, then in step 403 , the agreement terms are changed to allow for a larger number of terms and customer 140 is charged accordingly, or the terms are left unchanged and a surcharge is applied for the additional risk and/or volatility products to be delivered. Control then returns to step 405 , where a determination is made whether the risk product can be provided to customer 140 within terms of a time limit. [0154] If in step 410 , a determination is made that the risk product can be provided within the terms of a time limit, then in step 406 , risk and/or volatility products are delivered to customer 140 until the next subscription period. For example, the request for additional risk and/or volatility products may be received at the end of a subscription period and instead of renting the additional risk and/or volatility products immediately, they are instead delivered during the subsequent subscription period. Control then returns to step 404 where one or more additional risk and/or volatility products are rented to customer or the process is complete in step 410 . [0155] The approach for renting risk and/or volatility products described herein is now described in the context of renting to customers risk and/or volatility products, such as a means for measuring and/or monitoring credit risk, liquidity risk, settlement risk, operational risk, and systematic risk, and/or means for measuring and/or monitoring historical volatility and f implied volatility. FIG. 5 is a diagram 500 that depicts a set of customers 511 that desire to rent risk and/or volatility products from a set of providers 521 . Customers 511 communicate with providers 521 over links 512 , the global packet-switched network referred to as the “Internet,” and a link 518 . [0156] Links 512 and 518 may be any medium for transferring data between customers 511 and the Internet 523 and between the Internet 523 and providers 521 , respectively, and the invention is not limited to any particular medium. In the present example, links 512 and 518 may be connections provided by one or more Internet Service Providers (ISPs) and customers 511 are configured with generic Internet web browsers. Links 512 and 518 may be secure or unsecured depending upon the requirements of a particular application. [0157] In accordance with an embodiment, customers 511 enter into a rental agreement with providers 521 to rent risk and/or volatility products 510 from providers 521 according to the “Specific Time Limit” and/or “Negotiated Time Limit with Intermediate” approaches described herein. No limiting to any particular approach for entering into the rental agreement is placed on the invention. For example, customers 511 and providers 521 may enter into a rental agreement by fax, mail, telephone or over the Internet, by customers 511 logging into a web site associated with providers 521 . [0158] Customers 511 create and provide risk and/or volatility product selection criteria to providers 521 over links 512 and 518 and the Internet 523 . The invention is not limited to any particular approach for specifying and providing risk and/or volatility product selection criteria to providers 521 . For example, according to one embodiment, customers 511 provide risk and/or volatility product selection criteria to providers 521 in one or more data files. According to another embodiment, customers 511 log onto a web site of providers 521 and use a graphical user interfaced (GUI) to specify attributes of the risk and/or volatility product that customers desire to rent from providers 521 . [0159] The risk and/or volatility product selection attributes may include any attributes that describe, at least in part, risk and/or volatility product that customers 511 desire to rent. Customers 511 may identify specific risk and/or volatility product by the risk and/or volatility product selection criteria, or may provide various attributes and allow providers 521 to automatically manufacture and deliver risk and/or volatility product that satisfy the attributes specified. [0160] Once customers 511 and providers 521 have entered into a rental agreement and customers 511 have provided risk and/or volatility product selection criteria to providers 521 , then risk and/or volatility products 510 are rented to customers 511 over delivery channels 514 in accordance with the terms of the rental agreement. Specifically, according to the “Specific Time Limit” approach described herein, an initial set of risk and/or volatility products 510 , such as means for measuring, monitoring, and/or displaying “liquidity risk,” means for measuring, monitoring, and/or displaying “settlement risk,” means for measuring, monitoring, and/or displaying “operational risk,” means for measuring, monitoring, and/or displaying “credit risk,” and means for measuring, monitoring, and/or displaying “systematic risk,” means for measuring, monitoring, and/or displaying “historical volatility,” and/or means for measuring, monitoring, and/or displaying “implied volatility,” and/or means for measuring, monitoring, and/or displaying “FX” and means for measuring, monitoring, and/or displaying “FX options,” and means for measuring, monitoring, and/or displaying “Margin trading,” and means for measuring, monitoring, and/or displaying “Fixed Income,” and means for measuring, monitoring, and/or displaying “Interest rate derivatives,” and means for measuring, monitoring, and/or displaying “Energy derivatives,” and means for measuring, monitoring, and/or displaying “Commodity and Metals trading and derivatives and Equity trading,” [0161] are delivered to customers 511 over delivery channels 514 according to the terms of the rental agreement. Subsequent risk and/or volatility products 510 are delivered whenever the specified risk and/or volatility product delivery criteria are satisfied. For example, additional risk and/or volatility products 510 may be delivered upon the return of one or more risk and/or volatility products 510 to provider, a request from customers 511 , the arrival of a particular date, e.g., a specific day of the month, or the expiration of a specified period of time, e.g., fifteen days. [0162] In accordance with the “Specific Time Limit” approach described herein, once the maximum number of risk and/or volatility products 510 have been rented to a particular consumers 511 , then no additional risk and/or volatility products 510 are rented until one or more rented risk and/or volatility products 510 are returned to providers 521 , or unless a surcharge is applied to the particular consumers 511 . Alternatively, the rental agreement between the particular consumers 511 and providers 521 may be modified to increase the maximum number of risk and/or volatility products 510 that may be rented simultaneously to the particular consumers 511 . [0163] The rental agreement between customers 511 and providers 521 may also specify a maximum number of turns in combination with the “Specific Time Limit” approach. In this situation, a specific time limit restricts how quickly customers 511 may refresh their risk and/or volatility product 512 out baskets. For example, suppose that a particular consumers 511 agrees with providers 521 to rent up to four risk products with a time limit of 3 month. Under this agreement, the particular consumers 511 may maintain a personal register of up to four risk products for 3 months. Thus, the particular consumers 511 can completely “replace” his personal register once per month. If the particular consumers 511 agreed to a specific time limit of 2 months, then the particular consumers 511 would be able to completely replace his personal register for two months. [0164] Providers 521 may be centralized or distributed depending upon the requirements of a particular application. For example, providers 521 may be a centralized data processing center from which all risk and/or volatility products 510 are manufactured and delivered. Alternatively, providers 521 may be implemented by a network of distributed data processing center. [0165] FIG. 6 is a flow diagram that illustrates an approach for renting risk and/or volatility products 510 to customers over a communications network such as the Internet using both “Specific Time Limit” and “Negotiated Time Limit with Intermediate” according to an embodiment. Referring also to FIG. 5 , after starting in step 601 , in step 602 , a consumers 511 enters into a rental agreement with providers 521 . In the present example, consumers 511 uses a generic web browser to access an Internet web site associated with providers 521 and enter into a rental agreement that specifies that consumers 511 may maintain a personal register of four risk products for 1 month (“Specific Time Limit” of 1 month).
According to a computer-implemented approach for renting, customizing, manufacturing, intermediating, and delivering risk and volatility product to customers, customers specify what risk or volatility product to rent using a plurality of risk and/or product selection parameters. According to the approach, customers provide a plurality of risk and/or volatility product selection parameters to a provider provides the risk and volatility product indicated by the plurality of risk and/or volatility product selection parameters to customer over a delivery channel. The risk and/or volatility product provider may be either centralized or distributed depending upon the requirements of a particular application.
6
This is a division of application Ser. No. 06/273,378 filed June 15, 1981. FIELD OF THE INVENTION This invention relates to production of coal in situ wherein coal is set afire and consumed in place with energy values captured in surface facilities. More particularly the invention is directed to the integrity of the underground reaction zone during roof falls and subsidence, occasioned by creation of void space underground, as the coal is consumed in place. BACKGROUND OF THE INVENTION It is well known in the art how to produce coal in situ, such production having been accomplished on a commercial scale in Russia for more than 30 years. While not yet practiced commercially in the United States, numerous field tests in various parts of the country point to an emerging commercial industry. For production of coal in situ, wells are drilled from the surface of the earth into an underground coal seam, linkage channels are established through the coal thus connecting the wells in pairs, the coal is set afire with combustion sustained by injecting an oxidizer into one well of the pair and removing the products of reaction through the other well of the pair. Useful products recovered include carbon monoxide, hydrogen, methane and condensible liquids that contain valuable coal chemicals. In commercial practice a multiplicity of wells is drilled into the coal seam providing numerous pairs of wells. Generally each well during its useful life will be operated both as an injector well and as a producer well until a maximum amount of coal is consumed within the influence of the well. Preferably the pairs of wells are linked through the coal at the bottom of the seam. When the coal is set afire, the fire propagates along the linkage channel under pressure and thus establishes an underground reactor in the coal seam. Unlike an aboveground pressure vessel used for gasifying coal which is fixed in size by design, the underground reactor (sometimes called a georeactor) begins as a relatively small pressurized volume in the linkage channel and grows in size as coal is consumed. A properly operated georeactor grows in length from the ignition point and expands laterally and vertically as combustion proceeds. With properly placed wells and linkage channels at the bottom of the seam, it is possible to consume virtually all of the coal seam during production sequences. In the interest of maximum resource recovery, it is important that the seam be consumed from bottom to top. In this mode fresh fuel remains above the fire and residual ash below the fire. As combustion proceeds and the georeactor grows in lateral extent, the natural structure of the coal seam weakens and fresh coal spalls into the fire, such spalling continuing on an intermittent basis until all of the coal above the fire is consumed. Continuing growth of georeactor size results in additional underground void space with loss of support for the overburden and resultant roof fall from the overlying rock strata. When the overlying rock strata becomes dislodged, spalls and falls into the georeactor, such disturbance of overlying rock is generally characterized as roof fall within a vertical distance of twice that of the coal seam thickness. For greater vertical distances disruption of the overburden is generally characterized as subsidence. From a process efficiency point of view, it is desirable to contain the pressurized georeactor within the coal seam. From a resource recovery point of view, it is desirable to consume all of the coal within the influence of the wells. Thus an economic tradeoff is established trending toward maximum resource recovery, with attendant problems of roof fall and subsidence. Roof fall generally is a relatively minor problem that expands the pressurized georeactor into the overlying rock strata, exposing cool rocks that rob heat from the reactor. Subsidence is a more severe problem, particularly when the disturbed area intersects an overlying aquifer or propagates cracks to the ground surface. An overlying aquifer connected to a georeactor can result in quenching all useful reactions in the reactor. Cracks to the surface result in serious losses of pressure and produced gases. It is apparent that a relatively small in situ coal project will encounter the problems of roof fall. A project of commercial size will encounter problems both from roof fall and subsidence. A successful commercial project must cope with and manage the problems of subsidence. Subsidence has been a recognized problem for conventional underground coal mines since the industry began several centuries ago. Numerous studies through the years have contributed to the understanding of the forces of subsidence, which have made possible reasonably standardized designs for mine safety, the mine plan and the sequence of operations. In virtually all cases the designs require modification to the site specific requirements of a new mine. For conventional coal mines the planned amount of void space underground can be carefully controlled. For in situ production of coal, precise control of void space is difficult to attain. To provide a plan for mining sequence in each case, it is necessary to obtain information about the rock strata overlying the coal seam. It is well known that tests on rock cores result in strengths much higher than the actual strength of the rock mass. Test results of compressive strengths may approach the actual strength of the rock mass, but tensile strengths can vary considerbly due to faults, joints and bedding planes. Once a substantial void space is opened up by removing a portion of the underground coal, the overburden above the void must be supported by adjacent coal. The result is the establishment of a compression arch from the adjacent coal to an apex located above the center of the void. Overburden rock within the lower boundary of the compression arch thus becomes destressed and remains in place only if there is sufficient tensile strength to overcome weight of the destressed rock. Chances are good that there will be discontinuities in the destressed rock. Thus roof fall will begin with a chunk of rock falling into the void space. Later in time another chunk of rock will fall, then another and another, resulting in an upward stoping process that may continue intermittently for months or years. The vertical extent of this upward stoping may be approximated by the width of the underground void space. When the width of the void space exceeds the depth of the overburden, upward stoping probably will continue to collapse of the surface of the ground. Arrival of upward stoping at the ground surface normally appears without warning in the forms of a depression, pit, trough, tension crack and the like. Normally any lowering of the earth surface due to subsidence also will be accompanied by compression bulges near the center of the lowered surface. Another feature commonly occuring with surface collapse is the amount of area distrubed at the surface, generally a larger area than that of the underground void that initiated the sequence. The added area is commonly called the draw, being induced by the tensile strength of the rock which has moved into the disturbed zone. When it is known that underground void space is likely to result in ground surface depression, care should be taken in locating manmade structures above the void plus the expected draw. The expected depression area should be placed under limited access control until the disturbed area becomes stabilized. The changing size of the georeactor can be reasonably well controlled until significant subsidence is underway. It is highly desirable to maintain the pressurized space associated with the georeactor to the confines of the coal seam and immediately adjacent void space. It is apparent that upward stoping will significantly increase the vertical dimension of the reactor, thus it is highly desirable to place a pressure seal on the changing void space resulting from rock fall. Methods of accomplishing such a seal will be described hereinafter. Such a seal also is highly desirable to be in place before upward stoping encounters an overlying aquifer. A seal against water incursion serves two purposes: water is excluded from the georeactor and the processes underway, and water soluble products of reactions (phenols, ammonia and the like) are excluded from the aquifer. As previously mentioned production of coal in situ is accomplished by operating wells in pairs. The initial group of individual georeactors (sometimes called modules) will be located between each pair of wells. As production proceeds many of the reactors will merge, and at the point of merger it is desirable that subsidence be accelerated to lower the overburden into the void space, and to place pressure seals to restrict georeactor size. Accelerated subsidence can cause substantial damage to manmade structures within the disturbed area, specifically the injector-producer wells of the project. Special protection is required for these wells as will be more fully described hereinafter. Further, accelerated subsidence is desirable when the in situ production project contains multiple seams of coal and it is planned to produce an underlying seam without undue delay. In the ideal case the original production wells will have survived the forces of subsidence and are deepened for production of the lower seam. Accelerated subsidence can be induced by widening the underground void spaces to the maximum extent of the planned production area. A planned production area normally will be somewhat smaller than that defined by the perimeter of the property. It is common practice to leave unproduced coal within the outer boundaries of the mine property, a barrier pillar within the perimeter, for example a strip of unmined coal 150 feet wide. For conventional underground mining, the location of the barrier pillar can be positioned with accuracy. For in situ production of coal the barrier pillar will be uneven on the inside, due to imprecise dimensions of the georeactors paralleling the property line, thus leaving slightly more coal in the barrier pillar than for conventional mining. Also for in situ coal production the spans of the underground void space can be quite long, virtually assuring subsidence to the surface. In order for the ground surface immediately over the barrier pillar to remain intact, it is necessary to take steps to minimize the effect of subsidence draw in the barrier area. Likewise, a barrier pillar is established under the area of the property used for offices, shops, compressors, gas clean up facilities, and other aboveground facilities that are used in support of the project. Steps also must be taken to minimize the effect of subsidence draw on this set-aside surface area. Generally the preferred coals for in situ production are those of lower rank, subbituminous and lignite, which are more reactive than higher rank coals. In the United States most of the reserves of reactive coals are located in western states where it is common that the coal seams are overlain and innerbedded with shale. Generally these shales are relatively soft and pliable, characteristics that facilitate minimizing the effects of subsidence in that subsidence cracks frequently will heal and seal in the pliable shale under the influence of the weight of the overburden. It is quite common in western coals that the coal seam itself is an aquifer. Wet seams require dewatering prior to in situ combustion, a circumstance that is both an advantage and a disadvantage. Water recovered from the seam can be used in the in situ production processes, a desirable feature in the arid west. On the other hand, the relatively low permeability of the wet coal seam introduces difficulties in the drawdown of flowable water. Without adequate drawdown a portion of the seam remains relatively wet while another portion, generally the upper portion in flat lying seams, is relatively dry. Once the seam is ignited, the propagating fire tends to flourish in the upper part of the seam, eventually engulfing itself in its own ashes and bypassing the coal underneath. Steps should be taken to control this flame override situation as will be further described hereinafter. By way of example the present invention will be directed to coals in the western United States. In the prior art dealing with conventional underground coal mining and resulting subsidence, recent comprehensive reports include U.S. Geological Survey Professional Paper 969, Some Engineering Geological Factors Controlling Coal Mine Subsidence in Utah and Colorado (1976) and U.S. Geological Survey Professional Paper 1164, Effects of Coal Mine Subsidence in the Sheridan, Wyo., Area (1980). Recent art involving subsidence associated with in situ coal gasification include U.S. Dept. of Energy Report UCRL-52255, Ground Subsidence Resulting from Underground Gasification of Coal (1977) and U.S. Dept. of Energy Report UCRL-50026-79-4, LLL In Situ Coal Gasification Project, Quarterly Progress Report, October through December 1979. In establishing the georeactor in the coal seam, linkage may be accomplished between wells by any convenient method, but preferably is accomplished using the methods of U.S. Pat. No. 4,185,692 of Terry. Likewise in situ production of coal may be accomplished by any convenient method, but preferably is accomplished using the methods of U.S. Pat. No. 4,114,688 of Terry. Additional methods of sealing a georeactor are taught in U.S. Pat. No. 4,102,397 of Terry. SUMMARY OF THE INVENTION Coal is produced in situ using a series of georeactors between pairs of wells. Georeactors enlarge as coal is consumed resulting in loss of support structure for the overburden with attendant roof fall and subsidence. A foaming mud cement is used to maintain georeactor integrity, thus minimizing product gas leakage and ground water contamination during production, and facilitating module quenching when production is terminated. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatical vertical section through the earth showing a series of wells in various stages of the methods of the invention, together with arrangement of aboveground equipment. FIG. 2 is a diagrammatical vertical section through the earth showing a well with conductor pipe cemented to the ground surface and a lower bob-tailed string of casing cemented to the bottom of the hole with attached bonding apparatus. FIG. 3A is cross section side view of bonding apparatus affixed to the casing. FIG. 3B is side view of a portion of the casing affixed with four sets of bonding apparatus. FIG. 3C is cross section plan view of the casing with one set of bonding apparatus. FIG. 4 is a diagrammatical vertical section through the earth showing module quenching in one georeactor and production in a nearby georeactor. FIG. 5 is a diagrammatical vertical section through the earth showing a pair of wells in a wet coal seam prior to establishing a georeactor between the wells. FIG. 6 is a diagrammatical vertical section through the earth showing arrangement of apparatus for placing a seal above the georeactor. FIG. 7 is a plan view showing a possible well pattern for the barrier pillar. FIG. 8A is a plan view of the barrier pillar showing location of subsidence draw protective trench. FIG. 8B is a diagrammatical vertical section through the earth showing subsidence draw protective trench with explosive fracturing. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1, a series of production wells 40-46 has been drilled from the surface of the earth through overburden 13 and into upper coal seam 48. The production plan calls for producing coal seam 48 in its entirety, then deepening the wells through interburden 20 into coal seam 49 for continued production. In upper coal seam 48 production has been underway for a period of time with georeactors established between pairs of wells. Coal 1 adjacent to well 46 is virgin coal, not yet affected by heat. Coal 2 has been affected by heat to the extent that it has been dehydrated. Coal 3 is in the early stages of pyrolysis. Coal 4 is sufficiently warm for active pyrolysis. Coal 5 is undergoing combustion. Void 6 remains after coal has been reduced to ash. Fluid foaming backfill material 7 is in the process of becoming solidified. Rubble 8 is composed of residual ash and overburden roof-fall. Backfill material 47 is solidified. By way of example, coal seam 48 is located 500 feet below the surface of the earth with an average seam thickness of 25 feet and coal seam 49 is located at an average depth of 1000 feet and has a thickness of 50 feet. As shown in FIG. 1 well 40 has produced all of coal seam 48 within its influence and has been deepened into coal seam 49 in preparation for additional production. Likewise well 41 has completed its purpose for coal seam 48 and is ready for deepening into coal seam 49, at which time a georeactor can be established between wells 40 and 41 in lower coal seam 49. Well 42 is receiving backfill material to fill the void remaining after coal has been consumed. The georeactor is active between wells 43 and 44, with reactants 14 being injected into well 42 and products of reaction 15 being withdrawn from well 44. Preferably the reactants are alternating injections of air and steam. Products of reaction during air injection is a low BTU gas composed principally of hydrogen, carbon monoxide, carbon dioxide and nitrogen. Products of reaction during steam injection is water gas (H 2 +CO), a useful product for synthesis into a host of useful products such as methane, methanol, naphtha, various oils and the like. Well 45 is producing at a low volume, mainly hot gases of pyrolysis with well 46 in a standby status for future production. When the georeactor between wells 43 and 44 grows to substantially the top of coal seam 48, well 43 is shut in, well 44 is converted into an injector well and well 45 becomes an active producer with products of reaction from the georeactor between wells 44 and 45. At this time backfilling operations will have been completed in well 42 and backfilling begins in well 43. A major in situ coal production project will require a large volume of sealant material, and preferably the raw materials for such sealants are located on site or nearby. The volume of solid raw materials required can be reduced substantially by mixing the solids with water that is saturated with carbon dioxide, as will be more fully described herein. The resulting mud cement is then injected into the underground void under sufficient pressure to maintain water in the liquid phase until the mud is substantially in place as planned. Solid raw materials include lime and/or magnesium cement materials. The underground void space is relatively hot due to residual heat from coal production. Preferably only a portion of the void space is filled with mud, for example one half of the volume. Residual heat causes the water to flash to steam with the resultant release of carbon dioxide as gas, the combination causing the mud to foam and then congeal into concrete, filling the void completely. An abundance of carbon dioxide, that otherwise would be vented to the atmosphere, is available on site from the production processes. Likewise an abundance of waste heat is also available for the processes of the present invention. Referring again to FIG. 1, raw calcareous materials 21 are delivered to a crusher 22 with the crushed material delivered to a kiln 23 for calcining into clinkers. Heat 24 is added to the kiln and carbon dioxide 25 is withdrawn from the kiln 23. Carbon dioxide 25 is then compressed and sent to heat exchanger/cooler 28 and then to absorber 30 where water 32 is introduced as the carrier liquid for absorbed carbon dioxide. Clinker from kiln 23 is directed to pulverizer 26 for sizing of the cement clinkers, with the sized material then transferred 39 to mixer 27. A suitable mud material 33, for example native clay, is directed to pulverize 34 with the sized material then directed to mixer 35 where water 36 is added to make mud, which in turn is stored in mud pit 37. At mixer 27 cement from pulverizer 26, water supersaturated with carbon dioxide from absorber 30, and native mud from pit 37 are then mixed, with the resultant mixture, sometimes called sealant mud, then injected 10 through well 42 into the underground formation 7. Such injection is made under pressure as previously described until the planned volume of sealant mud is in place underground. Underground pressure is then reduced by backing off on the pressure maintained in well 42 with the resultant foaming and congealing of mud 7, also as previously described. Thus an underground seal is established that assists in stabilizing the overburden and such seal also filling a void space that might otherwise be linked to an adjacent georeactor. No particular novelty is claimed in making cement from calcareous materials or for making mud from native materials. It will be appreciated, however, that the resulting soil cement saturated with carbon dioxide serves several purposes underground including reduction of underground temperatures below the ignition temperature of adjacent coal thereby quenching the spent georeactor and preventing an unplanned burn in adjacent coal, the released carbon dioxide serves to expand the volume of the sealant mud and promotes rapid setting of the expanded sealant mud, and the conversion of sealant mud water to steam for further expansion of the sealant mud prior to formation of concrete. A further advantage of the congealed sealant mud is that residual ash from burned coal is sealed from water incursion should the spent georeactor become a part of an aquifer during the post production period. It will be further appreciated that all wells drilled into coal seam 48 will have proper wellhead fittings (not shown) for maintaining planned pressures underground as well as for injection and recovery of the various fluids described herein, and that each well will have suitable hermetic seals for the casing. The spacing between wells is determined by procedures common in production of coal in situ. In drilling production wells for a project that is expected to have severe subsidence problems, it is important that each well be provided with protection from subsidence effects. Generally this means that the well column be strengthened against bending of the casing from vertical and horizontal loads. It is highly desirable that the casing survive earth shifts and that the casing remain intact during lowering of the surrounding overburden. Further the casing should be protected from excessive heat generated in georeactors. To these ends a suitable casing is selected with additional protection being provided for a proper filling material between the installed casing and the well bore. Referring to FIG. 2, well 225 is drilled from the surface of the earth 201 through overburden 202 and 203 into coal seam 204 with the drill hole bottomed a few inches above the lower boundary of the coal seam. The drill hole diameter could be, for example, 18 inches. As illustrated two strings of casing are used, a conductor casing 205 and a bobtail string 206. Casing 205 could be, for example, 133/8 inches in diameter and casing 206 could be, for example, 103/4 inches in diameter. The casing strings are cemented 211 in place, preferably by injecting cement within the casing, and thus forcing cement to flow from bottom to the ground surface in the annulus between the casing and the well bore. Cementing procedures used are those common in the petroleum industry and in completing geothermal wells. The casing with its protective concrete lining located in coal seam 204 will be subjected to unusual stresses, therefore it is desirable to take steps beyond standard cementing practices. Apparatus 215 is added to increase the fidelity of the bond between the cement and the casing. In preparing well 225 for production, the cement below the bottom of the casing 210 is drilled out as is the cement plug 224. This leaves a few inches of exposed coal below the original well bore, the space being used to establish a communication channel at the bottom of the seam to a nearby well that has been completed in the same manner as well 225. In bringing the well 225 on production, tubing 212 is inserted through wellhead 213 and bottomed near the interface 209 of the concrete and the coal. When well 225 is used as the reactants injection well, tubing 212 will remain relatively cool, but with the excess of oxygen available at the discharge point of the tubing, the coal immediately surrounding the well bore will burn a void space around the protective cement. This void space will cause the cement to undergo thermal stresses, hence the requirement for a good bond to the casing. When well 225 is used for a producer well, hot gases from the reactor are removed from the well through tubing 212 and it is important that the bottom joints of tubing be of heat resistant material. In severe cases it may be necessary to provide cooling to the casing and tubing, which can be accomplished by injecting water into the annulus between the two (not shown). It will be noted that bonding apparatus 215 is shown in the bonding position while bonding apparatus 217 in the overlap section of the casings is shown in the retracted position. Referring to FIG. 3, metal projections of the bonding apparatus, identified as 215, 216 and 217 in the previous drawing, are identified as 316. The bonding apparatus is designed for installation at the ground surface prior to placing the casing in the well bore. The projection finger is designed to retract during lowering casing 206 through casing 205, then extend outwardly in a locked position once the finger clears casing 205. The projecting fingers 316 are constructed from preferably 3/8 inch steel rod and are of one piece construction making a pair of fingers with a center bearing surface, for example, 2 inches long between the fingers, the bearing surface being retained within a bracket 315 attached to hoop 321. A multiplicity of brackets with installed fingers is suitably affixed to hoop 321 which in turn is attached to casing 320. Preferably the fingers are formed in the shape of a shallow arc that removes the tip of the finger from contact with the outer casing when the finger is in the retracted position. The number of pairs of fingers on a hoop and the number of hoops affixed to the casing are selected with due regard to providing reinforcing and bonding requirements for the type of reinforced concrete being used, for example in a typical concrete, for each foot of casing three hoops are installed containing eight pairs of fingers. Preferably the curvature of the fingers is selected so that moderate compressive force is placed on the arc when the finger is retracted and is being lowered through the conductor casing. In this manner the fingers will serve as centralizers and will snap outwardly upon clearing the conductor casing. The fingers will fall by gravity to the extended position, being restrained from further rotation by lip 318 on bracket 315. Preferably fingers 316 lock in place upon rotating from the retracted position to the extended position, in order to assure remaining in the extended position upon being engulfed with cement grout. A suitable locking device may be selected from several commercially available, but preferably is of the type that may be manually unlocked prior to lowering the casing into the well but easily locks upon snapping into place by gravity, with a lock strength sufficient to overcome the force of an ascending cement column during grouting. In some cases it may be desirable to install the bonding apparatus arrangement to conductor casing 205 as well as to increase the size of the well bore to provide a thicker section of cement. Such arrangements are desirable when the well is planned to be deepened into one or more underlying seams whose production will cause multiple waves of subsidence forces. In some locations in western United States, production of coal from multiple seams could result in subsidence as much as 200 feet at the surface. Under this extreme circumstance it would be necessary to cut off a portion of the casing, perhaps on several occasions, to lower the well head to a convenient height. Referring to FIG. 4, two pairs of wells are shown drilled through overburden 405 and into coal seam 406. Georeactor 407 is nearing economic exhaustion, unproduced coal between wells 402 and 403 has been left in place for future production and georeactor 408 is in the early stages of production. It is desired to quench the module of georeactor 407 in preparation for backfill as previously described. Water is injected into well 401 which reacts with remnant hot coal in reactor 407 to produce water gas which is recovered as product gas. Since the air blow/steam run procedure has been terminated, the endothermic water gas reaction will lower the temperature of the hot coal and ultimately terminate the water gas reaction. During the cooling period the components of produced fluid recovered from well 402 will shift from water gas to water gas and steam, then finally to steam at about 1200° F. In order to assure that the module is quenched, temperature must be lowered below the ignition temperature of remnant coal, that is, a temperature below about 800° F. A considerable amount of sensible heat associated with module 407 may be recovered by continuing water injection until the quality of the steam is unsuitable for commercial use. Thus the steam generated in module 407 cooldown may be made from untreated water with produced steam used for the steam run in active module 408. When used in this manner well 402 is shut in during the repetitive air blows in well 403 and opened for the repetitive steam runs of georeactor 408. Referring to FIG. 5, wells 501 and 502 have been drilled through overburden 503 and into coal seam 504 which is an aquifer. After a considerable amount of pumping the localized water table has been lowered to the level indicated by the dashed line. Coal 504A is relatively dry in that flowable water has been removed. Coal 504B remains relatively wet with flowable water remaining in multiple angles of repose. Should linkage be attempted by a reverse burn in the coal between wells 501 and 502, conditions favor burning in the relatively dry coal 504A and thus the linkage will not be in the desired location at the bottom of the seam. If conditions are otherwise favorable for a reverse burn linkage, such as a thin shale break near the bottom of the seam, then steps must be taken to lower the water table to near the bottom of the seam. The procedure begins by opening well 501 and injecting a gas containing little or no oxygen, preferably carbon dioxide or nitrogen or a mixture thereof. With well 502 shut in, inert gas is injected into well 501 until the localized coal seam pressure comes up to near fracturing level, for example one pound per square inch of pressure for each foot of depth to coal seam 504. Injection in well 501 continues at the selected near fracturing pressure and water is produced through well 502 by holding a lesser back pressure on well 502. The procedure continues until water no longer flows out of well 502 when no back pressure is held in well 502. The remainder of water in the vicinity of well 502 may then be removed by pumping until drawdown occurs. Referring to FIG. 6, one well of a pair of wells is shown at a time when the georeactor had been operating in an undesirable flame override mode for an extended period. Well 601 was drilled from the surface of the earth through overburden 612, aquifer 613 and overburden 614. Casing 604 was set to the top of coal 618 and cemented 606 to the surface. The well was then deepened to the bottom of coal seam 618 and linkage channel 620 was established to the nearby well which served as an injector well to the georeactor. In the course of production, the burn preferentially moved from the linkage channel 620 to a higher location in the seam, burning a cavity in the upper portion of the seam and with burn-through to well 601 occurring at the top of the seam in channel 619. In overburden 614 both roof fall and subsidence have occurred resulting in cavity 616, rubble pile 617 and subsidence crack 615. The georeactor between the wells has lost its pressurized integrity through open channel 615 to the atmosphere, and cavity 616 adds a nonproductive volume to the reactor. In addition water from aquifer 613 is free to flow into the reactor and its hot environment. For remedial action both wells are shut in and some dirt work may be done at the surface to limit the lateral extent of the subsidence crack. Initially it is desirable to have water incursion into the reactor to quench the module, and quenching can be hastened by injection water into one or both of the wells, with steam venting through crack 615. When the georeactor is cooled to the planned temperature, well 601 is equipped with a sealant mud liner as shown in FIG. 6. The liner is composed of tubing 605, hung from flange 602 and bottomed near original linkage channel 620. Affixed to tubing 605 is mud deflector 608 composed of an upper swage connected to a lower collar, positioned near the bottom of channel 619. Affixed to mud deflector 608 is mud screen 609 which is a perforated 610 metal cylinder, positioned from a point within casing 604 to a point slightly below the bottom of tubing 605. Mud injection pipe 603 is located near the upper end of casing 604. The sealing procedure begins by shutting in the nearby well, then injecting sealant mud via pipe 603 into annulus 607. Sealant mud may be of any suitable type but preferably is the type identified in the discussion of FIG. 1 in a foregoing section. Initially the injected mud is allowed to flow by gravity through mud screen 609 and into the bottom of well 601, thus partially plugging linkage 620. Sealing continues with injection of mud through pipe 603 and with injection of inert gas into well 601 through tubing 605. The inert gas preferably is carbon dioxide, nitrogen or a mixture of the two. Pressure of the inert gas is established at a value preferably slightly below the pressure of the column of mud as it approaches mud deflector 608. Pressure of the georeactor, with the open vent to the atmosphere, is considerably below that of the injected mud and injected inert gas, therefore the sealant mud will flow under a gas drive into channel 619. With continued injections the mud will engulf rubble pile 617 and begin ascending into cavity 616. Mudding continues in this manner until injection pressures show a marked rise, signalling that the mud refusal point is near. Injection of mud and inert gas is terminated, and is immediately followed by injections of slugs of water both in annulus 607 and tubing 605 to flush mobile mud out of well 601. At this point tubing 605, with attached mud deflector and mud screen, is removed from well 601. The system is then shut in to allow time for the foaming mud to expand to its final position and properly set. With the seal thus placed on the reactor, subsidence crack 615 is sealed from the bottom up, excluding aquifer 613 from the georeactor, cavity 616 is substantially filled, channel 619 is plugged, and rubble pile 617 is sealed. Well 601 is reentered and accumulated cement is drilled through to the original bottom of the hole. The drill bit is removed and a perforating gun is lowered to the bottom of the hole and fired as necessary to reopen linkage channel 620. The gun is removed, well 601 is reequipped for production, coal 618 is reignited and production resumes with a growing georeactor in channel 620. Referring to FIG. 7, a plan view is shown of a portion of the project property limit 701, the location of the barrier pillar 708, outer water interceptor wells 702, inner water interceptor wells 703, minimum width of the barrier pillar 704, and the locations of underground georeactors 705, 706 and 707. The barrier pillar, as previously mentioned is a strip of unmined coal left at the perimeter of the property. The outside boundary of the barrier pillar can be a straight line coinciding with the property limit. The inner boundary of the barrier pillar is a theoretical straight line 704, which is the minimum planned width of the pillar, for example 150 feet. Actual inner boundary of the pillar is controlled by the shape of the georeactors for in situ production. The inner boundary is irregular with unproduced coal 709 occurring along the line. The barrier pillar is left to provide a buffer between the project and adjacent property. Migration of water in aquifers located above the coal seam is of concern. Water flowing into the project may cause a problem with underground georeactors during subsidence disturbances. Water flowing out of the project may be contaminated and thus should not be allowed to flow untreated into neighboring properties. Thus water flowing into the project site may be intercepted by maintaining localized drawdown of the water table by producing water from wells in the barrier pillar. Likewise contaminated water flowing out of the project site can be intercepted by pumping the wells, with produced water being directed to water treating facilities prior to further use. In some cases it may be desirable to block the flow of water through the barrier pillar area. In these cases the wells in the barrier pillar are used to inject mud in the aquifer, plugging the permeability of the formation. Such mud preferably is a slush mud slurry composed of water and fine clay, with a slurry solids content in the range of 10 to 50%. Sealant mud, as described previously, may also be used for this purpose. Plugging the aquifer is accomplished by injecting the slurry into one well, for example well 702, and opening a nearby well, for example well 703, and continuing slurry injection to refusal. This procedure continues until all wells in the pillar have been subjected to injection of the slurry to refusal. As a practical matter it is desirable to test the wells from time to time to assure that the seal remains, and if seal failure has occurred at any well such well should be re-mudded. Referring to FIG. 8A, a plan view of the project site is shown, including site perimeter 801, barrier pillar area 802 and subsidence draw protective trench 803. Trench 803 is dug to provide a discontinuity in the surface rock to a depth designed to protect surface installations from destructive forces of subsidence draw. The depth of trench 803 may vary from place to place on the site, for example the trench should be at least as deep around plant facilities as the lowermost portion of the foundations for structures within the plant facilities. It is common to locate service roads above the barrier pillar and a fence on the property periphery, thus the trench may be somewhat shallower in these locations as compared to the trench depth around plant facilities. FIG. 8B is a vertical section showing the ground surface 820 and trench 821 dug to depth 824. To provide additional depth to the discontinuities, explosive charges 822 are placed in the bottom of the trench. Explosive charges preferably are of the slow burning type, for example black powder, are spaced apart an appropriate distance, for example in the range of 5 to 10 feet, and of appropriate size, for example in the range of one-half to one pound. Preferably the charges are positioned, the trench is filled with excavation material and the charges are detonated. Resulting rock fracturing adds to the protection against lateral surface rock shifts during applied forces of subsidence draw. Thus it may be seen that a system of methods may be employed to minimize the effects of subsidence during production of coal in situ. In applying such methods problems become manageable in georeactor integrity including product gas leakage, ground water contamination and module quenching. It will be appreciated that this invention is not limited to any theory of operation, but that any theory that has been advanced is merely to facilitate disclosure of the invention. While the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof.
Coal is reduced to ash in place by gasification using in situ production techniques, resulting in significant void space underground, which in turn causes roof fall and subsidence. Overburden collapse is stabilized by backfilling with foaming mud cement that hardens into an expanded solid, which quenches and fills the production module and seals residual ash. Rubble volumes and subsidence cracks are sealed against water incursions and contaminated water excursions. Surface facilities above barrier pillars are protected from destructive forces of subsidence draw.
4
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 12/246,959 filed on Oct. 7, 2008. This application claims the benefit of U.S. Provisional Application No. 60/978,258, filed on Oct. 8, 2007. The entire disclosures of each of the above applications are incorporated herein by reference. FIELD The present disclosure relates to compressors, and more particularly, to a protection system for use with a variable speed compressor. BACKGROUND The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. Compressors may be used in a wide variety of industrial and residential applications to circulate refrigerant within a refrigeration, heat pump, HVAC, or chiller system (generically “refrigeration systems”) to provide a desired heating or cooling effect. In any of the foregoing applications, the compressor should provide consistent and efficient operation to insure that the particular application (i.e., refrigeration, heat pump, HVAC, or chiller system) functions properly. A variable speed compressor may be used to vary compressor capacity according to refrigeration system load. Operation of the compressor during a flood back condition is undesirable. A flood back condition occurs when excessive liquid refrigerant flows into the compressor. Severe flood back can dilute the oil and reduce its lubrication property, leading to potential seizure. Although some mixture of liquid refrigerant and oil in the compressor may be expected, excessive mixture may cause damage to the compressor. Likewise, operation of the compressor at excessive temperature levels may be damaging to the compressor. An overheat condition may damage internal compressor components including, for example, the electric motor. SUMMARY This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. A system is provided that includes a compressor connected to a condenser and a discharge line temperature sensor that outputs a discharge line temperature signal corresponding to a discharge line temperature of refrigerant leaving the compressor. The system also includes a control module connected to the discharge line temperature sensor. The control module determines a saturated condenser temperature, calculates a discharge superheat temperature based on the saturated condenser temperature and the discharge line temperature, and monitors a flood back condition of the compressor by comparing the discharge superheat temperature with a predetermined threshold. The control module also increases a speed of the compressor or decreases an opening of an expansion valve associated with the compressor when the discharge superheat temperature is less than or equal to the predetermined threshold. A method is also provided and includes determining, with a control module, a saturated condenser temperature of a condenser connected to a compressor. The method also includes receiving, with the control module, a discharge line temperature signal that corresponds to a discharge line temperature of refrigerant leaving the compressor. The method also includes calculating, with the control module, a discharge superheat temperature based on the saturated condenser temperature and the discharge line temperature. The method also includes monitoring, with the control module, a flood back condition of the compressor by comparing the discharge superheat temperature with a predetermined threshold. The method also includes increasing a speed of the compressor or decreasing an opening of an expansion valve associated with the compressor when the discharge superheat temperature is less than or equal to the predetermined threshold. Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. DRAWINGS The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. FIG. 1 is a schematic illustration of a refrigeration system. FIG. 2 is a perspective view of a compressor with an inverter drive. FIG. 3 is another perspective view of a compressor with an inverter driver. FIG. 4 is a cross-section view of a compressor. FIG. 5 is a graph showing discharge super heat correlated with suction super heat and outdoor temperature. FIG. 6 is a graph showing condenser temperature correlated with compressor power and compressor speed. FIG. 7 is a graph showing an operating envelope of a compressor. FIG. 8 is a graph showing condensing temperature correlated with evaporator temperature and compressor power for a given compressor speed. FIG. 9 is a graph showing discharge line temperature correlated with evaporator temperature and condenser temperature. FIG. 10 is a flow chart showing derived data for a refrigeration system. FIG. 11 is a schematic of a refrigeration system. FIG. 12 is a flow chart showing derived data for a refrigeration system. FIG. 13 is a graph showing mass flow correlated with inverter drive heat loss. FIG. 14 is a graph showing inverter speed correlated with inverter efficiency. FIG. 15 is a graph showing a control module with measured inputs and derived outputs. FIG. 16 is a schematic of a refrigeration system. FIG. 17 is a cross-section view of a compressor. DETAILED DESCRIPTION The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the terms module, control module, and controller may refer to one or more of the following: An application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality. As used herein, computer readable medium may refer to any medium capable of storing data for a computer or module, including a processor. Computer-readable medium includes, but is not limited to, memory, RAM, ROM, PROM, EPROM, EEPROM, flash memory, CD-ROM, floppy disk, magnetic tape, other magnetic medium, optical medium, or any other device or medium capable of storing data for a computer. With reference to FIG. 1 , an exemplary refrigeration system 5 includes a compressor 10 that compresses refrigerant vapor. While a specific refrigeration system is shown in FIG. 1 , the present teachings are applicable to any refrigeration system, including heat pump, HVAC, and chiller systems. Refrigerant vapor from compressor 10 is delivered to a condenser 12 where the refrigerant vapor is liquefied at high pressure, thereby rejecting heat to the outside air. The liquid refrigerant exiting condenser 12 is delivered to an evaporator 16 through an expansion valve 14 . Expansion valve 14 may be a mechanical or electronic valve for controlling super heat of the refrigerant. The refrigerant passes through expansion valve 14 where a pressure drop causes the high pressure liquid refrigerant to achieve a lower pressure combination of liquid and vapor. As hot air moves across evaporator 16 , the low pressure liquid turns into gas, thereby removing heat from evaporator 16 . The low pressure gas is again delivered to compressor 10 where it is compressed to a high pressure gas, and delivered to condenser 12 to start the refrigeration cycle again. With reference to FIGS. 1, 2 and 3 , compressor 10 may be driven by an inverter drive 22 , also referred to as a variable frequency drive (VFD), housed in an enclosure 20 . Enclosure 20 may be near compressor 10 . Inverter drive 22 receives electrical power from a power supply 18 and delivers electrical power to compressor 10 . Inverter drive 22 includes a control module 25 with a processor and software operable to modulate and control the frequency of electrical power delivered to an electric motor of compressor 10 . Control module 25 includes a computer readable medium for storing data including the software executed by the processor to modulate and control the frequency of electrical power delivered to the electric motor of compressor and the software necessary for control module 25 to execute and perform the protection and control algorithms of the present teachings. By modulating the frequency of electrical power delivered to the electric motor of compressor 10 , control module 25 may thereby modulate and control the speed, and consequently the capacity, of compressor 10 . Inverter drive 22 includes solid state electronics to modulate the frequency of electrical power. Generally, inverter drive 22 converts the inputted electrical power from AC to DC, and then converts the electrical power from DC back to AC at a desired frequency. For example, inverter drive 22 may directly rectify electrical power with a full-wave rectifier bridge. Inverter driver 22 may then chop the electrical power using insulated gate bipolar transistors (IGBT's) or thyristors to achieve the desired frequency. Other suitable electronic components may be used to modulate the frequency of electrical power from power supply 18 . Electric motor speed of compressor 10 is controlled by the frequency of electrical power received from inverter driver 22 . For example, when compressor 10 is driven at sixty hertz electric power, compressor 10 may operate at full capacity operation. When compressor 10 is driven at thirty hertz electric power, compressor 10 may operate at half capacity operation. Piping from evaporator 16 to compressor 10 may be routed through enclosure 20 to cool the electronic components of inverter drive 22 within enclosure 20 . Enclosure 20 may include a cold plate 15 . Suction gas refrigerant may cool the cold plate prior to entering compressor 10 and thereby cool the electrical components of inverter drive 22 . In this way, cold plate 15 may function as a heat exchanger between suction gas and inverter drive 22 such that heat from inverter drive 22 is transferred to suction gas prior to the suction gas entering compressor 10 . As shown in FIGS. 2 and 3 , electric power from inverter drive 22 housed within enclosure 20 may be delivered to compressor 10 via a terminal box 24 attached to compressor 10 . A compressor floodback or overheat condition is undesirable and may cause damage to compressor 10 or other refrigeration system components. Suction super heat (SSH) and/or discharge super heat (DSH) may be correlated to a flood back or overheating condition of compressor 10 and may be monitored to detect and/or predict a flood back or overheating condition of compressor 10 . DSH is the difference between the temperature of refrigerant vapor leaving the compressor, referred to as discharge line temperature (DLT) and the saturated condenser temperature (Tcond). Suction super heat (SSH) is the difference between the temperature of refrigerant vapor entering the compressor, referred to as suction line temperature (SLT) and saturated evaporator temperature (Tevap). SSH and DSH may be correlated as shown in FIG. 5 . The correlation between DSH and SSH may be particularly accurate for scroll type compressors, with outside ambient temperature being only a secondary effect. As shown in FIG. 5 , correlations between DSH and SSH are shown for outdoor temperatures (ODT) of one-hundred fifteen degrees Fahrenheit, ninety-five degrees Fahrenheit, seventy-five degrees Fahrenheit, and fifty-five degrees Fahrenheit. The correlation shown in FIG. 5 is an example only and specific correlations for specific compressors may vary by compressor type, model, capacity, etc. A flood back condition may occur when SSH is approaching zero degrees or when DSH is approaching twenty to forty degrees Fahrenheit. For this reason, DSH may be used to detect the onset of a flood back condition and its severity. When SSH is at zero degrees, SSH may not indicate the severity of the flood back condition. As the floodback condition becomes more severe, SSH remains at around zero degrees. When SSH is at zero degrees, however, DSH may be between twenty and forty degrees Fahrenheit and may more accurately indicate the severity of a flood back condition. When DSH is in the range of thirty degrees Fahrenheit to eighty degrees Fahrenheit, compressor 10 may operate within a normal range. When DSH is below thirty degrees Fahrenheit, the onset of a flood back condition may occur. When DSH is below ten degrees Fahrenheit, a severe flood back condition may occur. With respect to overheating, when DSH is greater than eighty degrees Fahrenheit, the onset of an overheating condition may occur. When DSH is greater than one-hundred degrees Fahrenheit, a severe overheating condition may be present. In FIG. 5 , typical SSH temperatures for exemplar refrigerant charge levels are shown. For example, as the percentage of refrigerant charge in refrigeration system 5 decreases, SSH typically increases. To determine DSH, DLT may be subtracted from Tcond. DLT may be sensed by a DLT sensor 28 that senses a temperature of refrigerant exiting compressor 10 . As shown in FIG. 1 , DLT sensor 28 may be external to compressor 10 and may be mounted proximate a discharge outlet of compressor 10 . Alternatively, an internal DLT sensor 30 may be used as shown in FIG. 4 . In FIG. 4 , a cross-section of compressor 10 is shown. Internal DLT sensor 30 may be embedded in an upper fixed scroll of a scroll compressor and may sense a temperature of discharge refrigerant exiting the intermeshing scrolls. In the alternative, a combination temperature/pressure sensor may be used. In such case, Tcond may be measured based on the pressure of refrigerant exiting compressor 10 as measured by the combination sensor. Moreover, in such case, DSH may be calculated based on DLT, as measured by the temperature portion of the sensor, and on Tcond, as measured by the pressure portion of the combination sensor. Tcond may be derived from other system parameters. Specifically, Tcond may be derived from compressor current and voltage (i.e., compressor power), compressor speed, and compressor map data associated with compressor 10 . A method for deriving Tcond based on current, voltage and compressor map data for a fixed speed compressor is described in the commonly assigned application for Compressor Diagnostic and Protection System, U.S. application Ser. No. 11/059,646, Publication No. U.S. 2005/0235660. Compressor map data for a fixed speed compressor correlating compressor current and voltage to Tcond may be compressor specific and based on test data for a specific compressor type, model and capacity. In the case of a variable speed compressor, Tcond may also be a function of compressor speed, in addition to compressor power. A graphical correlation between compressor power in watts and compressor speed is shown in FIG. 6 . As shown, Tcond is a function of compressor power and compressor speed. In this way, a three-dimensional compressor map with data correlating compressor power, compressor speed, and Tcond may be derived for a specific compressor based on test data. Compressor current may be used instead of compressor power. Compressor power, however, may be preferred over compressor current to reduce the impact of any line voltage variation. The compressor map may be stored in a computer readable medium accessible to control module 25 . In this way, control module 25 may calculate Tcond based on compressor power data and compressor speed data. Control module 25 may calculate, monitor, or detect compressor power data during the calculations performed to convert electrical power from power supply 18 to electrical power at a desired frequency. In this way, compressor power and current data may be readily available to control module 25 . In addition, control module 25 may calculate, monitor, or detect compressor speed based on the frequency of electrical power delivered to the electric motor of compressor 10 . In this way, compressor speed data may also be readily available to control module 25 . Based on compressor power and compressor speed, control module 25 may derive Tcond. After measuring or calculating Tcond, control module 25 may calculate DSH as the difference between Tcond and DLT, with DLT data being receiving from external DLT sensor 28 or internal DLT sensor 30 . Control module 25 may monitor DSH to detect a flood back or overheat condition, based on the correlation between DSH and flood back and overheat conditions described above. Upon detection of a flood back or overheat condition, control module 25 may adjust compressor speed or adjust expansion valve 14 accordingly. Control module 25 may communicate with or control expansion valve 14 . Alternatively, control module 25 may communicate with a system controller for refrigeration system 5 and may notify system controller of the flood back or overheat condition. System controller may then adjust expansion valve or compressor speed accordingly. DSH may be monitored to detect or predict a sudden flood back or overheat condition. A sudden reduction in DLT or DSH without significant accompanying change in Tcond may be indicative of a sudden flood back or overheat condition. For example, if DLT or DSH decreases by a predetermined temperature amount (e.g., fifty degrees Fahrenheit) within a predetermined time period (e.g., fifty seconds), a sudden flood back condition may exist. Such a condition may be caused by expansion valve 14 being stuck open. Likewise, a sudden increase in DLT or DSH with similar magnitude and without significant accompanying change in Tcond may be indicative of a sudden overheat condition due to expansion valve 14 being stuck closed. For example, if DLT or DSH increases by a predetermined temperature amount (e.g., fifty degrees Fahrenheit) within a predetermined time period (e.g., fifty seconds), a sudden overheat condition may exist. Control module 25 may monitor DSH and DLT to determine whether compressor 10 is operating within a predetermined operating envelope. As shown in FIG. 7 , a compressor operating envelope may provide maximum flood back and maximum and/or minimum DSH/DLT limits. In addition, a maximum scroll temperature limit (Tscroll) may be provided, in the case of a scroll compressor. In addition, a maximum motor temperature (Tmotor) may be provided. As shown in FIG. 7 , compressor speed and expansion valve 14 may be adjusted based on DSH and/or DLT to insure compressor operation within the compressor operating envelope. In this way, DSH and/or DLT may move back into an acceptable range as indicated by FIG. 7 . Compressor speed adjustment may take priority over expansion valve adjustment. In some cases, such as a defrost state, it may be difficult for expansion valve 14 to respond quickly and compressor speed adjustment may be more appropriate. In the event of a flood back condition, control module 25 may limit a compressor speed range. For example, when DSH is below thirty degrees Fahrenheit, compressor operation may be limited to the compressor's cooling capacity rating speed. For example, the cooling capacity rating speed may be 4500 RPM. When DSH is between thirty degrees Fahrenheit and sixty degrees Fahrenheit, compressor operating speed range may be expanded linearly to the full operating speed range. For example, compressor operating speed range may be between 1800 and 7000 RPM. The function correlating Tcond with compressor speed and power, may assume a predetermined or constant saturated Tevap. As shown in FIG. 8 , the correlation between compressor power and Tcond may be insensitive to variations of Tevap. For additional accuracy, Tevap may be derived as a function of Tcond and DLT, as described in commonly assigned U.S. application Ser. No. 11/059,646, U.S. Publication No. 2005/0235660. For variable speed compressors, the correlation may also reflect compressor speed. In this way, Tevap may be derived as a function of Tcond, DLT and compressor speed. As shown in FIG. 9 , Tevap is shown correlated with DLT, for various Tcond levels. For this reason, compressor map data for different speeds may be used. Tcond and Tevap may be calculated based on a single derivation. In addition, iterative calculations may be made based on the following equations: T cond= f (compressor power,compressor speed, T evap)  Equation 1: T evap= f ( T cond,DLT,compressor speed)  Equation 2: Multiple iterations of these equations may be performed to achieve convergence. For example, three iterations may provide optimal convergence. As discussed above, more or less iteration, or no iterations, may be used. Tevap and Tcond may also be determined by using compressor map data, for different speeds, based on DLT and compressor power, based on the following equations: T evap= f (compressor power,compressor speed,DLT)  Equation 3: T cond= f (compressor power,compressor speed,DLT)  Equation 4: Once Tevap and Tcond are known, additional compressor performance parameters may be derived. For example, compressor capacity and compressor efficiency may be derived based on additional compressor performance map data for a specific compressor model and capacity. Such additional compressor map data may be derived from test data. For example, compressor mass flow or capacity, may be derived according to the following equation: T evap= f (compressor speed, T cond,mass flow)  Equation 5: Mass flow may be derived according to the following equation: Mass Flow= m 0+ m 1* T evap+ m 2* T cond+ m 3*RPM+ m 4* T evap* T cond+ m 5* T evap*RPM+ m 6* T cond*RPM+ m 7* T evap^2+ m 8* T cond^2+ m 9*RPM^2+ m 10* T evap* T cond*RPM+ m 11* T evap^2* T cond+ m 12* T evap^2*RPM+ m 13* T evap^3+ m 14* T evap* T cond^2+ m 15* T cond^2*RPM+ m 16* T cond^3+ m 17* T evap*RPM^2+ m 18* T cond*RPM^2+ m 19*RPM^3  Equation 6: where m0-m19 are compressor model and size specific, as published by compressor manufacturers. Compressor map data may be stored within a computer readable medium within control module 25 or accessible to control module 25 . As shown in FIG. 10 , a flow chart for derived parameters is shown. In step 100 , Tcond may be derived from compressor power and compressor speed. In step 101 , Tevap may be derived from DLT and Tcond. In step 102 , capacity/mass flow and a compressor energy efficiency ratio may be derived from Tevap and Tcond. In addition, by monitoring run time in step 103 , additional parameters may be derived. Specifically, in step 104 , load and Kwh/Day may be derived from run time, capacity/mass flow, EER, and compressor power. By monitoring the above operating parameters, control module 25 may insure that compressor 10 is operating within acceptable operating envelope limits that are preset by a particular compressor designer or manufacturer and may detect and predict certain undesirable operating conditions, such as compressor floodback and overheat conditions. Further, control module 25 may derive other useful data related to compressor efficiency, power consumption, etc. Where compressor 10 is driven by a suction cooled inverter drive 22 , Tevap may be alternatively calculated. Because Tevap may be calculated from mass flow, Tcond, and compressor speed as discussed above, control module 25 may derive mass flow from a difference in temperature between suction gas entering cold plate 15 (Ts) and a temperature of a heat sink (Ti) located on or near inverter drive 22 . Control module 25 may calculate delta T according to the following equation: delta T=Ts−Ti   Equation 7: Ts and Ti may be measured by two temperature sensors 33 and 34 shown in FIG. 11 . Temperature sensor 33 measures the temperature of the heat sink (Ti) and may be incorporated as part of inverter drive 22 . Alternatively, temperature sensor 33 may measure a temperature of suction gas exiting cold plate 15 and may be located on or near the piping between cold plate 15 and compressor 10 . Temperature sensor 34 measures the temperature of suction gas entering cold plate 15 . Control module 25 may determine mass flow based on delta T and by determining the applied heat of inverter drive 22 . As shown in FIG. 12 , mass flow may be derived based on lost heat of inverter drive 22 and delta T. As shown in FIG. 13 , the relationship between mass flow, delta T and applied inverter heat may be mapped based on test data. Inverter heat may be derived based on inverter speed (i.e., compressor speed) and inverter efficiency as shown in FIG. 14 . With reference again to FIG. 12 , inputs include compressor speed (RPM) 120 , compressor current 122 , compressor voltage 124 , compressor power factor 126 , Ti 128 and Ts 130 . From compressor current 122 , compressor voltage 124 , and power factor 126 , compressor power 132 is derived. From temperatures Ti 128 and Ts 130 , delta T 134 is derived. From RPM 120 and power, Tcond 136 is derived. Also from RPM 120 and power 132 , inverter heat loss 138 is derived. From inverter heat loss, and delta T 134 , mass flow 140 is derived. From RPM 120 , Tcond 136 , and mass flow 140 , Tevap 142 is derived. From Tevap 142 and Ts 130 , SSH 144 is derived. From SSH 144 and ambient temperature as sensed by ambient temperature sensor 29 , DSH 146 is derived. Once DSH 146 is derived, all of the benefits of the algorithms described above may be gained, including protection of compressor 10 from flood back and overheat conditions. As shown by dotted line 141 , Tcond and Tevap may be iteratively calculated to more accurately derive Tcond and Tevap. For example, optimal convergence may be achieved with three iterations. More or less iterations may also be used. As shown in FIG. 15 , control module 25 takes as measured inputs compressor speed RPM, inverter drive current, voltage, and power, and heat sink temperatures Ti and Ts. Control module also takes as input ambient temperature as indicated by ambient temperature sensor 29 . As discussed above, control module 25 derives from these measured inputs the outputs of Tcond, Tevap, mass flow, SSH, DSH, and DLT. As shown in FIG. 16 , control module 25 may monitor SLT with SLT sensor 35 , which may include a combination pressure and temperature sensor may be used. In such case, Tevap may be measured based on the suction pressure as measured by the pressure portion of the combination sensor. Further, SSH may be calculated based on SLT, as measured by the temperature portion of the combination sensor, and Tevap. SLT sensor 34 , 35 may be located at an inlet to compressor 10 and may sense a temperature or pressure of refrigerant entering compressor 10 subsequent to inverter 22 , enclosure 20 , or cold plate 15 . Alternatively SLT sensor may be located at an inlet to enclosure 20 , inverter 22 , or cold plate 15 and may sense a temperature or pressure of refrigerant entering the enclosure 20 , inverter 22 , or cold plate 15 . In addition, similar to the calculation of DSH based on DLT described above, control module 25 may also calculate SSH. For example, compressor power, compressor speed, and compressor map data may be used to derive Tcond and Tevap may be derived from Tcond. Once Tevap is derived, SSH may be derived from SLT and Tevap and used as described above for monitoring various compressor operating parameters and protecting against flood back and overheat conditions.
A system and method for a compressor includes a compressor connected to a condenser, a discharge line temperature sensor that outputs a discharge line temperature signal corresponding to a discharge line temperature of refrigerant leaving the compressor, and a control module connected to the discharge line temperature sensor. The control module determines a saturated condenser temperature, calculates a discharge superheat temperature based on the saturated condenser temperature and the discharge line temperature, and monitors a flood back condition of the compressor by comparing the discharge superheat temperature with a predetermined threshold. The control module increases a speed of the compressor or decreases an opening of an expansion valve associated with the compressor when the discharge superheat temperature is less than or equal to the predetermined threshold.
5
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/068,791 filed Oct. 27, 2014, which is hereby incorporated by reference in its entirety herein. BACKGROUND OF THE INVENTION [0002] I. Field of the Invention [0003] The present disclosure relates generally to a user interface for a motorized exercise machine, and more specifically to a programmable and variable resistance machine for measuring and displaying various force and directional outputs. [0004] II. Description of the Prior Art [0005] Weight based resistance exercise generally relies on a fixed load (e.g. 50 lbs.) throughout the entire exercise range of motion, while motorized isokinetics continuously varies the load it delivers to accommodate the user. Isokinetic resistance works by allowing a moving element, such as a handle or grip, to travel at a fixed speed. As a user engages the handle and tries to increase speed, he is met with increased resistance as the handle speed remains unchanged. This may be accomplished with a motorized isokinetic resistance system wherein a motor controller regulates the speed and torque of the motor, where speed varies with input voltage, and torque varies with current. [0006] Both conventional weight based resistance exercise and isokinetic systems have their advantages and disadvantages. For example, monitoring a weight based workout involves counting repetitions and keeping track of the weight used, and since force is continually changing with isokinetic resistance, tracking progress during use is even more challenging. Additionally, if the isokinetic system utilizes multiple measuring devices, there is a need for multiple readouts. [0007] The present disclosure overcomes the problems associated with conventional weight based and isokinetic resistance systems by utilizing a logic device to make decisions about what information is to be presented on a single digital or graphic display. Accordingly, it is a general object of this disclosure to provide an improved user interface for a motorized isokinetic resistance exercise machine. [0008] It is another general object of the present disclosure to provide an exercise machine that manages the speed and torque produced at the isokinetic resistance mechanism. [0009] It is a more specific object of the present disclosure to provide an improved force measuring device for accurate calculation and display. [0010] These and other objects, features and advantages of this disclosure will be clearly understood through a consideration of the following detailed description. SUMMARY OF THE INVENTION [0011] According to an embodiment of the present disclosure, there is provided an exercise apparatus having a user engageable grip coupled to two resistive mechanisms and two force measuring devices through flexible elements. The devices are each capable of measuring force in one direction. A user interface calculates and displays force value and directional value. BRIEF DESCRIPTION OF THE DRAWINGS [0012] The present disclosure will be more fully understood by reference to the following detailed description of one or more preferred embodiments when read in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout the views and in which: [0013] FIG. 1 is a side view of a resistance machine according to the principles of an embodiment of the present disclosure. [0014] FIG. 2 is the side view of FIG. 1 with the user forcing the handle up. [0015] FIG. 3 is the side view of FIG. 1 with the user forcing the handle down. [0016] FIG. 4 is the side view of FIG. 1 with the user forcing the handle out. [0017] FIG. 5 is the side view of FIG. 1 illustrating a correctional factor. [0018] FIG. 6 is a screen shot of the user interface of FIG. 1 showing a sample left, right and total force displayed with maximum and average settings. [0019] FIG. 7 is a logic flow according to the principles of an embodiment of the present disclosure. [0020] FIG. 8 is a screen shot of the user interface of FIG. 1 showing a sample force imbalance indicator. [0021] FIG. 9 is a screen shot of the user interface of FIG. 1 showing a human figure filter for exercise videos. [0022] FIG. 10 is a logic flow according to the principles of an embodiment of the present disclosure. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0023] One or more embodiments of the subject disclosure will now be described with the aid of numerous drawings. Unless otherwise indicated, use of specific terms will be understood to include multiple versions and forms thereof. [0024] In any event, turning now to the Figures, and in particular FIGS. 1-4 , the elements of a dual motion isokinetic machine 10 are generally shown, together with the user 12 . In this embodiment, a bottom rope 14 exits the frame 16 from near the floor 18 through a multi-directional pulley 20 , and a top rope 22 exits the frame 16 above the bottom rope 14 through another multi-directional pulley 20 . Both ropes meet at a common handle or grip 24 for the user 12 to engage. Upon user engagement, three possible motions include up 26 , down 28 , and out 30 , where up 26 applies a force to the lower rope 14 , down 28 applies force to the upper rope 22 , and out 30 applies force to both ropes simultaneously. [0025] A user interface 32 , which may be in the form of a touch-screen display, includes a computer, such as a Google Nexus 10 (ten). It is desirable for the user interface 32 to have the ability to measure and display the force applied in any of three directions. A separate force detecting device is used to detect force applied to each rope. This can be accomplished by using a bottom strain gauge 34 to measure force from the bottom rope 14 , and a top strain gauge 36 to measure force from the top rope 22 . As such, these force measuring devices (e.g. load cells) are located at each of the isokinetic moving elements to measure the force applied by the user 12 and input into the computer 32 . The output of the strain gauges will be proportional to the amount of force applied to the respective ropes. A visual display on the interface 32 such as alphanumeric characters, a bar graph, etc. can be used to show this force in lbs., kgs., etc. While the present embodiment utilizes ropes and load cells/strain gauges, it will be appreciated that any user engageable grip coupled, with or without a flexible element, to a force measuring device may be used. [0026] Thus far described, the system provides accurate measurement in either of the two directions, up 26 ( FIG. 2 ) and down 28 ( FIG. 3 ). However, when the handle is pulled out 30 ( FIG. 4 ) (or pushed in 38 ), both force measuring devices will give a reading representing a fraction of the total force applied against the resistive mechanism 40 . Rather than displaying this information with two separate fractional readouts for each direction, the machine 10 calculates and displays the true user force and direction (e.g. up, down, out and in). [0027] In particular, each measuring device has a tare or zero value that is initially recorded and saved by the microprocessor. Accordingly, when a single measuring device exceeds its tare value (i.e. a user pulls straight up or pushes straight down), the appropriate directional indicator (up or down) is displayed and the value from that force measuring device is displayed. However, when both force measuring devices exceed their tare values (i.e. the user is either pulling 30 or pushing 38 ), then both ropes are being pulled simultaneously and the force vector applied is not parallel to either of the ropes. In such an action, in order to calculate an accurate force to be displayed, a correctional factor needs to be applied. [0028] One such correctional factor is the Pythagorean Theorem (a 2 +b 2 =c 2 ) illustrated in FIG. 5 where the ‘a’ force vector 42 is the value of one of the force measuring devices, the ‘b’ force vector 44 is the value of the other force measuring device and the ‘c’ force vector 46 is the actual force exerted. The processor makes the calculations and the user interface 32 displays a directional indicator as well as the actual force exerted. [0029] Although the above discussion contemplates a single set of opposing ropes, it may be desirable to utilize two or more sets of opposing ropes for a single exercise machine. In this case, the user interface can include a separate display for each of the combined sets of ropes. For example, if two sets of ropes are provided, the user will be able to observe the strength of his left vs. right side by viewing a left and right display. Other users may only be interested in the total combined amount of force that they are capable of producing. Accordingly, another feature of the disclosure is the ability to add the left and right outputs (or more if there are more than two sets of ropes) to display a combined total output. [0030] When exercising with isokinetic resistance, a user is continuously changing the amount of force exerted throughout his range of motion for each repetition. Therefore, unlike weight lifting where the force remains constant e.g. 50 lbs., a similar exercise done with isokinetics might see the user start at 0 lbs. of force at the beginning of the movement, and finish with 90 lbs. of force at the end of the movement. Because of this dynamic, and turning now to FIG. 6 , there are several metrics which can be useful to the user: maximum force 48 will show the peak strength within the range of motion; average force 50 can help train a user to maintain proper form and avoid impulse loads; and work 52 (or Calories) encourages the user to maintain strong force production throughout the full range of motion to achieve maximum benefit from the exercise. Maximum force is recorded by locking the display at the highest force reading recorded for a particular repetition 54 , set 56 , or entire workout. Average force is calculated by summing multiple samples of force readings throughout a repetition or set, and dividing by the number of samples taken. In the preferred embodiment, samples are taken every 10 ms to create an accurate average force reading. In physics, work=force×distance. The present disclosure allows for the display of actual work done with great accuracy. Using the technique described above, average force throughout a repetition or set can be measured. [0031] When using a motorized, speed controlled isokinetic mechanism for resistance, the distance of travel per repetition or set can be derived by using a look-up table and a clock. Each speed setting corresponds to a particular rope pay-out rate which can be measured in inches/second. A look-up table is created with the rate associated with each possible speed setting. Distance is calculated by starting a clock when a force measuring device exceeds its tare value, and stopping the clock when the force measuring device falls back to its tare value. Multiplying the rate and elapsed time will yield the distance traveled by the user. This distance multiplied by the average force equals work done. This can be displayed as work per repetition, work per set, or total work for an exercise session. The units displayed can be Joules, or with the proper multiplier, caloric expenditure, “Calories burned”. [0032] An alternative method for determining force and work involves monitoring the power dissipation of the motor during exercise. In one embodiment, as shown in FIG. 7 , an Allegro™ ATS712 chip 58 within the user interface 32 is used to measure the current consumption of the motor 40 during operation. Idle current values (no pressure on the ropes) are first recorded for all of the potential speeds of the motor and placed into a memory. During use, the current consumption is continually monitored, e.g. a value is read every 10 ms. When the current value exceeds the idle value, the differential is calculated (actual current value minus idle current value). By mathematically averaging these numbers and multiplying by a predetermined calibration constant, average force applied can be estimated and displayed on a per repetition, per set, or per work-out basis. Alternatively, the maximum value recorded can be multiplied by the predetermined calibration constant and displayed as the maximum force applied. By multiplying the average force times the travel distance (as calculated above), work, or Calories can be calculated and displayed. [0033] The present disclosure can present dynamic force and work metrics using both analog and digital displays. Although a digital display is useful in its ability to give highly accurate readings, an analog display can be more “user friendly” in its ability to accurately depict a dynamic metric. [0034] One drawback to using an analog bar graph is that in choosing a scale, one must pick a range which may not be suitable for all users. For example, a scale of 0-400 lbs. might work well for a football player who typically exerts 300 lbs. of force. In this case, the bar graph will range from zero to 75% of the full scale. However when a weaker person uses the same display and exerts 12 lbs., the bar graph will only be active from zero to 3% of the full scale, an almost indiscernible amount of movement. [0035] To overcome this issue, an embodiment of the disclosure uses an automatically scaling bar graph. When initially presented, the scale range is 0-25 lbs. If a user works within this range, the scale remains constant. However, when the user pushes hard enough to exceed a value, e.g. 95% of the full range, the scale range changes to 0-50 lbs. When 95% of this scale is exceeded, auto-scaling again takes place to display a 0-100 lbs. scale, and so on until the maximum scale is presented. The scale is reset to its original range when the user presses “next set” or “quick start/reset” on the user interface. [0036] Making an abrupt change from one scale to the next can result in confusion for the user as they will see the bar graph drop instantaneously from 95% of full scale, to 47.5% of full scale. Animation can be added to improve user's ability to smoothly follow the transition. In an embodiment, the transition involves displaying multiple scales in ascending value, e.g. 10 scales in quick succession, e.g. 50 ms each to create a smooth transition with the scale visually compressing as new high numbers are added. This process can be used for increasing or decreasing the scale range. [0037] A muscle imbalance means that the strength or size of muscle on one side of the body is not symmetrical to the strength or size of muscle on the other side of the body. Muscle imbalances can happen for all kinds of reasons. Athletes who play baseball, or golf for example, may produce muscle imbalances because they use a dominant side to throw or swing. Gym veterans and newbies alike can also develop muscle imbalances by relying on their naturally dominant side to support their lifts. It is always best to find the root cause of a muscle imbalance, and to make a precise effort to fix it. Muscle imbalance shouldn't be taken lightly as they can create bigger problems, from posture to spinal positioning, which can ultimately lead to issues walking, sitting and even lying down as time progresses. [0038] In one embodiment, and referring now to FIG. 8 , an analog visualization within the user interface 32 , e.g. horizontal bar graph 60 , moving dot 62 , etc. referenced to a centerline 64 is provided which gives a real-time indication of muscle balance. If left and right force measuring devices record the same amount of force, the indicator 62 is positioned at the centerline 64 . When one side sees a greater force exerted than the other, the indicator is moved in that direction to coach the user for proper adjustment. In the example of FIG. 8 , the left side 66 of the user is shown to be 40% 70 stronger than the right side 68 of the user. While in another embodiment, a chart-plotter draws two lines, each a different color, which represent left and right force output. As a user exercises, he can try to match the superimposed lines to achieve proper balance. In yet a further embodiment, the left and right side force readings are compared, and when they deviate in magnitude by more than e.g. 30%, for more than e.g. 3 repetitions, a message can be sent to the user indicating that an imbalance is apparent. The message may suggest that the user see a trainer or therapist to address the imbalance. The message may also be sent via email, Bluetooth, wifi, etc. to a clinician or therapist within a facility. [0039] During resistance based exercise it is often advantageous to count the number of repetitions completed for each set performed. This is generally an easy task, however when an isokinetic exercise machine with two opposing motions is utilized, more complicated exercises are often times performed making repetition counting more difficult. With input from force measuring/detecting devices for each of the isokinetic movement elements, the present invention electronically decides which motions constitute a repetition, what direction the movement was performed, and in some instances, what type of exercise was performed, e.g. biceps curl. This information is then counted, displayed, and in some instances used for reporting. In one form, counts are in ascending order to sum all repetitions completed. In another form (e.g. while doing a programmed work-out) counts are in descending order showing remaining repetitions to be performed. [0040] Logic is used to decide the conditions for determining when a repetition has been completed. For example, during a workout, there may be 4 different exercises which require four different logic decisions to determine how to characterize the movement. Examples of one repetition of each exercise may include: 1) Biceps hard up, light down—requires the user to pull up with force, and down with no force, and only the lower strain gauge will report a force value; 2) Triceps hard down, light up—requires the user to pull down with force, and up with no force, and only the upper strain gauge will report a force value; 3) Overhead press/Lat pull-down—requires the user to push up with force and then pull down with force, where first the lower, then the upper strain gauges report a value; and 4) Chest press—requires the user to push out with force and return with no force, where both strain gauges report force simultaneously. Repetitions for the above four examples are determined as follows: 1) If force on the lower rope exceeds tare value and then returns to tare value while force on the upper rope stays at tare value, and then lower rope exceeds tare value again, one repetition is reported in the upward direction; 2) If force on the upper rope exceeds tare value and then returns to tare value while force on the lower rope stays at tare value, and then the upper rope exceeds tare value again, one repetition is reported in the downward direction; 3) If force on the lower rope exceeds tare value and then returns to tare value followed by the upper rope exceeding tare value and then returning to tare value, one repetition is reported with a “both” direction; and 4) If force on both ropes exceeds tare value simultaneously and then returns to tare value, one repetition is reported with an “out” direction. [0041] In another embodiment, two sets of dual motion isokinetic movements are provided such that two handles are approximately shoulder distance apart. This further adds to the complexity of the task of reporting a repetition as even more complex combinations of movements are achievable, e.g. alternating military press/lat pull down, where one arm presses upward while the other arm pulls downward followed by opposite motion of each arm in order to complete one repetition. By knowing where and when a force is applied to the outputs of a multi-output isokinetic resistance machine, the present invention can report and track a variety of movements. [0042] An isokinetic resistance device is driven by an electric motor, and motor current consumption is monitored by the user interface. An idle current consumption value is recorded when the motor is running, but no force is exerted on the machine. When a current consumption value exceeds the idle current consumption value, then returns to the idle current consumption value, one repetition if reported. [0043] An exercise list or a variety of video clips showing individual exercises is stored or accessible on the computer. With isokinetic resistance, some exercises e.g. chest press, are performed at slower speeds than others e.g. high-to-low chop. Therefore, a predetermined default motor speed is associated with each exercise of the video library or exercise list. When an exercise or video is selected from the list, the computer commands the motor to run at the proper default speed for that exercise. [0044] To access the videos, a scrollable list is provided. In one embodiment, as shown in FIG. 9 , a filter allows an easier means of finding specific exercises on the list. An anatomical graphic of a human body 72 is displayed on the touch-screen 74 with touch-points located over each muscle group, e.g. biceps, shoulders, back, etc. Within the list, exercises for particular muscles are grouped together, e.g. biceps, shoulders, back, etc. When a user touches a point on the human body, (i.e. Chest 76 ) the exercise list displays the appropriate group 78 of exercises or videos. [0045] Varying the speed of the isokinetic motion varies the perceived intensity of the exercise by the user. Sometimes similar exercises are performed at different speeds to achieve different results. Videos within the exercise list are generally only filmed once with isokinetic speed set at a particular level. When a user exercises at a speed that is different from the speed used in the video, it can be confusing to watch, especially if the user tries to match the speed of the model in the video. In one embodiment, the present disclosure changes the speed of the video to match the selected isokinetic speed of motion. [0046] Another feature of the disclosure is the ability to lead a user through an entire workout consisting of multiple exercises. The user can select from a number of preprogrammed exercise routines on a list. Once selected, a message appears on the touchscreen showing how many repetitions per set are recommended. A toggle is provided to allow the user to increase or decrease this number. Additionally, the user is given the option to use default motor speed for the exercises, or increase or decrease default motor speed e.g. +10%. When the program is started, a video demonstrating the first exercise to be performed is displayed, the motor is set to the appropriate speed, and the repetition counter is set at the number of reps to be performed for the first set. Once the user views the video, he copies the movements and the rep counter decrements with each rep. Following the last rep, a new video automatically appears along with a new motor speed corresponding to the next exercise, and the rep counter is reset to the total number of reps to be performed for the next set. The user is automatically guided through an entire workout quickly without the need to make any adjustments to the machine. At the conclusion of the workout, a summary is provided detailing metrics such as average force applied, maximum force applied, total calories expended, etc. [0047] In one embodiment, during a programmed workout, motor speed is adjusted on a rep-by-rep basis in order to create a more dynamic experience. For example, rep 1—default speed, rep 2—default speed, rep 3—default speed, rep 4—105% of default speed, rep 5—110% of default speed, etc. [0048] The disclosure allows users to create their own custom programs. In one embodiment, a keyboard on the touchscreen panel is used for data entry. In another embodiment, a user can remotely create a workout on a separate computer, such as a home computer or cell phone, and export the workout to the user interface through direct connection such as a usb port, or wirelessly through Bluetooth, wifi, etc. [0049] During the workout, movement data is recorded for each rep. For example, force data is recorded and stored every 10ms during the repetition. This information can be displayed in real-time, or saved for future viewing. [0050] The present disclosure includes a tracking feature which presents performance data in at least three formats: 1) Real-time chart-plotting—a graph is composed with force applied on the y axis, and elapsed time on the x axis. As a user pulls on a handle, the graph draws a range-of-motion force profile for each repetition; 2) Rep-by-rep graphing—a graph is composed for each set with either average force applied per rep, maximum force applied per rep, or work done per rep on the y axis, and repetition number on the x axis. With each successive repetition, a new point is plotted on the graph to show trend information throughout a set; and 3) Historical tracking—one graph is composed for each exercise performed, e.g. biceps. Either average force applied per set, maximum force applied per set, or total work done per set appears on the y axis, and workout session number appears on the x axis. After multiple workouts have been performed, a user can view this graph to chart performance gains. [0051] As with the analog bar graphs, the present disclosure allows for automatic scaling on the graphs. For example, the x axis may display 10 points corresponding to 10 repetitions. As the user exercises and exceeds 10 repetitions, the x axis may automatically increase to 15 points to accommodate more data. The y axis may first be presented as zero to 25 pounds, however if the user pushes more than this amount, it may adjust to a new range of 20-50 pounds. [0052] Alternatively, a table of values can be displayed in lieu of the charts. Rather than showing the information in an analog format, the table simply displays all numerical values recorded. This tracking information can be viewed on the touch-screen, sent to a server for later retrieval, shared with others, or transferred to the user's phone or computer via Bluetooth, wifi, internet, or with use of a memory stick. [0053] Another feature of the disclosure is the ability to record and save performance data relating to a user and then replay that data (or “Ghost”) on a display during a similar workout in the future for comparison. This helps the user to monitor progress, and creates an incentive to “beat” a previous workout. For example, if a user performs a programmed workout, e.g. “Basic Strength”, force, work, and motor speed for each repetition of every set within the workout is recorded. The next time the user chooses “Basic Strength”, he is given the option to compete with the “ghost”. During a ghost competition, for each rep of each set, a metric is displayed showing the past performance for that rep. The user can now try to exceed the recorded value and beat the ghost. Ghosts can be saved and exported off of the computer to be shared with other similar machines for fun and competition. [0054] An isokinetic resistance device can generate extremely high loads and there is always a risk of injury if not used properly. This becomes especially important in a rehabilitative environment. For example, a patient recovering from shoulder surgery may be advised to perform interior and exterior rotation exercises. Often these exercises are performed with fixed weights or elastic bands. The therapist will typically specify a resistance which represents only a fraction of the patient's maximum strength. Isokinetics without added feedback can be difficult to administer in this environment as there is risk of the patient overexerting. [0055] The present disclosure uses visual feedback to display force production so a user can control his movement. Additionally, a user settable feature is disclosed which allows for a maximum resistance (e.g. 12 lbs) to be manually set. If the maximum resistance is exceeded by the user, the resistance is adjusted to protect from overload. This can be achieved in at least two ways: 1) Increase speed: when an overload is detected, the isokinetic speed control is commanded to change to a higher speed which makes it more difficult for the user to produce a high load; and 2) Constant force: when an overload is detected, the resistance is commanded to change from isokinetic to isotonic with a force equal to the maximum force set by the user. One method uses a dc motor to control isokinetic speed. The motor's ability to resist an increase in speed is limited by the amount of current available to the motor. When an overload is detected, the maximum current available to the motor is set at a value equal to the present amount of current being used by the motor. This will allow the motor to accelerate when greater amounts of force are attempted, thereby never exceeding the maximum force set. In any event, visual and audio alarms are also included to alert the therapist or patient that a maximum force has been applied. [0056] In one embodiment of the present disclosure as shown in the logic flow of FIG. 10 , a dc motor controller 80 drives a permanent magnet motor 82 at a fixed speed for isokinetic exercise by maintaining a constant voltage and varying the current based on the exercise load(s) 84 . When used in this mode, the user is able to generate greater loads simply by pushing harder against the machine. In another mode, current is limited at a selectable amount. This causes the motor to only resist movement until a certain load is applied, at which point a constant force is delivered to the handle (isotonic exercise). [0057] Another feature allows for visual and audio alarms to help a user work within a prescribed resistance level. For example, a trainer may direct his client to do 15 chest press exercises with a load of between 25-30 lbs. An alarm can be set to either alert the user when he achieves his goal, or when he doesn't achieve his goal. This feature can also be used within a programmed workout such that a program presents a series predetermined target force goals, for example: rep 1—55 lbs., rep 2—60 lbs, rep 3 65 lbs., rep 4—60 lbs, etc. With each new rep, a new force amount is displayed and feedback is given to alert the user as to whether he is achieving the goal. [0058] The foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom. Accordingly, while one or more particular embodiments of the disclosure have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the invention if its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the present disclosure.
An exercise device consisting of two or more flexible elements originating from different locations and connected to a common handle capable of being moved in a variety of directions. Each element also connected to a resistance mechanism and a force measuring device whereby a user interface and microcomputer determine force and direction and displays same in a plethora of varieties.
0
This application is a Continuation of application Ser. No. 09/421,930, filed Oct. 21, 1999, now abandoned. BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to an explosion relief valve for confined spaces, volumes or vessels, and more particularly for the crankcase of internal combustion engines, which includes a valve seat which may be fitted into a boundary wall of the space to be protected, a spring-loaded closure plate co-operating with the valve seat and at least one flame barrier having low pressure resistance installed in a gas path leading through the valve, which flame barrier preferably consists of sheet-metal strips stacked one above another transversely to the throughflow direction of the gas, which sheet-metal strips are preferably provided at least over part of their width with irregular corrugations, and at least one other perforated wall in the gas path. 2. The Prior Art A valve of this kind is described in DE 1 126 676 C and GB-A-2 017 269. Two flame barriers, one disposed behind the other, are provided in the relief valves described therein, the British publication disclosing the combination of a sheet-metal ring stack with expanded metal fabric layers disposed thereafter. However, there is no mention whatsoever in that publication of structures which increase the mechanical stability and/or of affecting the flow characteristic. A valve of an even simpler design is described in AT 311 129 and has very low conductance, a heat absorption capacity sufficient to prevent flames from passing through the valve being achieved without the application of vaporizable substances by means of the sheet-metal strips acting like cooling ribs. On the other hand, however, because of the substantially parallel sheet-metal strips, the flow resistance is not inadmissibly increased and the gas is able to flow away in a linear manner, with the result that the overpressure in the space protected by the valve can easily be reduced. Particularly important as fields of application for explosion relief valves of this kind are the protection of confined spaces such as, for example, the crankcases of two-and four-stroke diesel engines, gas containers, fairly large pipelines and other spaces in which explosive substances are stored or in which highly inflammable gases may form. Several of the relief valves described may also be provided in parallel or in series. It is desirable to provide a valve of the type specified in the introduction, in which a flame front is in every case reliably prevented from passing through the explosion relief valve for all fields of application, the throughflow of the valve is optimized, and the valve is also protected against mechanical damage, even after repeated explosions. SUMMARY OF THE INVENTION According to the invention, the perforated wall is made of an expanded metal strip. This material offers the facility of controllably influencing the flow behavior, and the shape and location of the lozenge-shaped openings of the expanded metal and the alignment of the webs can be selected depending on the influence desired. The corresponding uniform turbulence enables the cooling capacity of the flame barrier to be optimally utilized without excessively increasing the flow resistance. As well as making the flow through the other expanded metal perforated wall more uniform, the characteristics of the frame front, if applicable, are changed in such a way that no sparks form in closely confined areas, but rather distribution takes place over a larger area with the result that the heat absorption capacity of the flame barrier is better utilized and no local overloads are able to occur. The time taken for the flame front to pass through the valve is also thereby increased. The passing of any flames through the valve can thus be reliably prevented. Diesel and gas engines protected with the valve according to the invention can therefore also be used in hazardous areas, and/or complicated above-roof pressure and flame outlets are no longer necessary, and the non-hazardous relief of pressure into the working space is possible. The expanded metal of the valve construction provides greater mechanical strength, on the other hand, enabling even repeated explosions to be withstood without deformations occurring which adversely affect operation, the valve remaining fully effective and operational. This is of great economic significance as the overriding majority of ships today are built without redundancy and the failure of the one and only engine may have dire consequences. The effect of influencing the flow for improved utilization of the cooling capacity of the flame barrier is revealed particularly clearly if at least one expanded metal wall is positioned immediately in front of the first flame barrier. According to another optional feature of the invention, on the other hand, at least one perforated wall may be positioned immediately after the last flame barrier. According to another optional feature of the invention, at least one flame barrier and a perforated wall may be positioned behind the valve seat. As a result the first pressure peaks are caught by the closure plate of the valve before they impinge on the first flame barrier and/or perforated wall, which are thereby better protected from damage. In order to achieve a directed gas flow after its exit from the explosion relief valve, the perforated wall is preferably made of expanded metal and its webs are set in such a way that the gas flow emerging from the valve is directed at the surface of the space to be protected. This means that even in the most confined conditions, danger to operating personnel may be prevented to the greatest possible extent and without great effort. With the advantage of structural simplicity, the saving of weight and the low space requirement, the valve behind the last flame barrier can be free of any deflecting devices for the emerging gas flow. On the other hand, if there is available space provision, the valve may be larger in size and thus be more reliable in operation and/or suitable for higher explosion pressures. Advantageously, according to another optional feature of the invention, at least one flame barrier may be annular and permit throughflow over substantially 360° and at least one additional perforated wall may be provided in an annular shape on the exterior or interior periphery of at least one flame barrier. This feature increases the effectiveness of the action to make flow more even and ensures the least possible load per unit area on the flame barrier and also on the other perforated wall. To achieve advantageous weight and also size optimization and more economic production, at least one flame barrier may be made of aluminium or stainless strip steel. A preferred embodiment of the present invention will be described in more detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an axial center section to an explosion relief valve according to the invention; FIG. 2 is a corresponding section through a second relief valve according to the invention; and FIG. 3 is a corresponding section through a third relief valve according to the invention, showing two different arrangements. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The explosion relief valve represented in FIG. 1 is a version suitable above all for ships' engines and also diesel and gas engines for power plants, this version being installed in the crankcase or installation wall to avoid damage to the engine or installation when, specifically, gas or oil mist explosions occur. The valve consists of an annular valve seat 1 which is fixed externally by means of screws 2 or the like to an opening in the crankcase wall 3 . Cooperating with the valve seat 1 is a closure plate 4 loaded by means of a helical compression spring 5 wound preferably in an approximately conical shape. In addition, stay bolts 6 are screwed into the valve seat 1 concentrically around the closure plate 4 and hold an arresting device 7 which is designed as a cover plate and has a peripheral region bent towards the crankcase deflector 3 , at a distance from the valve seat 1 ; the bolts 6 are at the same time used for laterally guiding the closure plate 4 . The helical compression spring 5 is also supported on the valve cover or guard 7 . A sealing ring 8 fitted in a groove in the valve seat 1 ensures tight sealing in the closed position. The relief valve is provided, preferably behind the valve seat 1 and the closure plate 4 viewed in the direction of flow, in a known manner with at least one flame barrier 9 positioned concentrically around the stay bolts 6 , for example, the flame barrier 9 thus being in the gas path leading through the opening in the valve seat 1 . The flame barrier 9 consists preferably of sheet-metal strips 10 stacked one above another, corrugated over part of their width, preferably that part nearer the centre of the valve, and loosely clamped between the valve seat 1 and the guard 7 . The corrugations extend preferably over about half the width of the strips 10 and their height decreases continuously from the inside edge of the strips 10 radially outwards. If necessary, non-corrugated, flat sheet-metal strips may also be inserted between the corrugated sheet-metal strips 10 . In the embodiment of FIG. 1, there is at least one other perforated wall 11 immediately in front of the flame barrier 9 , preferably in front of the first flame barrier in the case of a consecutive series of flame barriers, in addition to the flame barrier 9 . This perforated wall 11 , like the flame barrier 9 also preferably behind the valve seat 1 and the closure plate 4 viewed in the direction of flow, is made of expanded metal, which is known per se. The webs and perforated openings thereof may be shaped as required so as to produce, when applied to the particular geometry of the valve, a more uniform pressure characteristic and flow characteristic of the explosion gases and to slow down the flame front so that the passing of the flame barrier 9 also takes longer and the gases are therefore better able to cool down. Moreover, the perforated wall 11 gives the valve construction greater mechanical stability, with the result that smaller sizes are possible with the same safety requirements and explosions do not directly lead to damage to the valve, i.e., it remains operational. If an explosion occurs in the crankcase, the increase in pressure thereby produced causes the closure plate 4 to be lifted off the valve seat 1 against the force of the spring 5 and to move as far as the guard 7 . The valve opening of the valve is thereby freed, with the result that the explosion gases are able to flow away through the valve seat 1 , the perforated wall 11 and the flame barrier 9 towards the exterior, causing a rapid release of pressure to occur in the crankcase. The perforated wall 11 causes the gases to slow down and the pressure distribution and flow to become more uniform over the whole extent of the valve, so that no excessive local pressure peaks are able to occur. The flame barrier 9 then extinguishes the flames and, due to the cooling of the gases flowing—relatively slowly because of the effect of the perforated wall 11 —and the widening flow cross-section, prevents the flames from escaping to the exterior through the relief valve. The cooled gases are deflected towards the engine by the edge of the arresting device 7 which is bent towards the crankcase, so that danger to operating personnel is minimized. The embodiment of FIG. 2 has, as well as the perforated wall 11 positioned immediately in front of the flame barrier 9 , another perforated wall 12 which is immediately behind the flame barrier 9 , if necessary immediately behind the last one of a series of flame barriers. While the inner expanded metal wall 11 is preferably clamped like the sheet-metal strips 10 of the flame barrier 9 between the valve seat 1 and the guard 7 , there are several attachment options for the outer perforated wall 12 . As represented on the left-hand side of FIG. 2, the valve seat 1 may have a portion 3 a projecting radially outwards and the perforated wall 12 may be clamped between this portion 3 a and the guard. On the right-hand side of FIG. 2 another attachment option is shown, in which the flame barrier 9 and the two perforated walls 11 , 12 are joined together by means of metal rings 13 , 13 a flanged on the outer and inner edge to form a stack which can be handled all together, like a filter cartridge. This stack may be replaced as one piece and the stack is held in its entirety by being clamped between the valve seat 1 and the arresting device 7 . In FIG. 3 —without going into the precise manner of its attachment—a single perforated wall 12 made of expanded metal behind the flame barrier 9 is shown, the webs 12 a of which are set in relation to the sheet-metal strips 10 of the flame barrier 9 , and thus also the emerging gas flow, in such a way that these gases are deflected towards the installation (ie. downwards as shown in FIG. 3 ). This means that there is no need for any other deflecting device, specifically the edge of the guard 7 bent towards the engine or the installation, which in this case should be flat on the outer edge and whose maximum diameter should be the size of the flame barrier 9 together with the perforated wall 12 . Thus, with the same dimensions of the valve seat 1 , and also of the flame barrier 9 , this valve requires less space or the valve seat 1 may have a larger diameter if there is available space. The perforated walls 11 , 12 , like the flame barrier 9 also, are preferably manufactured from material which is a good heat conductor and advantageously is relatively light, for example aluminium or stainless strip steel. Because the valve construction is reinforced by the at least one perforated wall 11 , 12 , despite the light materials there is no fear of any loss of mechanical strength. While the present invention has now been described in detail with respect to specific embodiments, changes can be made therein and still fall within the scope of the appended claims.
An explosion relief valve for a confined space, more particularly for the crankcase of an internal combustion engine, includes a seat ( 1 ) which may be fitted into a boundary wall ( 3 ) of the space to be protected, a spring-loaded closure plate ( 4 ) cooperating with the valve seat, at least one flame barrier ( 9 ) having low pressure resistance in the gas path leading through the valve, preferably consisting of sheet-metal strips stacked one above another transversely to the throughflow direction of the gas, which sheet-metal strips are provided preferably at least over part of their width with irregular corrugations, and at least one other perforated wall ( 11, 12 ) in the gas path of expanded metal.
8
BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a fluid power actuator comprising a cylinder, a piston, a piston rod and a positioning means for halting the piston rod in desired positions. 2. Description of Prior Art Such actuators are employed for applications in which a variable, preset terminal position of the piston and of the piston rod is necessary. Terminal abutments arranged in the caps of the actuator cylinder are able to be screwed into the interior of the cylinder varying amounts so as to limit the stroke of the piston to a certain extent. Such actuators are however relatively high in price since they are generally specially customized and in any case are of a complex design; in fact it is more or less essential to have a damper at the end of the stroke so that the terminal abutments will not be damaged by the piston striking them. A further shortcoming is that known actuators only make it possible for two abutment positions to be set with one position at a more or less retracted position of the piston rod and the other in a more or less extended one, and between these two end settings it is nearly impossible to preset exact intermediate positions of the piston or its rod at which such components may be precisely halted, at least for an instant. However in many applications it is essential to have an actuator whose piston rod may be moved in exact steps or sections of stroke, as for example when the actuator is to be used for a feed device in a machine tool, with which the workpieces are to have machining operations carried out on them, such as drilling or stamping, at positions with a precise setting between them. SUMMARY OF THE INVENTION One purpose of the present invention is to remedy such shortcomings of the prior art. A further object of the invention is to devise a fluid power actuator of the above noted type, which while being able to be produced at a low price, makes it possible for the piston rod to be set in a position intermediate the two terminal positions thereof. In order to achieve these or further objects appearing in the course of the following specification, the present invention is characterized in that the positioning device is embodied in a single integral unit with a series of consecutive detent depressions and is attached to the piston rod so as to extend in the longitudinal direction thereof, that the series of detent depressions is placed opposite a positioning plunger which may be engaged therewith and moved clear thereof, and there is a shutter between the row of detent depressions and the positioning plunger, and the shutter extends in the length direction of the series of notches and is connected therewith and has a positioning opening which is placed opposite to the detent depressions and is such that when the plunger arrives in a position during motion of the piston, it permits the plunger to extend into the detect depression, it being possible for one positioning opening to be associated with different detect depressions. There is thus the advantage that a conventional cylinder actuator may be fitted with a positioning device without modifications of the cylinder or the cylinder caps being required. It is an advantage if the positioning device acts on the part of the piston rod that is outside the cylinder. This makes the construction substantially cheaper since it is even possible for conventional, pre-existing cylinder actuators to be fitted with the positioning device in accordance with the invention. A further advantage of the fluid power cylinder actuator of the invention is that it becomes readily possible to set the end positions of the piston rod in whatever the position desired without any difficulty at any desired point within the range of the stroke of the actuator and also to define intermediate settings between the end positions of the piston rod. The actuator of the invention is thus suitable for operations in which feed of the piston rod in steps or increments is imperative. Positioning takes place with a high degree of accuracy, since on reaching the desired point of the stroke the piston rod is instantaneously locked. The adjustment of the respective positioning settings is very simple, since the adjustment mechanism is higly accessible and easily inspected by eye and at the setting of the positioning opening or openings opposite the row of detect depressions it is possible to directly see the one of more positions at which the piston rod is locked. A further point is that the individual positioning settings are able to be set or reset at any time with perfect accuracy, something that would be scarcely possible with the actuators of the initially mentioned sort. A further beneficial effect of the actuator of the invention is the fact that a very short stroke may be set subsequently even in the case of very long actuators, this being almost impossible in the case of known actuator designs with integrated end stops; in such a case the end stops have to be screwed so far into the interior of the cylinder that they are no longer firmly held in place. A further aspect of the positioning device of the actuator in accordance with the invention is that positioning of the piston rod may take place from one end of the cylinder or it is even possible for both end settings to be altered from one end of the cylinder, something that is naturally more especially an advantage when fitting the cylinder to a pre-existing machine, for example, since the cylinder will have comparatively small space requirement. In the case of known actuators the adjustment of the two end settings of the piston rod is only possible if both ends of the cylinder are accessible. In accordance with a preferred feature of the invention, the detect depressions are provided directly on the piston rod itself, this being a particularly compact way of providing the row of depressions since the dimensions of the piston rod do not have to be increased. The row of detent depressions may be formed on a detent member detachably joined to the piston rod so that it is then possible to modify a conventional actuator in a simple way. It is furthermore possible for the row of detent depressions to be in the form of a rack with its teeth placed transversely in relation to the direction of piston motion. This makes possible a particularly precise positioning of the piston rod. The row of detent depressions is comparatively simple to produce and furthermore the detent depressions may be placed very close together so that fine adjustment of the setting of the piston will be possible. A further useful effect of having the depressions in the form of a rack is that the teeth of the rack make possible a centering effect facilitating the insertion of the positioning plunger. Alternatively the row of depressions may take the form of a row of holes, thus providing a particularly simple and cheap way of producing the invention. If the length of the shutter is at least equal to the length of the row of detent depressions on may be certain that the positioning plunger is only able to fit into one of the detect depressions by way of the positioning openings. There is the advantage that the unused detent depressions are covered over so that trouble-free operation is guaranteed. It is possible for the shutter having at least one positioning opening to be in the form of a shutter slide able to be adjusted in the longitudinal direction of the row of detent depressions. This makes it possible to change the individual positioning settings of the piston rod in a simple way. A further useful development in this connection is one in which the shutter coaxially surrounds the piston rod at least partially and runs in at least one guide groove extending parallel to the piston rod and made in the rod or in another member with the depressions therein. At least one positioning opening of the shutter may be able to be fixed in its settings placed opposite to the detent depressions so as to be prevented from sliding. Such features of design provide a simple and effective way of reliably and exactly guiding the shutter. The feature involving the fixing of the positioning opening ensures that there is no chance of the positioning opening, once set, being unintentionally moved in relation to the row of depressions. It is for example possible for the shutter to have positioning lugs of the like on the points of engagement with the piston rod or other member with the depressions therein. A further possible way of locking the shutter in place is by the provision of a catch tooth on its surface nearest the row of depressions so that such tooth may fit into the detent depressions. It is possible for the shutter to be directly in contact with the row of depressions and be held in place thereon or on the piston rod by spring means for example, or to keep the parts in position it is possible to have a pin connection. It is possible for the shutter and/or the member with the detent depressions to be made of synthetic resin in order to reduce the costs of production. The member with the detent depressions therein may be made of metal, this ensuring a particularly reliable positioning of the piston rod with a low wear rate. It is possible to have means, such as spring or hydraulic means, urging the positioning plunger against the shutter during positioning of the piston rod and it may rest on the track along which the positioning opening moves. Such a design is characterized by an excellent response characteristic and it is an advantage that the positioning plunger quickly slips into the selected detent depression on arriving at the positioning opening. At the same time the design ensures that the positioning plunger does not slip out of the detent depression accidently. In order to prevent damage to the device the advance motion of the piston rod may be controlled by means of a controller connected with the positioning plunger in accordance with the setting of the positioning plunger. The controller may be so designed that it interrupts the advancing motion of the piston rod simultaneously with the entry of the positioning plunger into the positioning opening or into one of the detent depressions. This form of controller is particularly compact which simultaneously with the entry of the positioning plunger into one positioning opening at the same time causes the advance motion of the piston rod by interrupting the supply of fluid power to the cylinder and thus ensures reliable operation with a low wear rate. It is further possible for the positioning plunger to be adjustably set at a right angle to the plane of the detent depressions, this making it possible to undertake fine adjustment of the separate positioning settings of the piston rod. Owing to the adjustability of the positioning plunger the space between two consecutive detent depressions, which would not normally be used, may be bridged over. This feature of the invention accordingly makes possible a stepless positioning of the piston rod. The invention will now be described on the basis of only a few of the possible embodiments thereof, to be seen in the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a first embodiment of the fluid power actuator of the invention diagrammatically and in partial section. FIG. 2 shows a part of the structure of FIG. 1 as indicated II at FIG. 1 with the positioning plunger actuated. FIG. 3 is a cross section through the positioning device as taken on the line III--III of FIG. 1. FIG. 4 shows a further possible embodiment of the invention as part of the actuator. FIG. 5 is a section through the positioning device of FIG. 4 as taken on the section line V--V therein. FIG. 6 is a view looking down onto a further working example of a positioning device after removal of the positioning plunger. DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1 the reader will see a fluid power actuator 1 in accordance with the invention with the positioning device 2. The actuator comprises a cylinder 3, a piston 4 sliding within the cylinder 3 and a piston rod connected with the piston 4 and extending out of the cylinder through its end wall 5. The piston 4 makes sealing contact with the inner bore face of the cylinder 3 and so divides the cylinder into two cylinder spaces 7 and 7' into and from which a fluid under pressure (more especially air) may be admitted and released as desired. Each of the cylinder spaces 7 and 7' is connected via a pressure fluid line 8 and 8' with a controller 9 which will be explained in more detail below, controlling the supply of pressurized fluid to the cylinder spaces 7 and 7'. A member 10 having a row 12 of successive detent depressions 11 is joined, more particularly so that it may be detached, to the piston rod 6 as an axial extension thereof. The row of depressions runs parallel to the length direction 13 of the piston rod 6. A shutter 14 or cover member is placed directly on and adjacent to the row 12 of depressions and it has a positioning opening 15 opposite one of the detent depressions. A positioning plunger 17 is placed opposite the row 12 of depressions 11 and the shutter 14 so that it may be brought into engagement with one of the detent depressions 11 and may be moved towards and away from the said row 12 as marked by the arrow 16. The plunger 17 is resiliently urged towards the shutter 14, for example by a spring 18. Thus the shutter 14 is placed between the row 12 or depressions 11 and the positioning plunger 17. The plunger 17 is joined with the controller 9 for controlling or setting the advancing motion of the piston rod. To give the reader a better general grasp of the system a short account of the function of the system is to be given at this point: in the starting position assumed the piston 4 and the piston rod 6 are completely retracted into the cylinder 3. The positioning opening 15 in the shutter 14 is placed opposite a given detent depression 11. The positioning plunger 17 is urged into contact with the facing surface 22 of the shutter by the spring 18 (or by hydraulic means). When now the controller 9 is suitably operated there will be a supply of fluid under pressure into the cylinder space 7' which does not have any piston rod so that the piston rod 6 and the member 10 with the detent depressions will be advanced linearly. In the course of such motion the free end 23 of the positioning plunger 17 will be moved onto the surface of the shutter. If the positioning opening 15 comes into a setting opposite the positioning plunger 17, the plunger 17 will be moved through the positioning opening 15 and make locking engagement with the corresponding detent depression 11. Simultaneously with start of the lowering motion of the positioning plunger 17 the controller 9 is actuated in such a way that the supply of fluid under pressure to the actuator is interrupted. The piston rod is thus not exactly positioned and located. This cycle of functions may be used to exactly control the motion of a part of a machine that is not shown. This machine part is preferably connected by way of a suitable driving connected with the piston rod 6 or the member 10 with the depressions. As an example of this FIG. 1 shows a drive rod 24 extending from the member 10 with the depressions to form a coaxial extension thereof, for connection with a machine part such as a machine carriage. In what follows are more detailed account is now to be given of the member 10 with the depressions and the shutter 14. The shutter extends in the longitudinal direction of the row 12 of depressions and is connected with the member 10 having the depressions. In this respect the shutter 14 is in the form of an an adjustable cover slide 25 able to be moved in the longitudinal direction of the row 12 of depressions. The way of holding and guiding the cover slide 25 on the member 10 with the depressions will be seen more particularly from FIG. 3. In this case the member 10 has a square or other rectangular cross section and the cover slide 25 is placed directly on the surface 26 with the row of depressions 11. The breadth of the cover slide 25 as measured transversely in relation to the direction of advance is somewhat greater than that of the member 10 with the depressions so that on the two sides 27 and 27' of the cover slide 25 there is a lateral overlap past the member 10 with the depressions, and there is a molded-on guide rail 29 and 29' thereon at least partly covering the member 10 with the depressions in a lateral direction (at 28 and 28'). The cover slide 25 is in the form of a channel with the two legs of the channel section on the two sides of the member 10 with the depressions. At the free ends of the guide rails 29 and 29' there is molded a guide extension 30 running in the length direction of the member 10 with the depressions and pointing toward the two sides 28 and 28' thereof. This extension 30 is for its part slidingly mounted in in a complementary guide groove 31 in the member 10 with the depressions. A particular advantage of this form of the invention is that the shutter 14 or the covering slide 25 may be made of resin at this will ensure a particularly satisfactory sliding guiding effect with a low degree of wear. FIG. 3 furthermore shows the positioning plunger 17, a positioning opening 15 and a detent depression 11. In order to assure a particularly effective cooperation between the positioning plunger 17 and the row 12 of depressions the row 12 is preferably formed as a rack 32 with the flanks 33 of its teeth extending transversely in relation to the direction of motion of the piston rod (see FIG. 3). In longitudinal section as in FIG. 1, the teeth have a zig-zag form such that the separate teeth have the forms of isosceles triangles. The positioning plunger 17 also has its free end 23 in the form of a wedge to fit inbetween the teeth. The rack 32 may be made integral with the member 10 having the depressions. Manufacture by milling is possible, although it may be made separately and then attached to the member 10 with the depressions, as for example by screws so that it may be detached again if required. In this form of the invention it is possible to use racks 32 with a finer or a coarser pitch as may be desired for a particular application. To facilitate the passage of the positioning plunger 17 through the positioning opening 15 the opening tapers conically towards the detent depressions 11. The sizes of the openings 15 are in any case to be such that it is possible for the positioning plunger to be readily moved through. It will be clearly seen from the explanations so far that by adjustment of the cover slide 25 in relation to the member 10 with the depressions the position of the positioning opening along the row 12 of depressions may be changed so that variable setting of separate positioning settings for the piston rod 6 may be undertaken. To prevent unintentional shifting out of position of the cover slide 25 during operation, the slide may be locked in all its positions in which the positioning opening 15 is opposite one of the detent depressions 11 so that it may not be relatively slid. This may be made possible for example by having spaced recesses in the floor of at least one of the guide grooves 31 for cooperation with catches 35 made with a complementary form on the guide projections 30. These catches may for example be in the form of short pins. The distance between one recess or catch 35 and the next one will preferably be equal to the pitch of the rack 32. On the basis of FIGS. 4 and 5 a further example for the way of holding the covering slide 25 in relation to the row 12 of detent depressions will now be explained. In the case of this form of the invention the piston rod 6 itself functions as the member having the row 12 of depressions in the form of a rack 32. In this case the piston rod 6 is made flat along part of its length (at 36) and on this flattened part the rack 32 is attached for example by screws so that it may be removed. The breadth of the individual teeth 34 as measured in the transverse direction is less than the diameter of the piston rod 6 and at the same time in cross section the rack 32 is made so as to be generally T-like in cross section. The cover slide 25 has a matching T-like groove 36 so that while covering over the rack 32 and engaging the groove with the matching teeth, the cover slide is able to slide in relation to the piston rod 6 in the length direction. The covering slide 25 engages the free edges 38 of the rack 32 so as to make contact over a large area, such contact face 42 being provided with low braking teeth 43 corresponding to the rack 32 in pitch. These teeth prevent unintended slipping of the cover slide 25 and in this example of the invention the cover slide and the braking teeth 34 are fashioned of plastic material. FIG. 6 is a plan view of a further working example of the positioning device 2 after removal of the positioning plunger 17. In this case the depressions in the row 12 are in the form of a row of holes 44, it being possible for the individual holes 45 to be through or blind holes. The positioning opening 15 has a corresponding shape. As a general point, the cover slide 25 may be made with any desired number of positioning openings 15. The distance between the positioning openings 15 in each case defines the distance between two stop positions of the piston rod 6. By sliding the cover slide 25 in the relation to the member 10 with the depressions it is possible for these positions to be changed in a way dependent on the absolute position of the piston rod 6. The sliding guide means for the shutter 14 is however not necessary in all cases and it would also be possible to make the shutter 14 so that it would readily be able to be removed. In order to set different position settings in this case the shutter 14 may be replaced by another shutter which has positioning openings arranged in a different way (not shown). However both with the non-sliding and the sliding form of the shutter 14 its length will be such that it is equal to the length of the row 12 of detent depressions. This makes it possible to ensure that the positioning plunger 17 does not accidentally come into engagement with an uncovered detent depression. It is also to be added that the preferred combination of material for the shutter 14 and the member 10 with the depressions is a resin-metal one. Owing to the production of the shutter of resin its manufacture will be simple and cheap and will be molded in accordingly formed. The metal construction of the member 10 with the depressions assures positioning over a long period of time with a low wear rate. At the same time this combination of material facilitates the sliding of the two members in relation to each other. In what now follows a more detailed account of the positioning plunger 17 and the controller 9 will be given. The positioning plunger 17 is so placed that during the full stroke of the piston rod it is urged onto the surface 22 for the shutter 14 and rests on the track moved along by the positioning opening 15. If during the course of motion of the piston rod the positioning opening gets as far as the positioning plunger 17 it will move through the positioning opening 5 and will move back into the detent depression 11 while being urged by a loading force. This position will be seen in FIG. 2 with a simplified view of the controller 9. The force urging the plunger 17 into the depression is supplied by the spring 18. In order to be able to remove the plunger 17 from the detent depression 11 it has a drive piston 46 placed on its end opposite to the free end 23 and the piston 46 may be acted upon by fluid under pressure in the opposite direction to the resilient form of the spring 18 so that the plunger 17 is moved out of the detent depression 11 and the positioning opening 15. To prevent damage to the plunger 17, when it is slipped into the positioning opening 15, by the row 12 of depressions which is moving, the plunger is integrated with a controller controlling the supply of fluid under pressure into the actuator 3. In will be seen from FIG. 1 that the controller 9 has at its main component a 4/2 way valve 50 that has a port P for the feed line, two ports A and B for drive lines and a port R for the escape of air. The valve spool 47 controlling the connection of the separate ports with each other is connection with the valve plunger 17 and the two parts are able to reciprocate at a right angle to the surface of the covering structure. By adjustment of the positioning plunger 17 motion of the valve spool 47 takes place as well. On its end 48 opposite to the plunger 17 there is a spring 18 to load the valve spool and the plunger in a direction towards the shutter 14. The control operation takes place as follows; as long as the positioning plunger 17 is placed clear of a positioning opening 15 and contacts the covering 22 the fluid under pressure arriving from an accumulator 49 will be supplied via the ports P and A of the 4/2 way valve 50 and the fluid power pipe 8' joined therewith to the cylinder space 7 without any piston rod therein. The piston 4, the piston rod 6, the shutter and the member with the depressions will accordingly be moved forwards. When this takes place the cylinder space 7 with the piston rod will be vented via the line 8 and the ports B and R. Once the positioning opening 15 reaches a position opposite to the positioning plunger 17 the latter will move into the positioning opening 15 so that as a result the feed port P is closed by the valve spool 47. To make possible further motion of the piston rod 6 a part of the valve spool 47 is in the form of a drive piston 46 which may be acted upon via a control line 51 against the force of the spring 18. This control line leads to a control valve 52 and after its operation may be connected with the pressure accumulator 49. In order to release the detent connection it is therefore only necessary to operate the control valve 52 for a short time so that the valve spool 47 is moved out against the action of the spring 18 and is accordingly moved by the positioning plunger 17 clear of the positioning opening 15. After such removal the fluid is supplied in the way already described through the 4/2 way valve 50. To make it possible for the piston rod motion to be reversed, it is possible to fit a reversing valve 53, having some suitable means for operating it, between the two lines 8 and 8' running from the two drive ports A and B. It is possible, if desired, for the fluid to be supplied to one or other of the two cylinder spaces 7 and 7'. In the arrangement of FIG. 1 the minimum distance between to positioning settings of the piston rod 6 is determined by the pitch, i.e. the distance between one detent depression 11 and the next. If even finer positioning is to be possible, then in accordance with a further form of the invention (not shown) the positioning plunger 17 or the 4/2 way valve of the controller 9 is able to be adjusted parallel to the length direction and to the plane of the row 12 of detent depressions. With this form of the invention the piston rod may be set steplessly. The actuator of the invention and its positioning device are naturally not limited to the use of the controller 9 as described and any other suitable controller would be possible. In particular the control valve 52 may be worked by a machine element and the overall cycle of motion may be automatically controlled.
The invention relates to a fluid power actuator with a cylinder, a piston and a piston rod whose motion is controlled by a positioning device which halts it in selected settings. The positioning device has a row of depressions, for example gaps between the teeth of a rack, running parallel to the piston rod. A positioning plunger moves into a selected depression to lock the rod. A shutter with at least one opening therein covers the row of depressions and is adjustably affixed thereto so as to allow adjustment of the position at which the control plunger aligns with the shutter opening and slips into the selected uncovered depression to stop and lock the piston and rod.
8
FIELD OF INVENTION [0001] This invention entails a data transport system in a telecommunication network, using radio frequency subcarriers. DESCRIPTION OF THE STATE OF THE ART [0002] Since the early 90's, a large growth in telecommunication services has been experienced due to an intense and increasing use of Internet Protocol (IP)-based networks. Starting from dedicated and specific applications in the 70's, restricted to the scientific community, 64 kbps connections have become widely used on account of access availability, transport and a large number of microcomputer users. This stage, which can be considered the “first Internet wave”, had such an intense expansion that, in the mid-90's, data transport networks in the United States began to present occupation rates incompatible with the Quality of Service (QoS) required by American Internet server subscribers, due to line busy signals and long delays in Internet applications. [0003] Multiplex technology by wavelength division (WDM) has proved to be extremely effective and of very fast installation, dispensing with operations in the infrastructure of fiber optics already installed. The improved operation of data transport networks has been reflected immediately in Internet applications, allowing the immediate acceptance of new subscribers. [0004] By means of the subscriber incorporation of a second and a third home telephone line installation of WDM systems has begun in metropolitan optical networks. The number of optical carriers, which was initially limited to four units, has reached values of eight, sixteen, thirty-two and sixty-four units. Internet providers then started to offer multimedia services, e-commerce, e-business, web games, among others, by means of an Integrated Services Digital Network (RDSI-ISDN) and, more recently, ADSL (Asymmetrical Digital Subscriber Line). [0005] Another trend identified was the voice services transport over IP (Voice over IP—VoIP) by the Internet services providers (ISP), as an alternative to traditional telephone services. IP Providers based themselves on the high reliability of the optical means and abandoned the stringent telephone hierarchies and the protection and restoration schemes used till then. In this way, IP applications on DWDM (Dense Wavelength Division Multiplexer) and alternatives such as Packet-over-Sonet (PoS) have emerged, which are based on routers. A market segment has been created, wherein the Quality of Service exhibited by ATM (Asynchronous Transfer Mode) switches and the protection and restoration patterns of the telephone operators ceased to be used, in exchange for traffic without QoS, not protected and without a delivery guarantee, but with significantly lower costs. [0006] The trend towards the use of systems with high rates, which associate IP over DWDM, is becoming intense, although, as indicated previously, without protection, restoration or QoS. [0007] In fact, it can be noted that there is a scenario of competition between telephone operators and Internet providers, wherein the possibility of developing networks with the intelligence functions implemented on the physical optical layer can significantly alter the applications involving the current telecommunications networks. [0008] In order to clarify what is meant by a physical layer, with the aim of creating connectivity standards for the interlinking of computational systems, the OSI model was created (Open System Interconnect). [0009] General aspects of this connectivity were divided into seven functional layers in such a way as to try to facilitate the understanding of a communication process between the programs of a computer network. A brief summary follows describing what each layer is. [0010] The physical layer covers the hardware specifications used in the network, which include mechanical, electrical and physical aspects. Another layer is that of enlace, which is restricted to only two network nodes. The protocols in this layer aim to make the data sent from one computer to another interconnected with it arrive in a correct form and without damage or loss. In the network layer, its protocols deal with routing the messages in the network according to routing algorithms, addressing and stream control disciplines. In a transport layer, the transport protocols have an “end to end” view of the communication process, guaranteeing that data sent from the origin will arrive at its destination, and for this it uses mechanisms such as stream control, error correction and others. A session layer deals with the “dialogue” between the programs that run in a network while the presentation layer deals with the syntax and semantics of these programs' data, e.g. the cryptography. The last layer is that of application, which deals strictly with the definition of the application protocols themselves. [0011] U.S. Pat. No. 5,854,699 describes a data transport system, the addressing of which is made by an optical filter /λT, and subcarriers to supply the control information. This patent aims at dissociating traffic velocity from control signal velocity, as used in a LAN. There was a great concern with the high rates in control signal, because of silicon state of the art technology at the time this patent was filed. The control information is node identification, transmission channel identification, “free/busy” status, priority, acknowledgment, broadcast/unicast, and are extracted via information demodulation techniques transported by the subcarrier. Such a modulation is straight from the laser, and a single subcarrier is used to connect the control information common to all the nodes that use it by means of a token hierarchization. [0012] Because of the modulation need in the subcarriers, it has a high response time, so that keying packet by packet is not possible in real time. [0013] U.S. Pat. No. 5,847,852 describes an optical network, which has several subordinate optical networks that function as transmitters and receivers. The system used in this invention is an information transport system where frequency conversion occurs and addressing is WDM/SCM. Therefore, the signal check takes place by means of the conversion, and this procedure delays receiving the information via the node destination to which it is sent. [0014] European patent No. 550,046 A2 describes a system for routing and switching of optical packets with multiplexed header and data. The procedure comprises the use of a multiplexed carrier to contain routing information. Such a header is transmitted on the same optical carrier, but at a lower velocity than that of the data packets. This makes the receivers process and detect such information by means of a lower cost receiver. It is possible to lessen the costs of the receiver, although what happens in the systems of the previously mentioned patents also takes place here. The information receiving time via the destination node still remains excessively long. [0015] The great majority of current data transport systems transport data, which until it arrives at its destination, are open at each node along the path. This makes the information take a long time to arrive at its true destination. OBJECTS OF THE INVENTION [0016] It is an object of this invention to reduce time spent in data addressing, protection and restoration. [0017] It is an object of this invention to dispense with optical-electric and electric-optical conversions in the intermediate nodes during the transmission of the information held in a data packet. [0018] It is another object of this invention to use intelligence functions of the physical layer without altering protocols. [0019] It is still another object of this invention to expand the bandpass and use the intervals aimed at headers. [0020] It is still another object of this invention to avoid opening and reading each packet to know its destination in a data transport system. [0021] It is still another object of this invention to simplify the management of a data network—TMN (Telecommunications Management Network). [0022] It is still another object of this invention to guarantee the data packet delivery, which is to be sent in a data transport system. [0023] It is another object of this invention to allow the addressing and crosslinking directly on the optical layer. [0024] It is another object of this invention to operate without altering the original frame signaling. [0025] The objectives described above are achieved by means of a data transport system, which will be presented in further detail below. SUMMARY OF THE INVENTION [0026] According to the description of this invention, a data transport system and method and its components are as follows: [0027] The data transport system of this invention comprises: [0028] A data packet emission device, which acts on the physical layer of a data transmission network, and has a device to attach information to data packets in the form of a tag. A device for reading the information on the data packet tag is also provided. The tag is external to said data packet, unmodulated and contains information indicating the address of origin and the destination of the data packet. The tag comprises at least one unmodulated RF subcarrier. The number of addresses referred to is 2n−1, n being the number of subcarriers. The system has an additional subcarrier to indicate the existence of a data packet to be transmitted. [0029] The device for reading the information provided in the data packet tag detects the presence/absence of RF subcarriers and transforms them into a binary sequence. The data transmission is a telecommunications optical network. The data packet emission device comprises a Gigabit IP router, a microwave frequency generator, an RF logic switch, and a differential Mach-Zehnder modulator. The device for reading the information provided in the data packet tag comprises dielectric resonator filters, microwave detectors, a Gigabit detection switch and a Gigabit IP router. [0030] The data transport process comprises: creating an information code like an external tag; attaching the information code like an external tag to a data packet; non-modulation of the tag which comprises the information code; sending the data packet with the tag to its destination; and decoding the tag information code during the data packet path, including to its destination, in a data transport network. [0031] The tag information decoding of the data packet is effected by means of detecting the presence/absence of at least one unmodulated RF subcarrier. Then the information transposition for the information to a digital sequence indicating at least one destination address of the referred data packet takes place. The binary sequence identification is a function of a logic address. The attachment of the information code is accomplished in the manner of an external tag on a data packet. The data packet presence indication to be sent is attained by means of an RF subcarrier. [0032] The information of the subcarrier constellation comprises destination/origin nodes indication (avoiding packet reading in intermediate nodes), the presence/absence of the packet in each network node, power levels—which are used for protection/restoration and simplification of the network TMN management. [0033] The data transport system is passible for use in establishing an optical VPN (Virtual Private Network), which is selected and dedicated according to any telecommunications operator planning. In this data transport system, the subcarriers themselves carry information that will help in making decisions on protection and restoration and management agility in a telecommunications network. BRIEF DESCRIPTION OF THE DRAWINGS [0034] For a better understanding of this invention, reference is made to the drawings/figures in which: [0035] [0035]FIG. 1 shows a graphic in the frequency domain, a number of RF subcarriers are introduced above the payload spectrum; [0036] [0036]FIG. 2 shows schematically how the RF subcarriers are electrically generated and next introduced in the optical spectrum; [0037] [0037]FIG. 3 shows a complete schematic diagram of a node receiver, using subcarriers for protection and addressing; [0038] [0038]FIG. 4 shows a block diagram of a generic optical network node when using electrical subcarriers for protection, restoration and addressing functions; [0039] [0039]FIG. 5 shows a Microwave Carrier Generator, used in the system of FIG. 2; [0040] [0040]FIG. 6 shows a Logical RF switch, used in the system of FIG. 2; [0041] [0041]FIG. 7 shows an RF passive combiner, used in the system of FIG. 2; [0042] [0042]FIG. 8 shows a dielectric-resonator (DR) filter, used in the system of FIG. 3: (a) dielectric-resonator, (b) dielectric-resonator physics implementation, and (c) graphic results of a dielectric-resonator-filter with different bands; [0043] [0043]FIG. 9 shows a crystal quadratic RF detector, used in the system of FIG. 3; [0044] [0044]FIG. 10 shows a gigabit detection switch, used in the system of FIG. 3: (a) implemented with NAND logical gates, and (b) implemented with AND and NAND logical gates; [0045] [0045]FIG. 11 shows a block diagram of IP Gigabit Router. DETAILED DESCRIPTION [0046] The explosive traffic growth due to the increase in Internet utilization is well known. The Optical WDM technology has became the preferred solution for coping with the exponential increase and demand for the utilization of ever greater bandwidths. [0047] Optical WDM networks call for a very complex management array. Usually, there is a need to convert the optical data stream—in each network node—from the optical to the electric domain and also to open the data packets, in order to investigate whether or not the packets are aimed at the focused node. These operations are time-consuming (jeopardizing real-time voice and video transmissions) and also quite demanding with respect to equipment needs. [0048] Any further step addressed to decreasing management array cost and/or decrease management processing time is worthwhile considering. [0049] In this invention, restoration & protection, together with node routing, will be performed at the physical layer level. The mentioned protection may be also used for achieving protected IP transmissions—a procedure that it is not very usual. Rather, it is more a routine to convey IP—unprotected—over the so-called PoS (Packet over Sonet), where the Sonet protection bits have been removed. [0050] The above-mentioned restoration, protection and addressing operations will be performed by fast electronic circuitry in a very straightforward way or, in other words: notably fast when the software is used. In order to do so, when a node launches a data packet 1 , a number of RF sub-carriers 2 are introduced above the payload frequency spectrum. The electrical spectrum will then look as depicted below, in FIG. 1. [0051] In FIG. 1, a number of RF subcarriers 2 are introduced above the payload spectrum. Half of them identify the destination node 2 . 1 , the other half identifies the source 2 . 2 : an extra one 2 . 3 indicates that the circuit is on, to avoid misinterpretation of any link with a fault condition. [0052] Next, while the packets 1 are received at the correct node, suitable optoelectronic circuitry will process these subcarriers 2 in order to offer protection & restoration, together with routing operations. [0053] [0053]FIG. 2 shows a transmitter device 36 comprising an IP Router 4 associated with an RF sub-system. At the transmitter, the Microwave Carrier Generator 3 electrically generates nine RF/microwave subcarriers; one of them (f 9 ) will be introduced whenever a node emits a data packet. The subcarriers, f 1 , f 2 , f 3 and f 4 generated through the Source Generator 37 identify the source node, while the others four f 5 , f 6 , f 7 and f 8 generated through the Destination Generator 38 identify the destination node. [0054] A logical RF Switch 5 uses data from IP Router 4 to compose a subset of the subcarrier related with the destination node 2 . 1 and another Logical RF Switch 5 will compose a subset of the subcarrier related with the emitting (origin) node 2 . 2 , in the same manner. The generated subcarriers will be combined through the RF Passive Combiner 7 and next introduced in the optical spectrum by means of a differential Mach-Zehnder (MZI) 6 . The extra subcarrier (f 9 ), which controls the data packet existence, is introduced in the optical spectrum through the same Mach-Zehnder (MZI) differential 6 . [0055] The number of subcarriers and their respective frequency allocation is to be settled by the network designer. For doing so, the strategic approach is the following: [0056] (a) A subset comprising half of the subcarrier set is related with the emitting (origin) node; [0057] (b) The other half of the subcarrier set is related with the receiving (destination) node; [0058] (c) The specific subcarrier frequency positions are such that each subcarrier subset describes—unequivocally—a unique emitting node and a unique receiving node; [0059] (d) Furthermore, there is an extra subcarrier 2 . 3 , which indicates that the connection is “on”. Without this carrier, an idle traffic condition could be misinterpreted as a fault, as will be seen below. [0060] The total number of nodes is 2N−1, where N is the number of subcarriers used to form the addressing code. In principle, the subcarriers remain unmodulated. If they were modulated, their number might be substantially reduced. However, their action would only be effective after demodulating the information they carry. This latter operation is much slower than a simple detection of their presence. Consequently, if network management speed is the prime objective, CW (continuous wave) subcarriers are preferred. [0061] According to FIG. 3, the protection and restoration action using the subcarriers is performed according to the following steps: [0062] (a) For any receiving node there is a particular subcarrier subset combination related with the referred node address (called “bits b”); [0063] (b) A sample of the subcarrier subset related to destination node function is detected, filtered and sent to logical gates 15 ; The first two actions are performed by the destination detector 26 and filter 14 , respectively; [0064] (c) If a positive logical sign is obtained at the Gigabit Detection Switch 15 output, it means that the arriving data packet is designated to this node. Packet processing procedures are then activated; [0065] (d) If the above-mentioned positive sign is absent, either the data packet is not aiming at the referred node, or the link is faulty; [0066] (e) To solve the above question, there is an additional mechanism, traffic detector 28 , to detect if either the traffic indicator subcarrier 2 . 3 is absent (failure situation), or if it is present and/or still, at least one subcarrier is present (non-failure situation, momentarily with no traffic, or data seeking a different node, respectively). [0067] When a failure situation, as described above, occurs, there will be a commutation, at the first Optical Switch 9 , from the working (W) optical channel to that of protection (P). [0068] Previously, it was mentioned that—in each node—the subcarrier subset that is related to the node destination function 2 . 1 is detected locally and electrically processed. [0069] This processing comprises the use of narrowband filters 14 : each one tuned to one of the subcarrier frequencies. [0070] [0070]FIG. 3 shows a complete schematic diagram of the receiver circuitry 8 in each node, which is able to supervise the RF subcarriers 2 . The optical signal is divided into three parcels by a splitter 29 . The first one, (80%), follows transporting through an optical delay 30 . The second (10%) is used by the system to verify the optical signal level received through a power level monitor 10 . The third is converted to the electrical domain by a photodetector 11 . [0071] Subsequently, signal splitters 12 and RF amplifiers 13 will route the above-mentioned signal to a narrowband filter array 14 . In FIG. 3, this array is illustrated by an 8-dielectric-resonator-filter array. The array is composed of two sub-arrays: The first sub-array 14 comprises filters 1 , 2 , 3 and 4 , which deals with the subcarriers related with the origin node. The second sub-array 14 (filters 5 , 6 , 7 and 8 ) deals with the subcarriers related with the destination node. After detection 26 , each sub-array is able to furnish binary codes describing the origin and destination nodes, respectively. The origin binary code is later converted by the decode unit 31 , while the destination binary code is being analyzed by the Gigabit Detection Switch 15 and compared with the particular bits “b” sequence (b 5 b 6 b 7 b 8 ) implemented in each node. [0072] Additionally, the traffic indicator subcarrier f 9 (which is always on) is filtered 14 and detected 28 by the receiving node. This furnishes an indication of transmission of data packet 1 , even during an idle traffic condition. In this way, there will always exist the possibility of power monitoring. This latter operation is necessary for choosing between receiving either W (Working) fiber channel or P (Protection) fiber channel. After the W or P channels decision, there is binary code analysis related with the destination node. In order to do so, component 33 enables the identification bits “b”. [0073] In case the destination node is the one that is being focused, a second decision circuit 27 will connect the second optical switch 9 to the pertinent node router 4 (Drop Switch Router) in FIG. 3. [0074] Meanwhile, the RF subcarriers 2 will be “on” during a whole SONET frame, if this is the case. Observe the optical delay element 30 , providing correct timing with respect to the decision circuits 34 and the second optical switch 9 . [0075] Concerning the concatenated action of the transmitter, together with the receiver, FIG. 4 is furnishing a block diagram of a complete generic node. There, using a schematic diagram becomes clear what has been previously described in FIG. 2 and FIG. 3. [0076] Microwave Carrier Generator 3 [0077] The main function of the Microwave Carrier Generator 3 , described in FIG. 2, is to generate the RF subcarriers 2 . With reference to FIG. 5, which shows a detailed Microwave Carrier Generator, a Crystal Oscillator 16 in 100 MHz, combined with frequency multipliers 17 , narrow-band filters 18 and amplifiers 13 , generates eight different frequencies. These eight frequencies are separated from each other by 100 MHz, and will be used to form the addressing code. The subcarriers, 1.9, 2.0, 2.1 and 2.2 GHz identify the source node addressing, while the other four 2.3, 2.4, 2.5 and 2.6 identify the destination node address. It is worth mentioning that these numbers are just an example and other frequency ranges can also be used. [0078] Logical RF Switch 5 [0079] The Logical RF Switch 5 , detailed in FIG. 6, is responsible for combining the RF subcarriers in order to form the addressing codes 2 . 1 and 2 . 2 . Each network node has a fixed address, which is represented by a binary code. The “on/off” RF subcarriers 2 , indicating bits “ 1 / 0 ”, respectively, represent this code. [0080] To generate the right combination, a logical intelligence 39 is used. This intelligence will command the RF switches 40 enabling or not the subcarrier 2 transmission and then forming an addressing code. [0081] RF Passive Combiner 7 [0082] The previously generated subcarriers 2 form a code that indicates the addressing of origin node 2 . 2 that launch the data and the addressing of the destination node 2 . 1 at which this data is aimed. An RF Passive Combiner 7 , shown in FIG. 7, combines the four origin subcarriers and the four destination subcarriers, to later be amplified 13 and then added to the optical spectrum by means of a Mach-Zehnder device 6 . [0083] Dielectric-Resonator (DR) Filter 14 [0084] As in applied case subcarriers 2 are spaced from each other just in 5%, and since this distance is too small for the micro-strip or strip-line filters to be used, dielectric resonator filters (DR Filters) 14 were chosen. Dielectric cavities with very high εr values (for instance: εr=40, εr=80, . . . ) have been used in coupled lines structures, in association with the possible tuning of the cavity TE01δ mode, according to FIG. 8. [0085] Accordingly, filters in microwave frequencies with low insertion loss (<1 dB) e narrow tuning—due to a very high Qloaded value presented in resonators—can easily be constructed and at low cost. Tuning is made by metallic or dielectric screws, which descend on to the resonator. [0086] Detectors 20 [0087] The detectors 20 will transform the RF subcarriers 2 into a binary number that indicates an addressing code. The presence or not of these subcarriers 2 corresponds to bits “ 1 ” or “ 0 ”, respectively. [0088] The crystal microwave detector 20 works like an RF signal rectifier, taking the amplitude of the microwave signal off. This type of configuration can be dimensioned for rising time less than 10 picoseconds and it can be interfaced with Emitter Coupled Logic—ECL or Source Coupled FET Logic—SCFL. [0089] Gigabit Detection Switch 15 [0090] The main function of this block is to compare the binary code received—through bits “a”, with the local addressing binary code (bits “b”), in order to check if the node is intended to be the destination of the transmitted data packet 1 . [0091] The Gigabit Detection Switch 15 is implemented using ultra-fast logical gates like AND or NAND, depending on the local node addressing code (bits “b”). FIG. 10 shows examples of this implementation. [0092] In conclusion, based on these examples, AND gates are used when bit “b=0”, otherwise NAND gates will be used (“b=1”). It takes place like this in order to always take logical value results as “1” when the bit sequence “a 5 a 6 a 7 a 8 ” is equivalent to bits “b 5 b 6 b 7 b 8 ” or logical value results as “0” when these bits do not match. The examples show that when the binary code received (bits “a”) does not match with the local addressing code (bits “b”), it will generate a logical value “0” as a result, indicating that the data packet 1 is not aimed at this specific node. But if the codes match (bits “a”=bits “b”) the Switch 15 will indicate the logical value “1”, indicating that this specific node corresponds to the destination of the data packet 1 . [0093] IP Gigabit Router 4 [0094] This block can be considered as an additional unit, which selects and implements functions in order to synchronize the system proposed in this invention. This unit has at least four outgoing signals that will be applied at the transmission module. The two first indicate the start and stop clock time, respectively, and the third is the optical output corresponding to the data packet 1 , while the fourth provides the addressing codes. [0095] The byte A 1 initializes the system clock and, after approximately 20 μs, the information of origin and destination addressing have already been received by the Microwave Frequency Generator 3 . [0096] From this moment, the RF subcarriers 2 could be activated at up to 100 μs, coinciding with the payload transmission, transposed to the optic domain. In this way, each combination of destination and origin address will have a lifetime similar to its associated Frame. [0097] Therefore, it must be understood that the system and its described component parts above are only some of the modalities and examples of situations that could occur, while the real target of the object of the invention will be defined in the claims.
This invention refers to a data transmission system and process wherein a data packet ( 1 ) to be transmitted in a telecommunications network with a tag ( 2 ) containing destination and origin information ( 2.1, 2.2 ) of said packet ( 1 ). In each node of a packet path ( 1 ), tag ( 2 ) will be read and there will be no need to open the former. Information contained in tag ( 2 ) is constituted of a constellation of RF subcarriers ( 2 ) and its detection is accomplished by checking for absence or presence of subcarriers. The process is accomplished without needing to modulate subcarriers, whereby the checking of the information contained is accelerated.
7
FIELD OF THE INVENTION [0001] This invention relates to processes and apparatus for the contact printing of liquids onto sheet materials. BACKGROUND OF THE INVENTION [0002] In contact printing, a printing agent is applied onto a printing surface, a sheet material is impressed against the printing surface, and the sheet material is then separated from the printing surface. The processes and apparatus for such contact printing can take many forms. For example, the printing surface may be formed on a flat plate or block, on a cylindrical shell or roller, on a removable plate mounted on a shell or roller, or in any other required or convenient form. The sheet material may be processed as a continuous web, as individual sheets, as a web already partially separated into individual sheets, such as by perforation, as folded individual sheets or webs, and so on. The printing agent may be an ink, a dye, an adhesive, or any other material having the fluid properties necessary for the particular printing application. The printing agent may be applied onto the printing surface by means of an applicator, such as a roller, or may be extruded through a porous printing plate onto the printing surface. [0003] In a contact printing process, the printing agent may accumulate on the printing surface and form a hard protuberance or a mass that may detach from the printing surface and contaminate the process. Also, the printing agent may adhere to both the printing surface and the sheet material with sufficient strength to cause the rupture or distortion of the sheet material when it is separated from the printing surface. For example, the avoidance of ruptures or distortion is especially important when printing a relatively aggressive adhesive onto a relatively thin and conformable film, such as in the manufacture of a film for wrapping food or food containers, but may be especially difficult to achieve. [0004] It is preferable to prevent or minimize the strong adhesion of the printing agent to the printing surface, rather than to add process steps or equipment in an attempt to compensate for its occurrence. For example, a release agent such as an oil may be externally applied to a printing roller by means of an applicator roller, a brush, or a non-contact applicator. Such an approach is limited in its usefulness by practical considerations such as the requirement for space immediately adjacent the printing roller 16 and the difficulty inherent in attempting to apply the release agent in equal amounts per unit area on specific portions of the printing surface corresponding to where the printing agent will be applied, in order to minimize the usage of the release agent and the possibility of contamination of the process by excess release agent. [0005] Also, the consistent external application of a release agent in pure form at a relatively low rate is often difficult to achieve. An emulsion of a release agent may be used to facilitate the external application, but the emulsifier often has undesirable properties relative to the process and the finished product. Therefore, it may be necessary to volatilize a part of the emulsion immediately after its application to the printing surface, for example, through the application of heat energy. However, the temperature required for volatilization may be excessive for the material of which the printing surface is made, which is often selected on the basis of its ease of machining. [0006] In addition, printing processes in which the printing agent is extruded through a porous printing plate present additional difficulties with respect to the prevention of the adhesion of the printing agent to the printing surface. These difficulties arise from the direct application of the printing agent to the printing surface and the resultant effective preclusion of the use of an externally applied release agent, because of the impracticality of applying the release agent onto the printing surface beneath the printing agent. [0007] An alternative approach to the prevention of the adhesion of the printing agent to the printing surface is to use a printing plate impregnated with a fixed quantity of a release agent that is depleted over a number of cycles of the process. In this approach, the progressive depletion of the release agent may lead to a progressive reduction in effectiveness. A similar approach is to make the printing surface of a material such as silicone rubber or a urethane having good release properties. However, a printing plate fabricated of such a material often lacks the desired durability. Another approach is to apply a more durable release agent, which may be renewed when worn or degraded, to the printing surface. Examples of such durable release agents are various plasma coatings, polymer coatings, and films or sheets of such materials, which may be affixed to the printing surface. However, the use of such durable materials requires the continuing monitoring, maintenance, and replacement of the materials in order to maintain their effectiveness. Also, damage to such materials or their structural failure may result in the contamination of the process. [0008] Another alternative approach to the prevention of the adhesion of the printing agent to the printing surface is to apply a low surface energy coating to the printing surface. For example, silicone-based and fluoropolymer-based coatings may have the desired release properties. However, some such low surface energy coatings lack sufficient durability for practical use in contact printing processes. Also, the curing temperatures required for the proper application of some of these coatings exceeds the temperatures at which creep or the failure may occur in the materials of which the printing plates are made. For example, it may not be practical to apply a fluoropolymer having a curing temperature of approximately 400 degrees C. to a structural material having a creep temperature of approximately 110 degrees C. and a failure temperature of approximately 200 degrees C. [0009] Yet another approach is to maintain a process condition in which the printing agent will not strongly adhere to the printing surface. For example, some adhesives can be prevented from strongly adhering to a surface by maintaining that surface at a sufficiently high temperature. However, the required high temperature may be excessive for the sheet material being impressed in a contact printing process. In addition, at the required temperature, the adhesive may flow onto other surfaces where its presence is problematic. As another example, an adhesive may be prevented from adhering to a surface by chilling that surface to a temperature at which atmospheric moisture condenses and forms a layer of water on the surface. However, the presence of water in its liquid state is often problematic. Also, the rates of condensation and of the accumulation of water on the surface depends on the relative humidity, the rate at which the sheet material removes the water from the surface, and other factors. Variations in these factors can lead to the accumulation of ice on the surface, which often is unacceptable. In addition, the chilling of a surface to a condensation temperature typically requires a channel near the surface for the circulation of a chilling agent, which limits the configuration of the printing plate. [0010] Therefore, a need exists for a contact printing process and apparatus in which the adhesion to a printing surface of a printing agent and a sheet material onto which it is printed can be prevented, without an external application of a release agent, a progressive depletion of a fixed quantity of a release agent, a non-durable printing surface, a source of process contamination in the form of a durable release agent, or an extreme process condition. SUMMARY OF THE INVENTION [0011] The present invention provides methods and apparatus in which a first liquid is extruded through a porous printing plate to its printing surface, a second liquid is externally applied over the first liquid on the printing surface, and a sheet material is contacted with the printing surface in order to print the second liquid onto the sheet material. In some embodiments, the first liquid is a release agent, the second liquid is a printing agent that is applied over the release agent on the printing surface, and a sheet material is contacted with the printing agent on the printing surface to print the printing agent onto the sheet material, whereby the release agent prevents the adhesion of the printing agent and the sheet material to the printing surface and thereby allows the sheet material to be easily separated from the printing surface. In some embodiments, the printing agent is an adhesive and the release agent prevents the adhesive from strongly adhering to or accumulating on the printing surface. BRIEF DESCRIPTION OF THE DRAWINGS [0012] [0012]FIG. 1 shows an overview of the process flow and apparatus of the present invention. [0013] [0013]FIG. 2 shows a portion of the porous printing plate of the present invention. [0014] [0014]FIG. 3 shows a portion of the porous printing plate having particles lodged in the passages. [0015] [0015]FIG. 4 shows a portion of the porous printing plate with layers of the first and second liquids on the printing surface. [0016] [0016]FIG. 5 shows a portion of the printing surface having pattern and non-pattern zones. [0017] [0017]FIG. 6 shows a portion of the porous printing plate having a closed printing surface aperture. [0018] [0018]FIG. 7 shows a portion of the porous printing plate having raised and unraised areas. [0019] [0019]FIG. 8 shows a portion of the porous printing plate having raised and unraised areas and having closed apertures in the unraised areas. [0020] [0020]FIG. 9 shows a portion of the porous printing plate having raised and unraised areas and having closed apertures in the unraised areas, with layers of the first and second liquids on the printing surface. DETAILED DESCRIPTION OF THE INVENTION [0021] For the purposes of this description, the term “printing plate” is used to denote a component or an assembly having a prepared surface designated as its “printing surface” and with which printing is done by impressing a sheet material against the printing surface. Included in this meaning are the various forms that such a component or assembly can take, such as a flat plate or block, a cylindrical shell or roller, a removable plate mounted on a shell or roller, or any other required or convenient form. Corresponding terms such as “printing cylinder”, “printing roller”, and “printing shell” may be used to denote the specific form of a printing plate being described with respect to a particular embodiment. When one such specific form or embodiment is described, it is intended that the disclosed characteristics of that form or embodiment relevant to the present invention be understood to be applicable to the other forms and embodiments, as well. [0022] All documents cited herein are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. [0023] In this description, printing onto a sheet material is described in terms of the sheet material being impressed against, or brought into contact with, a printing surface. These terms are intended to convey the concepts of contact printing and, therefore, include the presence of a printing agent between the actual printing surface and the sheet material, i.e., the direct contact of the sheet material and the printing surface in the absence of any intermediary printing agent is not required for the two to be considered to be in an impressing or contacting state. [0024] The present invention may be used to print onto a sheet material 20 in an apparatus 10 , shown schematically in FIG. 1. The apparatus 10 may be integrated into a manufacturing line such that the printed sheet material 20 may be manufactured “on-line”. As used herein, the term “integrated” refers to interconnected process modules that operate concurrently to produce finished products from source materials. The term “on-line” is used to refer to the process of manufacturing an element of a finished product on an apparatus that is integrated with the manufacturing line. [0025] In this embodiment, the sheet material 20 is a web 22 , which may comprise a single material or a laminate of suitable materials. For example, in an embodiment in which the process of the present invention is used to make a film for wrapping food or food containers, the web 22 may comprise a high density polyethylene film. A food wrap film may have a thickness of at least about 0.005 mm. Also, a food wrap film may have a thickness of no more than about 0.05 mm. In some embodiments, the web 22 may comprise, for example, a monolithic film, a formed film, a foam, a non-woven material, a paper material, or any other sheet material. In some embodiments, the sheet material 20 may have the form of an individual sheet, such as a sheet of paper, a laminated wood product, or a surface of another manufactured product, for example. [0026] The web 22 is fed into the apparatus 10 by a web delivery system (not shown in the Figures). The web delivery system preferably feeds the web 22 into the apparatus 10 at a determinate feed rate, while maintaining a determinate level of tension. Each web delivery system preferably comprises an unwinder system, a tensioning and metering system, and a tracking device. The tensioning and metering system preferably comprises a tensioning device, such as a dancer, a metering device, such as a powered roll or S-wrap roll pair, and a feedback system to control the speed of the unwinder system. Suitable web delivery systems are available from the Curt G. Joa Corporation of Sheboygan Falls, Wis., U.S.A. The tracking device preferably guides the web 22 to place the centerline of the web exiting the tracking device at a predetermined lateral position. A tracking device manufactured by the Fife Corporation of Oklahoma City, Okla., U.S.A., under the trade designation Fife A9 is an example of a suitable tracking device. [0027] Examining the process of FIG. 1 in greater detail, the web 22 is provided to the apparatus 10 in a machine direction. As used herein, the term “machine direction” refers to the general direction of movement of the materials being processed. The machine direction is shown by the arrows MD, which point downstream along the machine direction. The term “downstream” refers herein to a position or a direction toward the latter steps of the process, relative to another position, while the term “upstream” refers herein to a position or a direction toward the earlier steps of the process, relative to another position, i.e., to the opposite of downstream. The term “cross machine direction” refers to both of the pair of opposing vectors defining an axis generally in the plane of the web material being processed and perpendicular to the machine direction. The term “orthogonal direction” refers to a direction generally orthogonal to both the machine direction and the cross machine direction. In general, in a typical web contact printing process, the web is fed in the machine direction, is guided in the cross machine direction, and is impressed against the printing plate in the orthogonal direction. [0028] The printing plate 14 in the embodiment of FIG. 1 has the form of a printing roller 16 , comprising a process roller 70 having a cylindrical shell 74 . The term “process roller” or, alternatively, “process roll”, is used herein to denote a machine element that is known in the art as commonly having a shaft aligned with its longitudinal axis, a structure generally mounting a solid body or a shell on the shaft, an associated supporting structure having a shaft bearing, and an associated drive system, if the roller is driven. An inner cavity 78 is formed by the cylindrical shell 74 and one or more partitions. The shell 74 has an inner surface 76 bounding the inner cavity 78 and an outer surface 72 , which is the printing surface 30 . A rotary union may be connected to the shaft to communicate with the inner cavity 78 . Such a printing roller 16 may be rotated at a tangential velocity that is equal to or different from the machine direction velocity of the web 22 , depending on the desired characteristics of the printed web. In other embodiments, in which the printing plate has a form other than that of a roller, such as that of a flat plate or a block, the printing plate may be moved in the machine direction at a velocity equal to or different from the machine direction velocity of the portion of the web 22 onto which the printing is being done. In some embodiments, the web 22 may be slowed or stopped while being impressed against the printing surface 30 . [0029] The cylindrical shell 74 of the process roll 70 is porous, meaning that it has apertures in both the inner and printing surfaces and contains passages 36 communicating between the inner surface apertures 34 and the printing surface apertures 32 , i.e., between the inner cavity 78 and the outer, printing surface 30 , as shown in FIG. 2. The shell 74 may be made porous by various fabrication techniques. For example, the shell 74 may be machined to form passages 36 , the shell 74 may be cast or molded with passages 36 , or the shell 74 may be assembled as a composite of materials forming passages 36 . Such fabrication techniques may include steps such as casting the shell 74 with removable materials present and then removing those materials to open the passages 36 . In general, a material having interconnected void spaces forming passages 36 through its thickness may be used for the shell 74 . It may be desirable to use a material that has substantially uniform porosity. Both the apertures and passages 36 have a size distribution, with the distribution of the sizes throughout the material being sufficiently random that the porosity and, therefore, the permeability, is essentially uniform over any selected cross section. A number of commercially available materials may be used for the porous shell 74 , such as porous sintered powdered metals, e.g., porous sintered powdered stainless steel, porous resin-bound granular metal materials, apertured sheets, porous polymeric materials, metal or ceramic matrix composites, etc. An example is a cast material fabricated of aluminum granules bound with an epoxy resin. [0030] It may be necessary to reduce the porosity of such a commercially available material in order to render it usable in the process of the present invention. Such a reduction in porosity may be effected by the modification of the commercially available material by the impregnation or infiltration of particles 38 of another material, such as a ceramic material, into some or all of its passages 36 , as shown in FIG. 3. The particles 38 that lodge in the passages 36 serve to restrict the flow of liquid through the affected passages 36 . A material is selected that can withstand the expected temperature range and is inert in the presence of the fluid that will later flow through the porous material. The particles of this material are then forced into the apertures and passages of the porous material. For example, a porous material may have apertures and passages 36 whose effective open dimension ranges from 0.1 to 10 microns. Ceramic particles having a diameter of 0.01 to 5 microns can be forced by pressure to flow into the porous material. Some of the particles will become trapped within an aperture or passage 36 , thereby reducing its open area and restricting the flow in that area. The amount of flow restriction that is achieved is a function of the quantity and sizes of particles 38 trapped in the porous material. This can be controlled through particle feed rate, particle size distribution, driving pressure, and infiltration time, until the desired permeability is achieved. [0031] The printing surface 30 may have a durable release coating 46 . A material providing a low surface energy effect in its solid or semi-solid form may be suitable for use as a release coating 46 on the printing surface 30 . For example, a plasma coating, a coating containing a silicone compound, or a fluoropolymer coating may be applied to the printing surface 30 as a release coating 46 . As mentioned above, the use of such a durable material may not be desirable in some embodiments. However, the use of such a durable release coating 46 in combination with the extrusion of a release agent or another first liquid may be particularly useful in some embodiments of the present invention. In some cases, the extruded liquid may, in effect, cushion or protect the durable release coating 46 and thereby extend its effective life. In some embodiments, portions of the printing surface 30 may be finished or polished to a high degree and thereby form a low energy surface without, or in addition to, a low surface energy coating. For example, a printing surface that is finished to a surface finish level of approximately Ra 315 microns may be suitable for use in a film printing process. As is known in the art, an Ra term expresses the arithmetical average surface deviation from a centerline through the relief in a surface. [0032] A first liquid 100 and a second liquid 200 are supplied to the process by liquid delivery systems (not shown in the Figures). Each liquid delivery system preferably delivers its liquid at a determinate condition. For example, a liquid may be delivered at a determinate volumetric or mass feed rate, at a determinate pressure, at a determinate temperature, at a determinate state of another parameter, or at a combination of two or more of these conditions. Each liquid delivery system preferably includes a supply system, a liquid transport system, and a control system. In a system delivering a liquid at a determinate flow rate, for example, the control system preferably includes a measuring device, such as a flow sensor, a metering device, such as a positive displacement pump, and a feedback system to control the feed rate. Each liquid may be delivered continuously or intermittently. For example, in some embodiments, the interaction of the flow characteristics of the first liquid 100 with the structure of the passages 36 may be such that an intermittent, or pulsed, supply of the first liquid 100 yields the desired extrusion onto the printing surface 30 . A continuous supply may be suitable for some embodiments, as well. [0033] The first liquid 100 is delivered to the inner cavity 78 of the process roller 70 and from there is extruded through the passages 36 of the porous shell 74 and from the printing surface apertures 32 onto the outer surface 72 . The direction of this flow through the passages 36 of the porous shell 74 is indicated by arrows 102 in FIGS. 1, 2, and 6 through 9 . The first liquid 100 may comprise a single material or a mixture, a solution, or a suspension of suitable materials. For example, in some embodiments, the first liquid 100 may comprise a wetting agent, a lubricating agent, a release agent, a catalytic agent, an activating agent, or any other material suitable for the intended purpose. In embodiments in which a release agent is extruded as the first liquid 100 , the release agent may contain any of various materials that may be suitable to prevent the adhesion of the second liquid 200 or of the sheet material 20 to the printing surface 30 . In general, any liquid material that is compatible with the structural material of the printing apparatus 10 and with the second liquid 200 and the sheet material 20 may be used. In particular embodiments, a form of silicone, mineral oil, other oils, mixtures of fluoropolymers, water, and many other liquid materials providing a low surface energy effect on the printing surface 30 may be suitable for use as release agents. In an embodiment in which the process of the present invention is used to make a film for wrapping food or food containers, for example, the first liquid 100 may be a release agent containing a polysiloxane material, such as neat silicone. [0034] The second liquid 200 is applied over and in contact with the first liquid 100 on the outer surface 72 of the process roller 70 , as shown in FIGS. 1, 4, and 9 . The second liquid 200 may be delivered to an applicator 18 having the form of a roller, a brush, an extruder, a sprayer, or any other form suitable for the application of the second liquid 200 . The second liquid 200 may comprise a single material or a mixture, a solution, or a suspension of suitable materials. For example, in some embodiments, the second liquid 200 may comprise an ink, a dye, an adhesive, a catalytic agent, an activating agent, or any other material suitable for the intended purpose. In an embodiment in which the process of the present invention is used to make a film for wrapping food or food containers, for example, the second liquid 200 may be a pressure sensitive adhesive. [0035] The sheet material 20 is contacted with the second liquid 200 on the outer surface 72 of the printing roller 16 to print the second liquid 200 onto the sheet material 20 . The level of force or pressure that is required to print the second liquid 200 onto the sheet material 20 varies in relation to the particular liquids and sheet material 20 being processed. For example, to print a liquid having a relatively low viscosity onto a sheet material 20 having a relatively high absorbency may require relatively little pressure. On the other hand, to print a relatively highly viscous liquid onto a sheet material 20 having a relatively hard surface may require a relatively high level of pressure. In some embodiments for printing onto continuous webs, the maintenance of some acceptable level of web tension in the machine direction, combined with the routing of the web 22 so as to wrap the printing roller 16 over some relatively small arc, may suffice to generate the required level of pressure. Thus, in such an embodiment, the web tensioning system and the rollers or other components that route the web over an arc on the printing roller may serve as the impressing mechanism. A more complex impressing mechanism may be required in some embodiments, in order to generate the required pressure. For example, in the apparatus 10 of FIG. 1, such an impressing mechanism may have the form of a platen roller 12 serving to impress the sheet material 20 situated between it and a printing roller 16 against the printing surface 30 . In another example, in an embodiment having a flat printing plate, a corresponding flat platen may serve to impress the sheet material 20 situated between it and the printing plate against the printing surface 30 , or a traversing platen roller may be moved to progressively impress the sheet material 20 against the flat printing plate. [0036] Some or all of the first liquid 100 may mix or react with the second liquid 200 . Depending on the characteristics of the liquids, the mixing or reaction may commence as soon as the second liquid 200 is applied or later, such as when the pressure exerted by the sheet material 20 as it is impressed against the printing surface 30 causes the two liquids to mix. In embodiments in which the first and second liquids react, the reaction may be completed while the two liquids are on the printing surface 30 or after the printing onto the sheet material 20 . As an example of such an embodiment, the present invention may be used to mix and activate a two part adhesive at the point of its application to a sheet material 20 . The partial mixing of a two part adhesive, such as an epoxy resin and a hardener, may occur on the printing surface 30 , so long as the adhesion of the mixed adhesive to the printing surface 30 is avoided. In some cases, it may be possible to mix the two parts when the sheet material 20 is impressed, in such a way that the fluid extruded through the printing surface 30 acts as a release agent to prevent the adhesion of the second fluid or of the mixed adhesive to the printing surface 30 . Similarly, a liquid containing a volatile material may be combined with another liquid and printed onto a sheet material 20 through the use of the present invention. [0037] An apparatus 10 of the present invention may be self-cleaning to some extent, since the first liquid 100 is supplied under pressure from beneath the surface on which an accumulation of the second liquid 200 might occur and therefore from beneath such accumulation. The processing of an otherwise unsuitable liquid or sheet material 20 may be made practical by this self-cleaning aspect of the present invention, especially, for example, in an embodiment as described above in which a two part adhesive is mixed, or in another embodiment in which the nature of a material or of an intended product precludes the use of a release agent as the first liquid 100 . [0038] After the second liquid 200 is printed onto the sheet material 20 , the sheet material 20 is separated from the printing surface 30 . In a web embodiment, the machine direction tension present in the web 22 may be sufficient to pull the web 22 away from the printing surface 30 . As noted above, in an embodiment in which a relatively aggressive adhesive is printed onto a relatively thin and conformable film, such as in the manufacture of a film for wrapping food or food containers, the avoidance of ruptures or distortion is especially important. Therefore, in such an embodiment, the present invention may provide an important benefit by reliably preventing the adhesion of the adhesive and the film to the printing surface 30 and thereby making it practical to separate the printed film from the printing surface 30 with an acceptably low level of machine direction tension. As shown in FIG. 1, some or all of the first liquid 100 may be removed from the printing surface 30 and travel with the sheet material 20 when the sheet material 20 is separated from the printing surface 30 . [0039] The amount of each of the first and second liquids delivered to the process may be controlled in various ways and with respect to various other factors. In some embodiments, because the second liquid 200 is the printing agent, the amount of the second liquid 200 may be controlled in proportion to the area of the sheet material 20 being processed. In an embodiment in which a film for wrapping food or food containers is printed with an adhesive, for example, the second liquid 200 , which is the adhesive, may be applied at a rate as low as 0.5 gram per square meter of the film. For some film wrap products, the rate of application of the adhesive may be as high as 5 grams per square meter of the film. A typical rate of application of the adhesive may be about 2 grams per square meter of the film for such an embodiment. [0040] The amount of the first liquid 100 may also be controlled in proportion to the area of the sheet material 20 being processed. In the film wrap embodiments described above, the first liquid 100 , which is a release agent, may be extruded at a rate as low as 0.0001 gram per square meter of the film through the use of the present invention. Under some conditions, such as at a relatively higher rate of application of the adhesive, the release agent may be extruded at a rate as high as 0.1 gram per square meter of the film. In particular embodiments, a typical rate of extrusion of the release agent may be about 0.003 gram per square meter of the film. [0041] Alternatively, the amount of the first liquid 100 may be controlled in proportion to the amount of the second liquid 200 being applied. For example, any proportional relationship of the application and extrusion rates and ranges already mentioned may be suitable for a particular embodiment in which a film wrap is processed. As a specific example, in an embodiment in which the adhesive is applied at a rate of 2 grams per square meter and the release agent is extruded at a rate of 0.003 gram per square meter, both areas being those of the film being processed, the amount of the release agent is 0.15 percent of the amount of the adhesive. For a particular adhesive and a particular release agent, this ratio may be suitable over a wide range of adhesive application rates, and the amount of the release agent may, therefore, be controlled in proportion to the amount of the adhesive, rather than being independently adjusted or controlled in proportion to the film area. Similarly, in other embodiments, the proportion of the first liquid 100 to the second liquid 200 may be a parameter of interest, for example, in the mixing of a two part adhesive or in the mixing of a first liquid 100 containing a volatile material with a particular second liquid 200 . [0042] The extruded amount of the first liquid 100 may be controlled in a variety of ways. For example, the extruded amount may be controlled by controlling the delivery pressure of the first liquid 100 , since the flow rate and the pressure reduction during extrusion are typically related in a predictable manner. Also, the extruded amount may be controlled directly by delivering the first liquid 100 under volumetric control, such as by means of a positive displacement pump. Alternatively, the viscosity of the first liquid 100 may be controlled in order to control the extruded amount. In an embodiment in which a silicone release agent is extruded, for example, the viscosity, and thereby the extruded amount, can be controlled by controlling the temperature of the release agent. The temperature of the first liquid 100 may be controlled by any suitable means, such as through the exchange of heat energy between the first liquid 100 and a liquid heat exchange medium. [0043] In embodiments in which a process roll 70 is rotated, the centrifugal force generated by the rotation may be used to control the extruded amount of the first liquid 100 . For example, the radially outward direction of the centrifugal force may align with the general direction of the flow of the first liquid 100 toward the printing surface 30 and may, therefore, act as a driving force for the flow. Also, in a more complex embodiment, the centrifugal force may serve to actuate a mechanism providing a differential pressure to drive the flow toward the printing surface 30 . The centrifugal force is proportional to the rotational velocity and the tangential velocity of the process roll 70 . Thus, in embodiments in which the process roll 70 is rotated at a tangential velocity that is proportional to the machine direction velocity of the sheet material 20 , the centrifugal force is also proportional to the rate at which the sheet material 20 , in terms of area, is being processed. In such an embodiment, the proportional centrifugal force may be used in a substantially automatic system for the control of the extruded amount of the first liquid 100 . [0044] The temperature of the printing plate may also be controlled in order to achieve certain desired effects, such as the control of the temperature of the first liquid 100 or the prevention of the adhesion of a second liquid 200 to the printing surface 30 . In such an embodiment, the temperature of the printing plate may be controlled by exchanging heat energy between the printing plate and a circulating liquid heat exchange medium in an internal heat exchanger, for example. In an embodiment in which the printing plate 14 has the form of a printing roller 16 , this internal heat exchanger may have the form of a second inner cavity 80 inside the process roll 70 . Other methods known in the art, such as radiant heating of the printing plate or heating of the printing plate by means of an internal electric resistance heating element, may also be used. [0045] The printing surface 30 may have a pattern zone 60 and a non-pattern zone 62 , as shown in FIG. 5. In such an embodiment, the first liquid 100 may be extruded from the printing surface 30 apertures in the pattern zone 60 and substantially not extruded from the printing surface apertures 32 in the non-pattern zone 62 . The apertures in the non-pattern zone 62 may be substantially closed and thereby restrict or block the flow of the first liquid 100 onto the printing surface 30 . For example, the apertures in the non-pattern zone 62 may be closed by the application of a coating 40 or other material onto the printing surface 30 , as shown in FIGS. 6, 8, and 9 . As another example, the apertures in the non-pattern zone 62 may be closed by molten material 42 formed during a treatment of the printing surface 30 with heat. In some embodiments, some or all of the printing surface apertures 32 may first be closed, such as by the application of a coating 40 or by molten material 42 , and then selected areas of the printing surface 30 may be treated or machined to remove the material blocking the printing surface apertures 32 , so as to reopen the printing surface apertures 32 in those areas. [0046] A portion of the printing surface 30 may be raised in relief, as shown in FIGS. 7, 8, and 9 . For example, the pattern zone 60 in an embodiment having pattern and non-pattern zones may be raised in relief, relative to the non-pattern zone 62 . In some embodiments, the raised pattern zone 60 may form a continuous network of interconnected raised areas 64 surrounding unraised areas 66 . Thus, in such an embodiment in which the apertures in the non-pattern zone 62 are closed, the first liquid 100 may be extruded onto only the raised portions of the printing surface 30 . For example, in an embodiment in which the process of the present invention is used to make a film for wrapping food or food containers, and in which the first liquid 100 is a release agent and the second liquid 200 is an adhesive, the release agent may be extruded onto the printing surface 30 of a process roll 70 only on a raised pattern zone 60 , the adhesive may be applied over the release agent on the raised pattern zone 60 , and the adhesive may then be printed onto the film in a pattern matching the raised pattern of the printing surface 30 of the process roll 70 . [0047] While particular embodiments and/or individual features of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Further, it should be apparent that all combinations of such embodiments and features are possible and can result in preferred executions of the invention.
Method and apparatus in which a first liquid is extruded through a porous printing plate to its printing surface, a second liquid is externally applied over the first liquid on the printing surface, and a sheet material is contacted with the printing surface in order to print the second liquid onto the sheet material. In some embodiments, the first liquid is a release agent, the second liquid is a printing agent, and a sheet material is contacted with the printing agent on the printing surface, whereby the release agent prevents the adhesion of the printing agent and the sheet material to the printing surface and thereby allows the sheet material to be easily separated from the printing surface. In some embodiments, the printing agent is an adhesive and the release agent prevents the adhesive from strongly adhering to or accumulating on the printing surface.
1
CROSS REFERENCE TO RELATED APPLICATION This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2006-238119, filed on Sep. 1, 2006, the entire contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a semiconductor device, and particularly relates to a semiconductor device incorporating a non-volatile semiconductor memory (such as a ferroelectric memory). 2. Description of the Related Art Generally, in a semiconductor device incorporating a ferroelectric memory, a voltage supplied via an external power supply pin or a voltage obtained by boosting/stepping down the voltage supplied via the external power supply pin is used as a power supply voltage of the ferroelectric memory. Among the semiconductor devices each incorporating the ferroelectric memory, in an IC card (Integrated Circuit Card), a RFID (Radio Frequency Identification), and so on, a stability capacitance (constituted of a ferroelectric capacitance) is often connected between a power supply pin of the ferroelectric memory and a ground line in order to stabilize the power supply voltage of the ferroelectric memory. The ferroelectric memory has a failure mode regarding data retention called a retention failure, and hence it needs to be guaranteed to retain write data for a predetermined time or more in a power-on state (state in which the power supply voltage is being supplied) and retain write data for a predetermined time or more in a power-off state (state in which the power supply voltage is not being supplied). Therefore, in a test process of the semiconductor device incorporating the ferroelectric memory, a screening test for a retention failure when the ferroelectric memory is powered off (power-off retention test) is performed in the following steps. First, predetermined data is written into the ferroelectric memory. Subsequently, the voltage supply from an external testing apparatus to an external power supply pin of the semiconductor device is stopped to stop the supply of the power supply voltage to the ferroelectric memory. Then, in a predetermined time after the supply of the power supply voltage to the ferroelectric memory is stopped, the voltage supply from the external testing apparatus to the external power supply pin of the semiconductor device is resumed to resume the supply of the power supply voltage to the ferroelectric memory. Thereafter, data is read from the ferroelectric memory, and the presence or absence of the retention failure is determined by comparing the read data and the predetermined data. Moreover, Japanese Unexamined Patent Application Publication No. 2000-299000 discloses a non-volatile semiconductor memory which is configured to be able to supply a voltage obtained by stepping down a power supply voltage to a memory block in addition to the power supply voltage and to ensure reliable data retention even when the memory block is constituted of a ferroelectric memory. Japanese Unexamined Patent Application Publication No. 2004-61114 discloses a self-diagnosis test circuit which can realize a reduction in test time, an improvement in yield, and an increase in test coverage in a test of a semiconductor device. In the conventional semiconductor device, to stop the supply of the power supply voltage to the ferroelectric memory in the power-off retention test of the ferroelectric memory, the supply of the voltage from the external testing apparatus to the external power supply pin of the semiconductor device needs to be stopped. Therefore, during the power-off retention test of the ferroelectric memory, the supply of the power supply voltage to functional blocks except the ferroelectric memory is also stopped. This causes a problem that during the power-off retention test of the ferroelectric memory, the functional blocks except the memory block cannot be tested, thereby increasing a test time of the semiconductor device. Further, with the stability capacitance, even if the voltage supply from the external testing apparatus to the external power supply pin of the semiconductor device is stopped to stop the supply of the power supply voltage to the ferroelectric memory in the power-off retention test thereof, the voltage is supplied to the ferroelectric memory only for a time taken for discharging an electric charge accumulated in the stability capacitance. Hence, whit the stability capacitance, it is necessary to lengthen the time for stopping of the voltage supply from the external testing apparatus to the external power supply pin of the semiconductor device by the waiting time for the completion of discharge of the electric charge accumulated in the stability capacitance, which causes a problem of an increase in the test time of the semiconductor device. SUMMARY OF THE INVENTION An object of the present invention is to reduce a test time of a semiconductor device incorporating a non-volatile semiconductor memory. In a first aspect of the present invention, a semiconductor device includes plural functional blocks, a voltage supply circuit, a cut-off circuit, and a self test circuit. The plural functional blocks include a non-volatile memory block. For example, the memory block is constituted of a ferroelectric memory. The voltage supply circuit supplies a power supply voltage to the functional blocks. The cut-off circuit cuts off the supply of the power supply voltage from the voltage supply circuit to the memory block. The self test circuit performs tests of the functional blocks. In a data retention test of the memory block, the self test circuit instructs the cut-off circuit to start an operation after writing predetermined data into the memory block, and instructs the cut-off circuit to stop the operation to check retention of the predetermined data in the memory block in a predetermined time after the instruction to the cut-off circuit to start the operation. For example, the semiconductor device further includes a stability capacitance and a discharge circuit. The stability capacitance is connected between a power supply pin of the memory block and a ground line. For example, the stability capacitance is constituted of a ferroelectric capacitance. The discharge circuit discharges an electric charge accumulated in the stability capacitance. In the data retention test of the memory block, the self test circuit instructs the discharge circuit to start an operation along with the instruction to the cut-off circuit to start the operation, and instructs the discharge circuit to stop the operation along with the instruction to the cut-off circuit to stop the operation. In the above first aspect, in the data retention test of the memory block by the self test circuit, the supply of the power supply voltage from the voltage supply circuit to the memory block is cut off, but the supply of the power supply voltage from the voltage supply circuit to the functional blocks except the memory block is not cut off. Hence, the self test circuit can perform tests of the functional blocks except the memory block in parallel with performing the data retention test of the memory block. Further, in the data retention test of the memory block by the self test circuit, the electric charge accumulated in the stability capacitance is discharged along with cut off of the supply of the power supply voltage from the voltage supply circuit to the memory block. Therefore, in the data retention test of the memory block by the self test circuit, the time taken for cutting off the supply of the power supply voltage from the power supply circuit to the memory block does not need to include waiting time for the completion of discharge of the electric charge accumulated in the stability capacitance. In the first aspect described above, the test time of the semiconductor device can be greatly reduced, which contributes to cost reduction. In a preferred example of the first aspect of the present invention, the cut-off circuit includes a voltage supply control switch. The voltage supply control switch is connected between a power supply line and the power supply pin of the memory block, the power supply line being supplied with the power supply voltage by the voltage supply circuit. The voltage supply control switch is turned off in response to the instruction from the self test circuit to the cut-off circuit to start the operation, and turned on in response to the instruction from the self test circuit to the cut-off circuit to stop the operation. Consequently, the cut-off circuit which cuts off the supply of the power supply voltage from the voltage supply circuit to the memory block can be easily constituted. In a preferred example of the first aspect of the present invention, the discharge circuit includes a discharge control switch. The discharge control switch is connected between the power supply pin of the memory block and the ground line. The discharge control switch is turned on in response to the instruction from the self test circuit to the discharge circuit to start the operation, and turned off in response to the instruction from the self test circuit to the discharge circuit to stop the operation. Consequently, the discharge circuit which discharges the electric charge accumulated in the stability capacitance can be easily constituted. In a second aspect of the present invention, a semiconductor device includes plural functional blocks, a voltage supply circuit, a cut-off circuit, and a self test circuit. The plural functional blocks include a non-volatile memory block. The voltage supply circuit supplies a first power supply voltage to the memory block and supplies a second power supply voltage to at least one of the functional blocks except the memory block. For example, the voltage supply circuit includes first and second voltage generating circuits. The first voltage generating circuit generates the first power supply voltage using an external input voltage, and the second voltage generating circuit generates the second power supply voltage by stepping down the first power supply voltage. Alternatively, the first voltage generating circuit generates the second power supply voltage using the external input voltage, and the second voltage generating circuit generates the first power supply voltage by boosting the second power supply voltage. The cut-off circuit cuts off the supply of the first power supply voltage from the voltage supply circuit to the memory block. The self test circuit performs tests of the functional blocks. In a data retention test of the memory block, the self test circuit instructs the cut-off circuit to start an operation after writing predetermined data into the memory block, and instructs the cut-off circuit to stop the operation to check retention of the predetermined data in the memory block in a predetermined time after the instruction to the cut-off circuit to start the operation. For example, the semiconductor device further includes a stability capacitance and a discharge circuit. The stability capacitance is connected between a power supply pin of the memory block and a ground line. The discharge circuit discharges an electric charge accumulated in the stability capacitance. In the data retention test of the memory block, the self test circuit instructs the discharge circuit to start an operation along with the instruction to the cut-off circuit to start the operation, and instructs the discharge circuit to stop the operation along with the instruction to the cut-off circuit to stop the operation. The above second aspect can obtain the same effect as the above first aspect, although in the second aspect an operation voltage of the memory block is different from an operation voltage of at least one of the functional blocks except the memory block, and the semiconductor device has two separate internal power supply systems; one with the first power supply voltage and the other with the second power supply voltage. BRIEF DESCRIPTION OF THE DRAWINGS The nature, principle, and utility of the invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings in which like parts are designated by identical reference numbers, in which: FIG. 1 is a block diagram showing a first embodiment of the present invention; FIG. 2 is a flowchart showing the operation of a BIST circuit in the first embodiment; FIG. 3 is a block diagram showing a second embodiment of the present invention; and FIG. 4 is a block diagram showing a third embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Embodiments of the present invention will be described below using the drawings. FIG. 1 shows a first embodiment of the present invention. A semiconductor device 10 of the first embodiment includes a power supply circuit 11 , a logic block 13 , a memory block 14 , a BIST (Built-In Self Test) circuit 15 , a voltage supply control switch 16 , a stability capacitance 17 , and a discharge control switch 18 . The power supply circuit 11 generates a power supply voltage VDD 1 using an external input voltage VDD (voltage supplied from outside via a power supply pin PE) and supplies the power supply voltage VDD 1 to a power supply line PL 1 . The logic block 13 embodies a processor function, a timer function, a communication interface function, and so on. The logic block 13 can perform a read access and a write access to the memory block 14 . The memory block 14 is constituted of a ferroelectric memory including plural memory cells (each constituted of a ferroelectric capacitance and a transfer transistor) arranged in a matrix. In the memory block 14 , the ferroelectric capacitance and the transfer transistor which constitute the memory cell are connected in series between a plate line and a bit line, and a gate of the transfer transistor is connected to a word line. The BIST circuit 15 performs various tests of the logic block 13 and the memory block 14 (an operation test of the logic block 13 , an operation test of the memory block 14 , a power-on retention test/power-off retention test of the memory block 14 , and so on). The BIST circuit 15 performs on/off control of the voltage supply control switch 16 and the discharge control switch 18 when performing the power-off retention test of the memory block 14 . Details of this operation will be described later using FIG. 2 . The voltage supply control switch 16 is provided to cut off the supply of the power supply voltage VDD 1 from the power supply circuit 11 to a power supply pin PM of the memory block 14 and connected between the power supply line PL 1 and a power supply line PL 1 a (power supply pin PM of the memory block 14 ). The power supply control switch 16 is turned on/off in response to an instruction of the BIST circuit 15 . The stability capacitance 17 is provided to stabilize a voltage (voltage of the power supply line PL 1 a ) supplied to the power supply pin PM of the memory block 14 and connected between the power supply line PL 1 a (power supply pin PM of the memory block 14 ) and a ground line GL. The stability capacitance 17 is constituted of a ferroelectric capacitance. The discharge control switch 18 is provided to discharge an electric charge accumulated in the stability capacitance 17 and connected between the power supply line PL 1 a (power supply pin PM of the memory block 14 ) and the ground line GL. The discharge control switch 18 is turned on/off in response to an instruction of the BIST circuit 15 . FIG. 2 shows the operation of the BIST circuit in the first embodiment. When performing the power-off retention test of the memory block 14 , the BIST circuit 15 operates as follows. First, the BIST circuit 15 writes predetermined data into the memory block 14 (step S 11 ). Then, the BIST circuit 15 gives an instruction to turn off the voltage supply control switch 16 (step S 12 ). Consequently, the voltage supply control switch 16 is turned off, the power supply line PL 1 and the power supply line PL 1 a are disconnected, and the supply of the power supply voltage VDD 1 from the power supply circuit 11 to the memory block 14 is cut off. Subsequently, the BIST circuit 15 gives an instruction to turn on the discharge control switch 18 (step S 13 ). Consequently, the discharge control switch 18 is turned on, and the electric charge accumulated in the stability capacitance 17 is immediately discharged to the ground line GL. Then, in a predetermined time T after the instruction to turn on the discharge control switch 18 is given, the BIST circuit 15 gives an instruction to turn off the discharge control switch 18 (step S 14 ). Hence, the discharge control switch 18 is turned off. Subsequently, the BIST circuit 15 gives an instruction to turn on the voltage supply control switch 16 (step S 15 ). Consequently, the voltage supply control switch 16 is turned on, the power supply line PL 1 and the power supply line PL 1 a are connected, and the supply of the power supply voltage VDD 1 from the power supply circuit 11 to the memory block 14 is resumed. After this, the BIST circuit 15 checks retention of the predetermined data in the memory block 14 (step S 16 ). To put it in more detail, after reading data from the memory block 14 , the BIST circuit 15 determines the presence or absence of a retention failure by a comparison between the read data and the predetermined data (data written into the memory block 14 in step S 11 ). In the above first embodiment, when the BIST circuit 15 performs the power-off retention test of the memory block 14 , the supply of the power supply voltage VDD 1 from the power supply circuit 11 to the memory block 14 is cut off, but the supply of the power supply voltage VDD 1 from the power supply circuit 11 to the logic block 13 is not cut off. Hence, the BIST circuit 15 can perform an operation test of the logic block 13 in parallel with performing the power-off retention test of the memory block 14 . Further, when the BIST circuit 15 performs the power-off retention test of the memory block 14 , the supply of the power supply voltage VDD 1 from the power supply circuit 11 to the memory block 14 is cut off, and along with this, the electric charge accumulated in the stability capacitance 17 is discharged. Therefore, when the BIST circuit 15 performs the power-off retention test of the memory block 14 , the time (predetermined time T) taken for cutting off the supply of the power supply voltage VDD 1 from the power supply circuit 11 to the memory block 14 does not need to include waiting time for the completion of discharge of the electric charge accumulated in the stability capacitance 17 . In the first embodiment described above, the test time of the semiconductor device 10 can be greatly reduced, which contributes to cost reduction. FIG. 3 shows a second embodiment of the present invention. The second embodiment ( FIG. 3 ) will be described below, but the same reference symbols as used in the first embodiment will be used to designate the same elements as described in the first embodiment ( FIG. 1 ), and a detailed description thereof will be omitted. A semiconductor device 20 of the second embodiment is the same as the semiconductor device 10 of the first embodiment except that it includes a step-down circuit 22 and includes a logic block 23 and a BIST circuit 25 instead of the logic block 13 and the BIST circuit 15 . The step-down circuit 22 steps down the power supply voltage VDD 1 (voltage of the power supply line PL 1 ) to generate a power supply voltage VDD 2 and supplies the power supply voltage VDD 2 to a power supply line PL 2 . The logic block 23 and the BIST circuit 25 are the same as the logic block 13 and the BIST circuit 15 except that they receive the power supply voltage VDD 2 supplied to the power supply line PL 2 instead of the power supply voltage VDD 1 supplied to the power supply line PL 1 (except that operation voltages are different). In the above second embodiment, the operation voltage of the logic block 23 is lower than the operation voltage of the memory block 14 , and an internal power supply system of the semiconductor device 20 is separated into two systems: a power supply system for the memory block 14 (power supply system with the power supply voltage VDD 1 generated by the power supply circuit 11 ) and a power supply system for the logic block 23 (power supply system with the power supply voltage VDD 2 generated by the step-down circuit 22 ), and also in such a case, the same effect as in the above first embodiment can be obtained. FIG. 4 shows a third embodiment of the present invention. The third embodiment ( FIG. 4 ) will be described below, but the same reference symbols as used in the first and second embodiments will be used to designate the same elements as described in the first and second embodiments ( FIG. 1 and FIG. 3 ), and a detailed description thereof will be omitted. A semiconductor device 30 of the third embodiment is the same as the semiconductor device 20 of the second embodiment except that it includes a power supply circuit 31 and a boost circuit 32 instead of the power supply circuit 11 and the step-down circuit 22 . The power supply circuit 31 generates the power supply voltage VDD 2 using the external input voltage VDD (voltage supplied from outside via the power supply pin PE) and supplies the power supply voltage VDD 2 to the power supply line PL 2 . The boost circuit 32 boosts the power supply voltage VDD 2 (voltage of the power supply line PL 2 ) to generate the power supply voltage VDD 1 and supplies the power supply voltage VDD 1 to the power supply line PL 1 . In the above third embodiment, the operation voltage of the logic block 23 is lower than the operation voltage of the memory block 14 , and an internal power supply system of the semiconductor device 30 is separated into two systems: a power supply system for the memory block 14 (power supply system of the power supply voltage VDD 1 generated by the boost circuit 32 ) and a power supply system for the logic block 23 (power supply system of the power supply voltage VDD 2 generated by the power supply circuit 31 ), and also in such a case, the same effect as in the above first embodiment can be obtained. Incidentally, in the second embodiment, the example in which the operation voltage of the logic block 23 is lower than the operation voltage of the memory block 14 and the step-down circuit 22 which supplies the voltage (power supply voltage VDD 2 ) obtained by stepping down the voltage (power supply voltage VDD 1 ) of the power supply line PL 1 to the power supply line PL 2 is provided is described, but the present invention is not limited to this embodiment. Also when, for example, the operation voltage of the logic block 23 is higher than the operation voltage of the memory block 14 and instead of the step-down circuit 22 , a boost circuit which supplies a voltage obtained by boosting the voltage of the power supply line PL 1 to the power supply line PL 2 is provided, the same effect can be obtained. Further, in the third embodiment, the example in which the operation voltage of the logic block 23 is lower than the operation voltage of the memory block 14 and the boost circuit 32 which supplies the voltage (power supply voltage VDD 1 ) obtained by boosting the voltage (power supply voltage VDD 2 ) of the power supply line PL 2 to the power supply line PL 1 is provided is described, but the present invention is not limited to this embodiment. Also when, for example, the operation voltage of the logic block 23 is higher than the operation voltage of the memory block 14 and instead of the boost circuit 32 , a step-down circuit which supplies a voltage obtained by stepping down the voltage of the power supply line PL 2 to the power supply line PL 1 is provided, the same effect can be obtained. The invention is not limited to the above embodiments and various modifications may be made without departing from the spirit and scope of the invention. Any improvement may be made in part of all of the components.
A cut-off circuit cuts off supply of a power supply voltage from a voltage supply circuit to a non-volatile memory block. A discharge circuit discharges an electric charge accumulated in stability capacitance. In a data retention test of the memory block, a self test circuit instructs the cut-off circuit to start operation after writing predetermined data into the memory block, and instructs the cut-off circuit to stop the operation to check retention of the predetermined data in the memory block in a predetermined time after the instruction to the cut-off circuit to start the operation. Further, in the data retention test of the memory block, the self test circuit instructs the discharge circuit to start operation along with the instruction to the cut-off circuit to start the operation, and instructs the discharge circuit to stop the operation along with the instruction to the cut-off circuit to stop the operation.
6
FIELD AND BACKGROUND OF THE INVENTION This invention relates in general to sewing machines and in particular to a new and useful sewing machine feed mechanism which operates with very low inertia. A sewing mechanism similar to the present invention is disclosed in U.S. Pat. No. 3,742,879. That prior art feed mechanism comprises two swing arms designated X and Y, which are mounted on fixed bolts and carry each a stepping motor as a positioning drive. The stepping motor secured to the Y arm drives through a pinion a geared rack which is mounted for displacement in the Y arm and hinged to the X arm. The stepping motor secured to the X arm drives, through the pinion, a geared rack which is mounted for displacement in the X arm and to which a work holder is secured. Even though the two-member drive linkage of this reference reduces the number of component parts to be moved, as compared to a prior art four member drive linkage, known for example from U.S. Pat. No. 3,983,845, inertia of this mechanism is still relatively too high since the stepping motors are secured to the swing arms and therefore are moved along with the arms. A low inertia mechanism for driving a fabric clamp comprising a single sewing arm is known from U.S. Pat. No. 3,974,787. This is a telescopic structure where a slide is mounted in a swing carrier. Two stationary stepping motors drive the swing carrier and the slide by means of two ropes trained about rollers which are partly fixed and partly carried on the swing arm. The advantageous low inertia is outweighed by the disadvantage that this drive system is suitable only for small seam patterns, thus with a large radial displacement of the swing arm, a retracted swing arm produces small angular increments of the fabric clamp per step of the driving motor, while an extended swing arm causes large such increments. A relatively expensive stepping motor system would therefore be needed for driving the swing carrier, to obtain a highly accurate and fast feed, namely a system with small steps and a large stepping frequency. Among other drawbacks, the ropes may become permanently extended, for example due to the material fatigue with the result of transmitting the motor steps inaccurately, or the drive system may oscillate at certain frequencies because of the shock absorbing springs provided between the machine frame and the stepping motors. SUMMARY OF THE INVENTION The present invention is directed to a low inertia feed device which is simple in construction and always accurately executes the control instructions supplied to the positioning motors, irrespective of whether the sewing pattern is small or large. The two-member design of the linkage, mounting of the swing arm on slides which are driven by stationary positioning motors, and a slip-free positive drive connection between the motors and the slides, result not only in a low inertia of the system but also in a high accuracy in transmission of the movements to the work holder. The positive connection may be effected by a cog belt, geared rack, or screw spindle drive. Electrical or hydraulic stepping motors, or position controlled DC drives may be employed as the positioning motors. Since the feed movements of the work holder are affected by shifting a slide and thus displacing the pivotal axes of the swing arms and, consequently, the length of the swing arms and spacing of the work holder from the pivotal axes do not vary, uniform steps of the positioning motors cause substantially constant displacements of the work clamp at any location of the sewing pattern. No modification of drive conditions need therefore be provided for small and large sewing patterns, or within large patterns. The inventive feed mechanism is universally usable for producing any sewing pattern. With the design of the swing arm the spring steel strips are sufficiently prestressed to completely take up maximum bending loads introduced by the coupled swing arm, so that the center bar is subjected only to loads acting in the longitudinal direction thereof. It is therefore satisfactory to make the central bar resistant only to buckling. A non-buckling bar may be embodied simply by a low inertia hollow or I section of a light metal alloy. Since a sufficient prestressing may already be obtained with relatively thin and thus also light spring steel strips, the entire swing arm has a very small mass. The inertia of the feed mechanism is thus further reduced. Sufficiently prestressed spring steel strips make sure in addition that the swing arm cannot elastically bend under shocks. This still increases the accuracy transmission of the linkage. The feature of a low inertia swing arm resistant to bending is not limited to feed mechanisms with two-member design of the linkage, it may advantageously be applied also to feed mechanisms of different design. To ensure an exactly equal prestressing of both of the steel spring strips, a clamping machanism may be associated with each of them. In accordance with the invention, a sewing machine feed mechanism for a sewing machine having a needle which reciprocates over a support along which a workpiece is moved, comprises a work holder which is moved by two swing arms, each of which has one end which is pivotally mounted on a movable slide. One of the swing arms includes the transversely extending cross bar which is braced against a workpiece holder. The pivotal ends of each swing arm are moved along guide paths by stepping motors. The two swing arm members driven by the stationary motors results in a lightweight and unbending swing arm connection to the workpiece holder. One swing arm which is directly connected to the work holder includes a non-buckling center bar, a transverse bar at its end which is braced against the work holder and two prestressed spring steel strips which connect the ends of the cross bar to the swing arm adjacent its pivotal connection to the movable slides. Accordingly, it is an object of the invention to provide an improved drive for a workpiece of a sewing machine in which a non-bending connection to the workpiece holder is effected with very low inertia of the feed mechanism. A further object of the invention is to provide a feed mechanism which is simple in design, rugged in construction and economical to manufacture. 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 uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 is a top plan view of a sewing assembly constructed in accordance with the invention; FIG. 2 is a front elevation of the sewing machine of FIG. 1; FIG. 3 is an enlarged sectional view taken along the line III--III of FIG. 1; and FIG. 4 is a sectional view taken along the line IV--IV of FIG. 1. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings in particular the invention embodied therein comprises a feed mechanism for a sewing machine 3 having a needle 9 which reciprocates over a support for supporting plate 13 along which a workpiece is moved. The arrangement includes a work holder 10 which is moved by engagement of a cross member or cross bar 17 of a first swing arm assembly generally designated 15. The assembly 15 includes a first swing arm having a center arm portion 16 with a pivotal end pivotal on a pin 61 and an opposite end carrying the cross bar 17. The cross bar 17 extends outwardly from each side of the center arm 16. A second swing arm 34 has a first pivotal end pivotally mounted on a pin or bolt 39 and a second pivotal end opposite to the first end which is pivotally connected to the center arms 16 adjacent the end thereof which is connected to the cross bar 17. Means are provided for the control displacement of the pivotal end of each arm 16 and 34. This includes a first slide 62 pivotally supporting the pivotal end of the center arm 16 and a second slide 36 pivotally supporting a first pivotal end of the arm 34. The respective slides are moved along selected slide movement paths by stepping or positioning motors 55 and 69 respectively. On a frame 1, a table plate 2 is supported to which a sewing machine 3 is secured. The sewing machine comprises a base plate 4, a post 5, and an arm 6 terminating with a head 7. Within head 7 a needle bar 8 is mounted in a manner known per se, carrying a needle 9. The work to be sewed is clamped in a work holder 10 comprising a plate 11 for frictionally engaging the work, in which an aperture 12 having a shape corresponding to the seam to be produced is provided permitting the needle 9 to pass therethrough. Plate 11 is supported on a supporting plate 13 having a common upper level with base plate 4 of the sewing machine. By means of tommy screws 14, work holder 10 is detachably connected to a swing arm 15 comprising a non-buckling center bar 16 having an I section (FIG. 4), and a cross bar 17 which is braced against center bar 16 by two gussets 18 and has two forked end extensions 19, 20. To each of these extensions, a spring steel strip 21, 22 is secured by its end. By its other end, each of these strips 21, 22 is secured to a clamping mechanism 31. Clamping mechanism 31 comprises a fork head 23, 24 with a threaded neck 25, 26 and an adjusting nut 27, 28. The threaded necks 25, 26 are passed through extensions 29, 30 of center bar 16. Center bar 16 and cross bar 17 are made of a light metal alloy. Since spring steel strips 21, 22 can be made relatively thin, the inertia of the swing arm assembly 15 is low. Center bar 16 is provided with an eye 32 (FIG. 4) in which a hinge bolt 33 is received. By means of bolt 33, the forked end forming two eyes of a swing arm 34 is hinged to center bar 16. Swing arm 34 also has an I section and is made of a light metal alloy. Bolt 33 is secured axially by two lock washers 34 (FIG. 4). The other end of swing arm 34 is hinged to a slide 36. As shown in FIG. 3, this hinge connection comprises a bolt 39 which is secured to slide 36. Two ball bearings 37, 38 held axially by two lock washers 40, 41, two spacers 42, 43, and a plain washer 44. By means of a ball guide 45, slide 36 is displaceable on a slide rod 46 having its ends fixed in two clamps 47, 48 which are secured to table plate. Parallel to slide rod 46, a channel section guide rail 49 is secured to table plate 2 by one its leg portion. The other leg portion designated 50, of guide rail 49 forms two running surfaces for rollers 52, 54 which are carried on threaded bolts 51, 53 secured to slide 36, and are applied against portion 50 from above and below, respectively. To the underside of table plate 2, a stepping motor 55 is secured. The shaft 56 of motor 55 is passed through table plate 2 and carries a cog wheel or gear 57 for a cog belt or gear belt 58. Belt 58 is further trained about a tail wheel 59, with the belt sections between wheels 57 and 59 extending parallel to slide rod 46. Cog belt 48 is firmly connected to slide 36 through a conformable pressure plate 60. The other end of swing arm 15, opposite to hinge bolt 33, is hinged to a bolt 61 which is secured to a slide 62. This hinge connection is identical with that between swing arm 34 and slide 36 through bolt 39. Also identical is the mounting of slide 62 for displacement on a slide rod 63. Further, through two rollers (not shown), slide 62 applies against a guide rail 64 extending parallel to slide rod 63. Through a conformable pressure plate 65, slide 62 is connected to a cog belt 66. The belt is trained about a cog wheel 67 carried on the shaft 68 of a stepping motor 69 which is secured to the underside of table plate 2 and about a tail wheel 70 mounted for rotation on plate 2. Stepping motors 55, 69, slides 36, 62 and swing arms 15, 34 form together with work holder 10 a feed mechanism 71. The sewing assembly operates as follows: The assembly is intended for sewing pockets on trousers for example, and forms a part of a larger operating unit comprising also a doubling station (not shown). At the doubling station, the pocket edges are folded in a manner known per se, and then the pocket is put in place on the trousers. Thereupon, work holder 10 detached from swing arm 15 is placed against the pocket and the trousers in such a position that aperture 12 coincides with the area of the seam. Next, work holder 10, now frictionally engaging the trousers and the pocket, is moved on supporting plate 13 to reestablish its connection with swing arm 15. Since the detachable connection between work holder 10 and swing arm 15 is not included in the subject matter of the present invention, this connection is indicated, for clarity, in a very simplified manner by tommy screws 14 to be actuated manually. After work holder 10 has been connected to swing arm 15, the working cycle of the sewing assembly is started. With the sewing machine 3 initially at standstill, work holder 10 is moved from its rest position shown in FIG. 1 into its sewing position, by a program controlled action of stepping motors 55, 69 executing a corresponding number of drive steps. The control of stepping motors 55, 69 may be effected through a microcomputer (not shown) by which the number of drive pulses necessary for each of the motors is computed from position data recalled from a storage. Stepping motors 55, 69 drive cog belts 58, 66 by which slides 35, 62 are displaced on slide rods 46, 63. The motion of slides 36, 62 is transmitted to the respective swing arms 15, 34, whereby work holder 10 is displaced on supporting plate 13 relative to sewing machine 3 in accordance with the program, until the location at which the seam is to start is vertically aligned with needle 9. Then the sewing machine 3 is started and the desired seam is produced, with the stepping motors 55, 69 being controlled by the program. While being displaced from its rest position to its sewing position, work holder 10 can be moved substantially continuously. During the sewing operation, however, it is moved only when needle 9 is not engaged in the work, so that it moves intermittently. The jerky stepwise movements thus transmitted from swing arm 34 to swing arm 15 act on the latter as bending loads with the maximum bending moment appearing in the area of hinge bolt 33. By correspondingly adjusting the two clamping mechanisms 31, the tension in spring steel strips 21, 22 is adjusted to amounts such that the maximum bending loads introduced by swing arm 34 are entirely taken up by strips 21, 22, and center bar 16 is exposed only to normal forces acting in the longitudinal direction thereof. Therefore, swing arm 15 cannot be elastically bent by the intermittent drive movements of swing arm 34. The non-bending construction of swing arm 15 and the low inertia of the entire feed mechanism, as well as the slip-free drive connections between stepping motors 55, 69 and slides 36, 62 result in a highly accurate transmission of the movements produced by motors 55, 69 to work holder 10. While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
A sewing assembly equipped with a feed mechanism comprises a work holder which is supported by two swing arms hinged to each other, and moved by two stationary positioning motors. Each of the positioning motors is in positive drive connection with a slide carrying one of the swing arms. The swing arm directly carrying the work holder comprises a non-buckling center bar, a cross bar, and two prestressed spring steel strips by which the ends of the cross bar are connected to the end close to the swing axis of the center bar. The two member linkage with the stationary motors and the light-weight and yet non-bending swing arm result in a very low inertia of the feed mechanism.
3
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Divisional Application of U.S. patent application Ser. No. 10/529,568, filed on Mar. 28, 2005 now U.S Pat. No. 7,617,961, which is a National Stage Application of PCT/US03/31653, filed on Oct. 6, 2003 under 35 U.S.C. §371(a), which claims priority from U.S. Provisional Patent Application Ser. No. 60/416,056, filed Oct. 4, 2002, entitled “Tool Assembly for Surgical Stapling Device,” now expired, the entire contents of each being incorporated herein by reference. BACKGROUND 1. Technical Field The present disclosure relates generally to a surgical tool assembly for manipulating and/or applying fasteners to tissue. More specifically, the present disclosure relates to a surgical tool assembly having a pair of jaws including a unique approximation mechanism to facilitate improved clamping and manipulation of tissue. 2. Background of the Related Art Surgical staplers and tool assemblies for clamping tissue between opposed jaw structure of a tool assembly and thereafter fastening the clamped tissue are well known in the art. These devices may include a knife for incising the fastened tissue. Such staplers having laparoscopic or endoscopic configurations are also well known in the art. Examples of endoscopic surgical staplers of this type are described in U.S. Pat. Nos. 6,330,965, 6,250,532, 6,241,139, 6,109,500 and 6,079,606, all of which are incorporated herein by reference in their entirety. Typically, such staplers include a tool member or assembly having a pair of jaws including a staple cartridge for housing a plurality of staples arranged in at least two laterally spaced rows and an anvil which includes a plurality of staple forming pockets for receiving and forming staple legs of the staples as the staples are driven from the cartridge. The anvil and cartridge are pivotally supported adjacent each other and are pivotable in relation to each other between open and closed positions. In use, tissue is positioned between the jaws in the open position and the jaws are pivoted to the closed position to clamp tissue therebetween. One problem associated with conventional staplers and tool assemblies is that as the anvil and cartridge pivot in relation to each other, closure occurs first at the proximal end of the jaws and thereafter at the distal end of the jaws. This sequence of jaw closure has the effect of moving tissue positioned between the jaws towards the distal end of the jaws, thus, forcing tissue from the jaws. During laparoscopic or endoscopic procedures, access to a surgical site is achieved through a small incision or through a narrow cannula inserted through a small entrance wound in a patient. Because of the limited area available to access the surgical site, endoscopic staplers are sometimes used to grasp and/or manipulate tissue. Conventional staplers having an anvil or cartridge mounted to a fixed pivot point which are pivotable to a closed position are not particularly suited for grasping tissue because only a limited clamping force is produced at the distal end of the jaws. Accordingly, a need exists for an endoscopic surgical stapling tool member or assembly having pivotal jaws which can be operated to effectively grasp, manipulate and/or fasten tissue, including with the end of the jaws, without, or while minimizing, distal movement of the tissue positioned between the jaws. SUMMARY In accordance with the present disclosure, a tool assembly having a pair of jaws is disclosed. Each of the jaws has a proximal end and a distal end and the first jaw is movable in relation to the second jaw between a spaced position and an approximated position. First and second cam followers are supported on the first jaw. An approximation member is movable in relation to the first jaw and includes at least one cam surface positioned to engage the first and second cam followers. The approximation member is movable in relation to the first jaw to move the at least one cam surface in relation to the first and second cam followers to effect movement of the first and second jaws from the spaced position to the approximated position. The at least one cam channel is configured to approximate the distal ends of the first and second jaws prior to approximation of the proximal ends of the first and second jaws. By approximating the distal ends of the first and second jaws first, tissue positioned between the jaws is not pushed forward within the jaws during closure of the jaws. Further, the jaws are better able to grip and manipulate tissue using the distal ends of the jaws. Preferably, the first jaw includes an anvil and the second jaw includes a cartridge assembly housing a plurality of staples. In a preferred embodiment, the at least one cam surface includes first and second cam channels, and the approximation member includes a flat plate having the cam channels formed therein. The first jaw includes a longitudinal slot formed in its proximal end and the approximation member is being slidably positioned in the longitudinal slot. The first and second cam followers are supported on the proximal end of the first jaw and extend across the longitudinal slot adjacent the first and second cam channels. The first cam follower extends through the first cam channel and the second cam follower extends through the second cam channel. Preferably, the tool assembly is pivotally attached to a body portion by an articulation joint. The body portion may form the distal end of a surgical stapling device or a proximal portion of a disposable loading unit. In another preferred embodiment, the tool assembly includes an anvil, a cartridge assembly housing a plurality of staples and a dynamic clamping member. The anvil and cartridge assembly are movable in relation to each other between spaced and approximated positions. The dynamic clamping member is movable in relation to the anvil and the cartridge assembly to eject the staples from the cartridge assembly. The tool assembly is pivotally attached to a body portion and is pivotable in relation to the body portion from a position aligned with the longitudinal axis of the body portion to a position oriented at an angle to the longitudinal axis of the body portion. An articulation and firing actuator extends at least partially through the body portion and the tool assembly. The articulation and firing actuator is operably associated with the dynamic clamping member and the tool assembly and is movable in relation thereto to selectively pivot the tool assembly in relation to the body portion and/or move the dynamic clamping member in relation to the tool assembly to eject the staples from the cartridge. Preferably, the articulation and firing actuator includes a flexible band having a first end portion extending at least partially through the body portion and through the cartridge assembly, a central portion extending from the first end portion operably associated with the dynamic clamping member and a second end portion extending from the central portion through the cartridge assembly and at least partially through the body portion to a position adjacent the first end. The articulation and firing actuator is operably associated with the tool assembly such movement of either the first end portion or the second end portion of the flexible band proximally and independently of the other end portion effects pivoting of the tool assembly in relation to the body portion, and movement of both the first and second end portions of the flexible band simultaneously effects movement of the dynamic clamping member to eject the staples from the cartridge assembly. In a preferred embodiment, an approximation member is operably associated with the tool assembly and is movable in relation to the tool assembly to move the anvil and cartridge assembly from the spaced to the approximated position. BRIEF DESCRIPTION OF THE DRAWINGS Various preferred embodiments of the presently disclosed tool assembly for use with a surgical stapling device are disclosed herein with reference to the drawings, wherein: FIG. 1 is a side perspective view of one preferred embodiment of the presently disclosed tool assembly in the approximated position; FIG. 2 is a side view of the tool assembly shown in FIG. 1 ; FIG. 3 is a side, exploded perspective view of the tool assembly shown in FIG. 1 ; FIG. 4A is a schematic view of the jaws of the tool assembly shown in FIG. 1 at a first stage of jaw approximation; FIG. 4B is a schematic view of the jaws shown in FIG. 4A at a second stage of jaw approximation; FIG. 4C is a schematic view of the jaws shown in FIG. 4B in an approximated position; FIG. 5 is a side perspective view of another preferred embodiment of the presently disclosed tool assembly in the approximated position; FIG. 6 is a side, exploded perspective view of the tool assembly shown in FIG. 5 ; FIG. 7 is a side perspective view of the approximation member of the tool assembly shown in FIG. 6 ; FIG. 8 is a side perspective view of the dynamic clamping member of the tool assembly shown in FIG. 6 ; FIG. 9 is a top partial cross-sectional view with portions broken away looking through a portion of the cartridge assembly and showing the articulation and firing actuator of the tool assembly shown in FIG. 6 ; and FIG. 10 is a cross-sectional view with portions removed and portions added, as would be seen along section lines 10 - 10 of FIG. 9 . DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Preferred embodiments of the presently disclosed tool assembly for a stapling device will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. FIGS. 1-3 illustrate one preferred embodiment of the presently disclosed tool assembly shown generally as 10 for use with a surgical stapling device. Tool assembly 10 includes a pair of jaws including an anvil 12 and a cartridge assembly 14 and an approximation member 16 . Cartridge assembly 14 includes a support channel 18 for receiving a staple cartridge 14 a . Support channel 18 includes distal open channel portion 18 a and a proximal portion 18 b defining a truncated cylinder 18 c . Although not shown in detail, staple cartridge 14 a houses a plurality of staples and can include conventional pushers (not shown) for translating movement of a staple drive assembly that typically includes a sled (e.g., 131 in FIG. 6 ) to movement of the staples through openings or slots in a tissue engaging surface 25 of cartridge 14 a. Anvil 12 has a tissue engaging surface 20 having a distal end 20 a and a proximal end 20 b and a proximal body portion 22 . A longitudinal slot 24 extends along the central longitudinal axis of anvil 12 through tissue engaging surface 20 and is dimensioned to slidably receive a portion of a drive assembly. The drive assembly typically includes a drive bar, a closure assembly, a sled, and a plurality of pushers. The drive assembly functions to eject staples from the cartridge and preferably also maintains a desired uniform tissue gap between the cartridge and the anvil during firing of the device. Proximal body portion 22 of anvil 12 is dimensioned to be generally pivotably received within truncated cylinder 18 c of proximal portion 18 b of support channel 18 such that tissue engaging surface 20 of anvil 12 is pivotable from a position spaced from tissue engaging surface 25 of cartridge 14 a to an approximated position in juxtaposed alignment therewith. Tool assembly 10 includes an approximation member 16 having one or more cam channels 28 and 30 . Preferably, approximation member includes a pair of cam channels although a single cam channel having a pair of cam surfaces is envisioned. Approximation member 16 is dimensioned to be linearly slidable through proximal portion 18 b of channel 18 and through a slot 22 a formed in proximal body portion 22 of anvil 12 . A cam follower 32 extends through a bore 34 formed in proximal portion 22 of anvil 12 and through a hole 35 in proximal portion 18 b of support channel 18 and is positioned within cam channel 28 . A cam follower 36 extends through a second bore 38 formed in the proximal portion 22 of anvil 12 and through a hole 39 in proximal portion and is positioned within cam channel 30 . When approximation member 16 is advanced through slot 22 a in proximal portion 22 of anvil 12 , cam followers 32 and 36 move through cam channels 28 and 30 , respectively. Since approximation member 16 is confined to linear movement within slot 22 a , movement of approximation member 16 in a distal direction effects pivotal movement of anvil 12 from the open or spaced position to the closed or approximated position. The angles of the cam slots can be configured to provide a great variety of approximation motions to improve mechanical advantage and achieve specific results, e.g., grasping of tissue. Referring also to FIGS. 4A-4C , cam channels 28 and 30 preferably are configured to pivot anvil 12 from an open position ( FIG. 4A ) towards cartridge assembly 14 in a controlled manner to initially facilitate grasping of tissue and thereafter provide for substantially parallel closure of the anvil and cartridge assembly. More specifically, cam channels 28 and 30 are preferably configured to position the distal end 20 a of tissue contact surface 20 of anvil 12 substantially in contact with cartridge 14 ( FIG. 4B ) during the initial portion of an actuating stroke of approximation member 16 . This facilitates grasping of tissue even very thin tissue. During a second portion of the actuating stroke of approximation member 16 , distal end 20 a of anvil 12 is moved away from cartridge assembly 14 to a resultant position in which tissue engaging surface 20 of anvil 12 is parallel or substantially parallel to tissue engaging surface 25 of cartridge assembly 14 . During the final portion of the actuating stroke of approximation member 16 , the anvil 12 and cartridge assembly 14 are brought together in parallel or substantially parallel closure to define a desired tissue gap ( FIG. 4C ). It is noted that any desired motion of anvil 12 can be achieved using the cam followers described herein. By moving anvil 12 in relation to cartridge assembly 14 from the spaced to the approximated position in the manner described above i.e., front or distal to back or proximal closure, the tendency for tissue to move forward within the jaws, as in conventional devices, is substantially eliminated. Although approximation member 16 is illustrated as being in the form of a plate with two distinct cam channels, differently configured approximation members are envisioned. For example, a single cam channel may be provided to engage two cam followers. Further, the cam channels need not be confined but rather can be formed on the surface of a plate, bar or the like. In such a device, the anvil may be urged by a biasing member to the closed or clamped position. Although one or more actuators has not been disclosed to advance the approximation member and/or fire staples from the cartridge assembly, it is envisioned that one or more of a variety of known pivotable, rotatable, or slidable actuators, e.g., trigger, knob, lever, etc., may be used to approximate the presently disclosed cartridge assembly and/or fire staples from the cartridge. It is also noted that the disclosed tool assembly may be or form the distal portion of a disposable loading unit or may be incorporated directly into the distal end of a surgical instrument, e.g., surgical stapler, and may include a replaceable cartridge assembly. FIGS. 5-10 disclose another preferred embodiment of the presently disclosed tool assembly shown generally as 100 . Tool assembly 100 includes an anvil 112 and a cartridge assembly 114 , an approximation member 116 , and an elongated body portion 120 including an articulation joint generally referred to as 122 . Elongated body portion 120 may form the proximal end of a disposable loading unit or the distal end of a surgical stapling device. Tool assembly 100 also includes a combined articulation and firing actuation mechanism 124 for articulating tool assembly 100 about articulation joint 122 and ejecting staples from cartridge assembly 114 . Although the articulation joint illustrated as a flexible corrugated member with preformed bend areas, articulation joint 122 may include any known type of joint providing articulation, e.g., pivot pin, ball and socket joint, a universal joint etc. Approximation member 116 is substantially similar to approximation member 16 and also includes cam channels 128 and 130 ( FIG. 7 ). Approximation member 116 further includes a pair of guide channels 126 . Guide channels 126 are dimensioned to receive guide pins 128 which extend through elongated body portion 120 and function to maintain approximation member 116 along a linear path of travel. Approximation member 116 is constructed from a flexible material, e.g., spring steel, which is capable of bending around articulation joint 122 . Alternately, it is envisioned that approximation member 116 may include a resilient rod, band or the like with cam surfaces formed thereon. Approximation member 116 operates in substantially the same manner as approximation member 16 and will not be discussed in further detail herein. Cartridge assembly 114 includes a support channel 118 , a sled 131 and a dynamic clamping member 132 which, preferably, includes an upper flange 134 a for slidably engaging a bearing surface of the anvil and lower flange 134 b for slidably engaging a bearing surface of the cartridge. A knife blade 134 is preferably supported on a central portion 134 c of dynamic clamping member 132 to incise tissue. Knife blade may be secured to dynamic clamping member 132 in a removable or fixed fashion, formed integrally with, or ground directly into dynamic clamping member 132 . Sled 131 is slidably positioned to translate through cartridge 114 in a known manner to eject staples from the cartridge. Sled 131 or the like can be integral or monolithic with dynamic clamping member 132 . Sled 131 is positioned distal of and is engaged and pushed by dynamic clamping member 132 . The position of 131 is to effect firing or ejection of the staples to fasten tissue prior to cutting the stapled tissue. Flange 134 b preferably is positioned within a recess 138 formed in the base of cartridge 114 . Flange 134 a is preferably positioned within a single or separate recess formed in anvil 112 . Again, flanges 134 a and 134 b need not be positioned in a recess but can slidably engage a respective surface of the anvil and cartridge. Dynamic clamping member 132 preferably is positioned proximal of sled 130 within cartridge assembly 114 . Dynamic clamping member 132 functions to provide, restore and/or maintain the desired tissue gap in the area of tool assembly 100 adjacent sled 130 during firing of staples. It is preferred that the anvil and preferably the dynamic clamping member be formed of a material and be of such a thickness to minimize deflection of the anvil and dynamic clamping member during firing of the device. Such materials include surgical grade stainless steel. The anvil is preferably formed as a solid unit. Alternatively, the anvil may be formed of an assembly of parts with conventional components. Referring to FIGS. 6 , 9 and 10 , articulation and firing mechanism 124 includes a tension member 140 which can have loops 124 or other connection portions or connectors for connection to suitable connection members of one or more actuators or of an actuation mechanism. Although illustrated as a flexible band, tension member 140 may be or include one or more of any flexible drive member having the requisite strength requirements and being capable of performing the functions described below, e.g., a braided or woven strap or cable, a polymeric material, a para-aramid such as Kevlar™, etc. Kevlar™ is a trade designation of poly-phenyleneterephthalamide commercially available from DuPont. A pair of suitable fixed or rotatable members, preferably rollers 142 a and 142 b , are secured at the distal end of cartridge assembly 114 . Rollers 142 a and 142 b may be formed or supported in a removable cap 114 b ( FIG. 6 ) of cartridge assembly 114 . Alternately, cap 114 b may be formed integrally with staple cartridge 114 a or cartridge channel 118 . Rollers 142 a and 142 b can also be secured to or formed from cartridge support channel 118 . Tension member 140 extends distally from elongated body 120 of tool assembly 100 , distally through a peripheral channel 142 in staple cartridge 114 a , around roller 142 a , proximally, preferably, alongside central longitudinal slot 144 formed in cartridge 114 a , through a slot 200 , preferably a transverse slot, in or around a proximal portion of dynamic clamping member 132 , distally around roller 142 b , and again proximally through a channel 146 formed in cartridge 114 a to a proximal portion of elongated body 120 . Alternately, two tension members can be employed, each of which may be secured to dynamic clamping member 132 . As illustrated in FIG. 10 , channels 142 and 146 can be at least partly defined by an inner and/or outer wall of cartridge 114 a and/or by cartridge support channel 118 . Unlike as shown, channels 142 and 146 should be in a consistent, i.e., same, functionally same or corresponding location on both sides of the staple cartridge. Thus, it is envisioned that there would be two peripheral channels 142 , or two channels 146 . In use, when a first end or portion 150 of tension member 140 is retracted by suitable means in the direction indicated by arrow “A”, as viewed in FIG. 9 , tool assembly 100 will articulate about pivot member 122 a in the direction indicated by arrow “D”. When second end or portion 152 of tension member 140 is retracted in the direction indicated by arrow “B”, tool assembly 100 will articulate in the direction indicated by arrow “C”. When both ends of tension member 140 are retracted simultaneously, tension member 140 will advance dynamic clamping member 132 distally through slot 144 in cartridge 114 a to advance dynamic clamping member 132 and sled 130 through cartridge 114 a and by engaging pushers, eject staples from the cartridge and incise tissue in the tissue gap. In order to prevent dynamic clamping member 132 from advancing through slot 144 when the tool assembly is being articulated, i.e., when only one end of tension member 140 is retracted, a lockout device (not shown), e.g., a shear pin, may be provided to prevent movement of the dynamic clamping member or delay it until a predetermined force has been applied to the dynamic clamping member. It is envisioned that multiple tension members, e.g., bands, can be employed, respectively, to perform individual or a combination of functions. For example, a pair of tension members can be employed, one to articulate, and the other to approximate, clamp and fire. The tension members can be fixed to the dynamic clamping member or a knife carrying member or to a combination dynamic clamping member, knife member and/or sled member. The above-described tool assembly may be incorporated into a disposable loading unit such as disclosed in U.S. Pat. No. 6,330,965 or attached directly to the distal end of any known surgical stapling device. Although a handle assembly for actuating the approximation member and the combined articulation and firing mechanism have not been specifically disclosed herein, it is to be understood that the use of a broad variety of different actuating mechanisms and handle configurations are envisioned including toggles, rotatable and slidable knobs, pivotable levers or triggers, pistol grips, in-line handles, remotely operated systems and any combination thereof. The use of an above-described tool assembly as part of a robotic system is envisioned. It will be understood that various modifications may be made to the embodiments disclosed herein. For example, although this application focuses primarily on the use of surgical staples, other fastening devices, such as two-part fasteners, may be included in this device. In a device in which two-part fasteners are used, each of the anvil staple forming pockets may be configured to receive one part of the two-part fastener. Further, it is envisioned that the teachings provided in this disclosure may be incorporated into surgical devices other than stapling devices including graspers. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
The present disclosure describes a surgical device with a body portion defining a longitudinal axis, a tool assembly including an anvil, a cartridge assembly housing a plurality of staples, a dynamic clamping member movable relative to the tool assembly to eject the staples, and an articulation and firing actuator extending at least partially through the body portion and the tool assembly. The tool assembly is pivotally attached to the body portion for movement from a position aligned with the longitudinal axis to a position oriented at an angle thereto. The articulation and firing actuator extends at least partially through the body portion and the tool assembly, is operably associated with the dynamic clamping member and the tool assembly, and is movable in relation thereto to selectively pivot the tool assembly relative to the body portion and move the dynamic clamping member relative to the tool assembly to eject the staples.
0
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is the formal patent application for provisional application Ser. No. 61/201,444, filed Dec. 10, 2008, entitled “Ultra-short Slip and Packing Element System”. Applicant hereby claims priority from said application. BACKGROUND OF THE INVENTION [0002] 1. Field of the invention [0003] This invention relates to downhole tools for oil and gas wells and similar applications and more particularly to improved well packers, plugs, and the like. [0004] 2. Description of Prior Art [0005] Well packers are used to form an annular barrier between well tubing or casing, to create fluid barriers, or plugs, within tubing or casing, or the control or direct fluid within tubing or casing. Packers may be used to protect tubulars from well pressures, protect tubulars from corrosive fluids or gases, provide zonal isolation, or direct acid and frac slurries into formations. [0006] Typical well packers, bridge plugs, and the like, consist of a packer body. Radially mounted on the packer body is a locking or release mechanism, a packing element system, and a slip system. These packers tend to be two feet or longer depending on the packer design. The packing system is typically an elastomeric packing element with various types of backup devices. The packing system is typically expanded outward to contact the I.D. (internal diameter) of the casing by a longitudinal compression force generated by a setting tool or hydraulic piston. This force expands the elastomer and backups to create a seal between the packer body and casing I.D. This same longitudinal force acts through the sealing system and acts on the slip system. The slip system is typically an upper and lower cone that slides under slip segments and expands the slip segments outwardly until teeth on the O.D. (outer diameter) of a series of slip segments engage the I.D. of the casing. Teeth or buttons on the O.D. of the slip segments penetrate the I.D. of the casing, to secure the packer in the casing, so the packer will not move up or down as pressure above or below the packer is applied. A locking system typically secures the seal and slip systems in there outward engaged position in order to maintain compression force in the elastomer and, in turn, compression force on the slip system. Certain part configurations allow the locking mechanism to disengage to allow retrieval of the packer. The presence of the release mechanism usually classifies the packer as a “retrievable packer” and the absence of the release mechanism classifies the packer as a “permanent packer”. [0007] Problems with prior art packers, in some cases, can be the excessive length of the packers since all of the above combined systems require length. An increased length of the tool results in an increased effort to mill or drill out the tool if and when necessary, particularly at the end of the useful life of the tool. It would advantageous to have a packer that is much shorter in that reduced material would certainly lower material and manufacturing costs. It would be advantageous to have a very short packer, so if packer removal is required, milling time would be greatly reduced. [0008] Some of the drillable frac plugs on the market are the Halliburton “Obsidian Frac Plug”, the Smith Services “D2 Bridge Plug”, the Owen Type “A” Frac Plug, the Weatherford “FracGuard”, and the BJ Services “Phython”. By comparison, all of these plug designs are very long in comparison to the current invention. Also, a very short packer would reduce cost and simplify the task of creating a “Pass-through” packer. “Pass- through” packers are used for intelligent well completions and allow the passage of, for example and not limited to, hydraulic control lines, fiber optic lines, and electrical lines. [0009] Both retrievable and permanent packers are sometimes drilled or milled out of the casing. If the packer is being used as a “Frac Plug”, it is commonly milled out after the frac is completed. Typical packers, as described above, tend to have mill-out problems because the packer parts tend to spin within the engaged slips. The mill operation becomes very inefficient because the packer parts spin with the rotation of the milling tool. Some packer designs exist, for example the BJ Services U.S. Pat. No. 6,708,770, to reduce this spinning tendency. It would be advantageous to have a packer design that would offer alternative features to prevent spinning of parts while milling out. It would also be advantageous if this same design feature would provide a means to equally distribute the slip segments around the packer body to evenly distribute the load on the I.D. of the casing, and also function as packer retrieval devices to retain and retract the slip segments during retrieving. [0010] Another problem is that the slip system is loaded through the packing element system. Any degradation or extrusion of the packing element system reduces stored energy in the slip system thus allowing the slip system to disengage, especially during pressure reversals, the casing and in turn cause packer slippage and seal failure. [0011] Typical packers have a seal system that has elastomers backed up by anti-extrusion devices and the anti-extrusion devices are backed up by gage rings. The gage rings typically have a built-in extrusion gap between the O.D. of the gage ring and the I.D. of the casing to provide running clearance for the packer. The built-in extrusion gap can be a problem and is commonly the primary mode of seal system failure at higher temperatures and pressures. This is because the elastomers and backup devices tend to move into the extrusion gaps. When this movement occurs, the stored energy is lost in the seal system and the seal engagement is jeopardized to the point of seal failure. It would be an advantage to remove the majority of the extrusion gap to prevent the seal from extruding or moving. Attempts have been made to reduce the extrusion gap by use of expandable metal packers, for example, the Baker expandable packer patent numbers U.S. Pat. No. 7,134,504 B2, US 2005/0217869, and U.S. Pat. No. 6,959,759 B2, or the Weatherford Lamb metal sealing element patent #US 2005/023100 A1. [0012] Typical retrievable packers have slip systems that, when expanded, contact the I.D. of the casing at 45 degree or 60 degree increments around the I.D. of the casing. Each slip segment has a width and there is typically a space between each slip segment. The space between each slip segment creates a surface area where no slip tooth engagement occurs. The total slip contact with the I.D. of the casing may, for example, only be 50% of the surface area on the inside of the casing. If pressure is applied across the packer, the slips are driven outward into the casing. It is a problem in that due to the incremental contact on the I.D. of the casing, high non-uniform stresses in the casing wall can cause deformation or even failure of the casing wall. It would be very desirable to have a slip system that approaches a full 360 degree contact in the I.D. of the casing to minimize damage to the casing. Also, with slip engagement approaching 360 degrees, there is more slip tooth engagement due to increased radial surface contact area, thereby providing the opportunity to reduce length of the slip. Reduced length of the slip then reduces the overall length of the packer. [0013] Typical permanent packers have slip systems that “break”. Slips that “break” approach the 360 degrees of contact. These slips are usually made by manufacturing a ring, cutting slots in the ring to create break points, and then treating the teeth on the O.D. of the ring for hardness purposes. When longitudinal load is applied to a cone, the cone moves under the slip ring and the ring tends to break at the slots to create slip segments. History has shown that the slip segments, break unevenly or don't break at all, break at different forces, and engage the I.D. of the casing in irregular patterns. These breaking problems can reduce the performance and reliability of the packer. It would be advantageous to have slips that approach the 360 degrees of contact and are not required to break, don't require a variable force to break, and evenly distribute themselves around the I.D. of the casing. [0014] Some packers have built-in “boosting” systems. Boosting systems exert additional force on packer seal systems when differential pressure is applied from either above or below, or both, relative to the packer. The additional boosting force tends to help the packer maintain a seal with the I.D. of the casing. The boosting systems typically added to packers require additional parts that add complexity to the packer and require the use of additional seals. Additional seals increase the risk of packer leaks if the seal should fail. [0015] It would be advantageous to have a packer slip/seal design that inherently provides a seal and slip boosting feature, without additional seals and parts, when pressure is applied from either above or below the packer and in which design the slips and seals are arranged in a manner to provide sufficient well sealing and anchoring with component parts which are considerably shorter than those found in conventional packers and similar well plugs. SUMMARY OF THE INVENTION [0016] A tool is provided for sealing along a section of a wall of a subterranean well. The wall may be uncased hole or the internal diameter wall of set casing inside the well. The tool is carriable into said well on a conduit. The conduit may be any one of a number of conventional and well known devices, such as tubing, coiled tubing, wire line, electric line, and the like, and moveable from a run-in position to a set position by a setting tool manipulatable on or by said conduit. The tool comprises a plurality of anchoring elements, sometimes referred to as slips with a set of profiled angularly positioned teeth around the exterior for biting engagement into the wall of the well upon setting of the tool. The tool is shiftable from a first retracted position when the well tool is in a run-in position to a second expanded position after manipulation of the setting tool. The tool also includes seal means, preferably made of an elastomeric material, but may be metallic, or a combination thereof, which are carried around the anchoring elements for sealing engagement along the wall of the well in concert and substantially concurrently with the anchoring elements when the anchoring elements are shifted to the set position. [0017] Stated somewhat differently, the tool of the present invention provides a packer device including an interior packer body and radially surrounding cone, slip and seal system that seals and engages the surrounding casing or other tubular member. The cones expand both the seal system and the slip system simultaneously. The slip system provides a means for supporting the seal system when pressure is applied from above or below the packer. The close proximity of the seal and slip system provides for a very short packer or a “minimum material packer” that offers lower cost, higher performance, and if required, faster mill-out. [0018] The seal system can be of several configurations and one such configuration is an expandable metal seal combined with an optional elastomeric or non-elastomeric seal for high temperature and pressure applications. [0019] This invention also provides an improved packer for cased or uncased wells or for a tubular member positioned inside of casing. A very short and simple packer design, with features that increase overall packer reliability, is created by effectively combining synergies of the cone, slip and seal elements to work in unison. [0020] This packer can be set on standard or electric wireline, or with hydraulic setting tools conveyed on jointed pipe or coiled tubing. The packer can be ready modified to serve several applications. A hydraulic setting cylinder can be added so the packer can be run as part of the casing or tubing. The packer can utilize a fixed frangible disc or a flapper device to serve as a bridge plug, frac plug, or frac disc-type of component. [0021] The materials of the packer can be optimized to reduce mill-out time. Mill-out time is greatly reduced due to the very short length of the packer, typically, 3″ to 4″, so expensive composite materials aren't necessarily required, 3) a seal bore can easily be attached to the packer body. Since the slip system creates a metal-to-metal interface with the I.D. of the casing, the packer can readily be adapted to a high pressure and temperature well environment.. The packer can address applications as simple as low cost plug and abandonment to highly complex applications in hostile environment wells. Finally, the packer, due to it's short length, is ideal for incorporating “control line pass-thru” for intelligent well completions. BRIEF DESCRIPTION OF THE DRAWINGS [0022] FIG. 1 is a schematic view of the present invention in the “running position”. [0023] FIG. 2 is a schematic view of the present invention in the “set position”. [0024] FIG. 3 is a cross-sectional view of the packer mandrel and slip segments of the present invention in the fully expanded “set position”. [0025] FIG. 4 is a close-up quarter-section view of the packer mandrel lugs inside of a slip segment pocket in the “running position”. [0026] FIG. 5 is a schematic of the present invention with a “flapper valve” attached. [0027] FIG. 6 is a schematic of the present invention with a “seal bore” attached. [0028] FIG. 7 shows two examples of the present invention in the “set position” inside of a section of casing with a workstring placing fluid into the formation above a set packer. [0029] FIG. 8 shows a schematic of the present invention with a control line pass-thru added. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0030] With reference to FIG. 1 , a schematic of the present invention shows a 180 degree cross-section of the packer. A mandrel 1 has a running thread 16 with a separation recess 17 immediately below the running thread. Seal 11 is located on the O.D. of the mandrel 1 . At the bottom of the mandrel are an internal thread 18 and a seal 13 . A setting tool (not shown) is made up to running thread 16 in order to convey the packer into the well. A millable, frangible or disintegrable disc 14 is a fluid barrier and is threaded into thread 18 and seals on seal 13 . Cone surface 3 is shown of the O.D. of the mandrel 1 . [0031] Lower seals 7 and 8 are shown to be positioned on cone surface 3 . Seal portion 7 is a deformable material but has sufficient rigidity to bridge the gap between slip segments 4 . Seal portion 8 is a deformable seal material that is fixably attached to seal portion 7 so that it can be reliably transported into the well. Rotational lock pin 12 is either attached to, or part of, mandrel 1 . The number of rotational pins is equal to the number of gaps between slip segments 4 . The rotational pins assist in positioning the slip segments equally around the mandrel and a modified version can act as a pickup shoulder if used in a retrievable packer configuration. The slip segments 4 are positioned almost 360 degrees around the O.D. of the mandrel 1 . Each slip segment has a series of teeth 19 , or some other casing penetrating profile, on the O.D. of the slip segment. The teeth are sufficiently hard to penetrate the inside of the casing wall in order to grip the wall and prevent the packer from moving relative to the casing. The slip segments have an O.D. that is machined to be almost equal to the I.D. of the casing. The slip segments are machined to minimize any gaps between the O.D. of the slip segments and the I.D. of the casing. Similarly, the angles on the I.D. of the slip segments are machined to almost match the O.D. of the cone surfaces 2 and 3 when the slip is fully expanded, in order to minimize gaps between the parts. [0032] Seal 11 does not seal in the “running position” but in the “set position” seals on the I.D. of upper cone 15 . Upper seals 5 and 6 are the same as seals 7 and 8 . These seals, of course, can assume different geometries and materials based on the application of the packer. Upper and lower seals, 5 , 6 , 7 , 8 , are of sufficient strength to capture and retain slip segments 4 inward during the trip into the well. [0033] Upper cone 2 has a surface 15 . The setting tool (not shown) pushes against surface 15 while pulling on threads 16 during the setting operation. Upper cone 2 has internal thread that engage body lock ring 9 . Body lock ring 9 can ratchet freely toward the slip segments 4 but engages and prevents movement away from the slip segments 4 by engaging the threads on the top O.D. of the mandrel 2 . [0034] FIG. 2 shows the packer in the “set position”. In operation, the setting tool (not shown) pushes on surface 15 and pulls on thread 16 . Upper cone 2 moves toward the slip segments 4 and in the process expands the slip segments 4 and the deformable seals 5 , 6 , 7 , and 8 . Expansion continues until sufficient contact is made with the I.D. of the casing to achieve slip tooth 19 penetration in the inner wall of the casing. At this point the teeth of the slip segments have nearly closed any seal extrusion gaps between the O.D. of the slip segments and the I.D. of the casing. Extrusion gaps have been minimized nearly 360 degrees around the packer. Additionally, slip load has been nearly evenly distributed around the I.D. of the casing to minimize distortion of the casing. Slip segment 4 distribution around the O.D. of the mandrel 1 is more uniform due to the pins 12 . Also, extrusion gaps have been closed where the I.D. of the slip segments contact the surfaces of the cones at 20 and 21 . At his point the only extrusion gaps that exist are the ones between the slip segments. This can be seen in FIG. 3 identified as 31 . These extrusion gaps are blocked with the seal portions 5 and 6 that additionally minimize extrusion of seal portions 6 and 8 . The seals portions are expanded with the cones until surface 23 makes sufficient sealing contact with the I.D. of the casing. At this point the upper and lower cones have simultaneously engaged the slips and expanded the seals. Sufficient force is placed on the slips and cones to achieve tooth penetration and store seal compression. As a result, loss of seal compression does not create loss of slip tooth engagement and vise-versa. Furthermore, in the set position, all extrusion gaps have been closed to a minimum. [0035] As the setting tool continues to stroke, body lock ring 9 ratchets on mandrel 1 until the slip segments and seals are fully energized. Lock ring 9 will not allow reverse movement to occur; therefore the packer is locked in the “set position”. In the FIG. 2 packer configuration, the setting tool continues to add force to the packer until a pre-planned tensile load is reached. This load is sufficient to shear the mandrel 1 at recess 17 so that ring 25 separates from mandrel 1 . Removal of ring 25 leaves a minimum amount of material to aid any milling operations that may be planned. Other methods of separation from the mandrel 1 are available depending on the application of the packer. [0036] In the set position, FIG. 2 , when pressure is applied from below the packer, the cone surface 3 acts on the seal 7 and 8 and the slip segment 4 to further energize tooth engagement and the seals. Pressure from below acts on seals 7 and 8 to achieve a better seal. Conversely, pressure from above acts on seals 5 and 6 and cone surface 2 to achieve a better tooth engagement and seal pack-off. [0037] FIG. 3 shows a cross-sectional view of the mandrel 1 and the slip segments 4 . Notice that lugs are protruding from the mandrel as indicated by the arrow labeled 1 and surface 28 . The lugs also have ears 29 that fit into the pockets 30 . The pockets 30 are shaped to allow the slip segments to move from the “run position” to the “set position” and back again. When the ears 29 touch surface 33 , the slip segments are trapped and can not expand further. This is a modification of the rotational lock pins 12 that are positioned between the slip segments. In this case some length, maybe 2 inches maximum, needs to be added to the slip segments. This configuration would apply more to a retrievable type packer where it is desired to retain the slips during retrieval. Referencing FIG. 4 , the mandrel lugs 1 are shown in a cross-sectional longitudinal view. During packer retrieval, lug surface 28 contacts slip segment surface 32 and pulls slip segment 4 off cone surface 3 . Of course, upper cone surface 2 is configured to move upward, when connected to a retrieving tool, from cone surface 3 to allow retraction of slip segment 4 . Simultaneously, the inner surface of ear 29 of the lug 28 , engages a lip 44 on the inside of the slip segment to retain the slip segment. [0038] FIG. 5 shows a cross-section of the packer with the frangible disc removed from the bottom. Instead, a flapper valve 34 has been added to the top end of the packer. The flapper is hinged with pin 35 and seal on mandrel 45 at seal 36 . This configuration would allow treatment of the well above the packer and flow of the well from below at a later time without removing any flow barriers. [0039] FIG. 6 shows the packer modified to be a seal bore packer. Seal bore 38 has been added to create a production packer that would allow installation of a production string (not shown). Seals (not shown) on the end of the production string are placed in the seal bore to direct fluid up the production string. [0040] FIG. 7 shows well casing 39 in a formation 43 . The well casing 39 has two sets of perforations 41 and two packers 40 positioned between the perforations. A work string 42 places fluid, acid or proppant, into the formation. The packer 40 forces the fluid into the formation. Every time a zone is treated, a packer can be set, the formation treated, and then go to another zone up the hole if desired. When all zones are treated, the packers can be milled out prior to production. If milling is not desired, the frangible disc or flapper packer configuration can be used. [0041] FIG. 8 shows the packer modified to serve as a “pass-thru” packer. The compact geometry of the slip and seal system reduces the length required to create a control line bypass through the body of the packer. This short distance can eliminate the expensive gun drill process that is usually needed to drill long holes through long packer bodies. FIG. 8 shows the same slip, seal and cone parts as in FIG. 1 . Drilled hole 46 provides a path for the control line, or fiber optic or electrical line to pass through the packer body. Fitting 47 acts as a fluid barrier between the hole 46 and the control line 47 . Thread 48 would be a typical connection on the packer to allow connection with the completion string (not shown). The top end of the packer is not shown for this example, but the top end of the packer would have some type of setting mechanism to stroke the packer to the set position. [0042] Although the invention has been described above in terms of presently preferred embodiments, those skilled in the art of design and operation of subterranean well packers and the like will readily appreciate modifications can be made without departing from the spirit of the description and the appended claims, below. Accordingly, such modifications can be considered to be included within the scope of the invention disclosure and the claims.
A subterranean well tool is provided for sealing along a section of a wall of the well and is carried on a conduit into the well. The tool is designed to be comparatively short in length to afford easier mill or drill out subsequent to the tool's useful need in the well. A plurality of anchoring elements and seal means are provided for respective anchoring and sealing engagement along the wall of the well in concert and substantially concurrently with one another when the tool is shifted to the set position. The anchoring means are sandwiched in between first and second, or upper and lower, sets of seal means.
4
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an original reader apparatus which reads an original image while the original passes over a reading position, and stores image data corresponding to this reading in storing means. 2. Description of the Related Art Sorting in known photocopiers has been performed by causing the original document to be passed through repeated cycling for photocopying onto output paper, which has been a cause of damage to the original document. In order to deal with such a situation, an electronic sorter has been proposed. Such an electronic sorter uses memory which accumulates image data. Such memory has used either a low-speed large-capacity hard disk or a high-speed low-capacity semiconductor memory, wherein limitations in accumulation speed or accumulation capacity caused long periods of waiting for the image to be input, or input thereof being disabled for long periods of time. Also, various types of job scheduling have been proposed, wherein users bringing original documents to the digital photocopier proper would be given priority. However, in accordance with the present large-capacity photocopying area and large-volume outputting from PCs, spontaneous response and improvement in processing speed is being required. This improvement in spontaneous response and improvement in processing speed is being dealt with by means of using large-capacity semiconductor memory. However, there are limitations to the accumulation capacity of such large-capacity semiconductor memory, and control of the equipment at this accumulation capacity limit has been problematic. Also, in the event that such an accumulation capacity limitation occurs, continuous reading of original documents becomes impossible, so there is the necessity to have intervals between reading of the original documents. However, leaving the original exposure lamp on not only wastes electricity, but with original reading apparatuses arranged such that the original documents are fed and read at high speeds, the temperature in the immediate vicinity of the lamp fixed for passing documents over and reading suddenly rises, and this has been problematic from the point of overheating prevention, as well. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide an original reader apparatus which solves the above problems. It is another object of the present invention to provide an original reader apparatus which prevents overheating at the reading position. Further objects and characteristics of the present invention will become apparent from the following specification and drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view illustrating a schematic construction of an image processing apparatus according to a first embodiment of the present invention; FIG. 2 is a longitudinal cross-sectional view illustrating the construction of an automatic document feeder device for the image processing apparatus; FIG. 3A-3F constitute an explanatory diagram of the document feeding operation of the automatic document feeder device; FIG. 4, consisting of FIGS. 4A and 4B, is a block diagram showing the inner construction of the image processing apparatus of FIG. 1; FIGS. 5A and 5B constitutes a diagram illustrating an example of the image processing of the image processing apparatus illustrated in FIG. 1; FIGS. 6A and 6B constitutes a diagram illustrating another example of the image processing of the image processing apparatus illustrated in FIG. 1; FIGS. 7A and 7B constitutes a diagram illustrating yet another example of the image processing of the image processing apparatus illustrated in FIG. 1, different from the examples illustrated in FIGS. 5A and 5B and FIGS. 6A and 6B; FIG. 8 is a block diagram illustrating the construction of the print buffer memory (PBM) of the image processing apparatus illustrated in FIG. 1; FIGS. 9A and 9B constitutes a diagram illustrating the job operation of the print buffer memory; FIG. 10 is a state transition diagram (STD) of the image processing apparatus illustrated in FIG. 1; FIG. 11 is a flowchart illustrating the operation control steps in the normal operation mode of the image processing apparatus illustrated in FIG. 1; FIG. 12 is a flowchart illustrating the operation control steps in the Almost Full mode of the image processing apparatus illustrated in FIG. 1; FIG. 13 is a flowchart illustrating the operation control steps in the PBM Full mode of the image processing apparatus illustrated in FIG. 1; FIG. 14 is a time-chart illustrating the image input-output timing corresponding to page memory in the normal operation mode of the image processing apparatus illustrated in FIG. 1; FIG. 15 is a time-chart illustrating the image input-output timing corresponding to page memory at time of transition from normal operation mode to Almost Full mode of the image processing apparatus illustrated in FIG. 1; FIG. 16 is a time-chart illustrating the image input-output timing corresponding to page memory at time of transition between Almost Full mode and PBM Full mode of the image processing apparatus illustrated in FIG. 1; FIG. 17 is a time-chart illustrating the image input-output timing corresponding to page memory at time of recovery from Almost Full mode of the image processing apparatus illustrated in FIG. 1; FIG. 18 is a time-chart illustrating the image input-output timing corresponding to page memory at time of recovery from Almost Full mode of the image processing apparatus illustrated in FIG. 1; FIG. 19 is a schematic diagram illustrating the page memory in a case wherein image 1 occupies the page memory of the image processing apparatus illustrated in FIG. 1; FIG. 20 is a schematic diagram illustrating the page memory in a case wherein output of the image 1 from the page memory of the image processing apparatus illustrated in FIG. 1 begins; FIG. 21 is a schematic diagram illustrating the page memory in a case wherein image 1 and image 2 co-occupy the page memory of the image processing apparatus illustrated in FIG. 1; FIG. 22 is a schematic diagram illustrating the page memory in a case wherein image n-1 and image n co-occupy the page memory of the image processing apparatus illustrated in FIG. 1; FIG. 23 is a schematic diagram illustrating the operating portion of the image processing apparatus illustrated in FIG. 1; FIG. 24 is a schematic diagram illustrating the operating screen of the operating portion of the image processing apparatus illustrated in FIG. 1; FIG. 25 is a schematic diagram illustrating the operating screen of the operating portion of the image processing apparatus illustrated in FIG. 1; FIG. 26 is a schematic diagram illustrating the operating screen of the operating portion of the image processing apparatus illustrated in FIG. 1; FIG. 27 is a diagram illustrating an example of the display of the operating screen of the operating portion of the image processing apparatus illustrated in FIG. 1, when in the Almost Full mode; FIG. 28 is a diagram illustrating an example of the display of the operating screen of the operating portion of the image processing apparatus illustrated in FIG. 1, when in the PBM Full mode; FIG. 29 is a diagram illustrating the construction of the original document irradiation lamp control portion of the image processing apparatus illustrated in FIG. 1; FIG. 30 is a diagram illustrating the relation between the PBM 15 of the image processing apparatus illustrated in FIG. 1 and the first and second threshold values which determine the state thereof; FIG. 31 is a diagram for describing the original document irradiation lamp control system of the image processing apparatus illustrated in FIG. 1; FIG. 32 is a flowchart illustrating the operation control steps of the lighting and extinguishing sequence of the original document irradiation lamp of the image processing apparatus illustrated in FIG. 1; FIG. 33 is a flowchart illustrating the operation control steps of the lighting and extinguishing sequence of the original document irradiation lamp of the image processing apparatus illustrated in FIG. 1; and FIG. 34 is a flowchart illustrating the operation control steps of the lighting and extinguishing sequence of the original document irradiation lamp of the image processing apparatus illustrated in FIG. 1. DESCRIPTION OF THE PREFERRED EMBODIMENT This embodiment of the present invention is now explained with reference to the drawings. FIG. 1 shows a side view of a construction of an image processing apparatus (copying machine) of the present embodiment. In FIG. 1, numeral 51 denotes an image recording unit (hereinafter referred to as a printer unit), numeral 52 denotes an image read unit (hereinafter referred to as a reader unit), numeral 53 denotes a control unit (hereinafter referred to as an operator control unit (OCU)) and numeral 54 denotes a finishing unit. The reader unit 52 comprises an automatic document sheet feeder unit (hereinafter referred to as an ADF) 200 for automatically feeding the document sheet to a read position and a scanner unit 250 for optically reading the document sheet image. A specific operation of the reader unit 52 will be explained with reference to FIG. 2. The printer unit 51 visualizes the image read by the reader unit 52 or the image sent from a computer terminal or an external equipment (not shown) such as a facsimile machine to print on a record sheet such as a transfer sheet. The printer unit 51 is provided with a large capacity print buffer memory (hereinafter referred to as a PBM) 65 as shown in FIG. 8 to store the image inputted from the ADF 200 or the external equipment and conduct the sorting process such as the rearrangement of pages after the storing. A specific operation of the printer unit 51 will also be described later. The OCU 53 comprises a display and a keyboard (or a touch panel type display) to enter various settings by a user such as number of sheets setting, number of sets setting, edition of image and processing of image and display information representing the selected mode and status of the apparatus. The finishing unit 54 post-processes the output sheet obtained by having recorded on the record medium in the printer unit 51 and conducts the sorting, stapling or bookbinding. A basic operation in the image processing apparatus of the configuration shown in FIG. 1 is now explained. When the user sets a plurality of document sheets on the ADF 200 of the reader unit 5, sets the mode of the OCU 53 and designates the start of copying, the ADF 200 feeds the document sheets one by one and the images thereof are read by the scanner unit 250. The scanner unit 250 photo-electrically converts the reflected light 110 from the exposed document sheet by a CCD line sensor 111 (see FIG. 2) to read it as an electrical signal. The read image signal is processed in various manners by an image processing unit 61 to be described later and it is compressed and transferred to the PBM 65 of the printer unit 51. The printer unit 51 sequentially reads the images from the PBM 65 in accordance with the user setting from the OCU 53 and the read image is converted to an optical signal for the exposure of the photo-conductor. Then, the conventional electro-photographic processes. that is, charging, exposing, Latent image forming, developing, transferring, separation and fixing are conducted and the image is recorded on the record medium. The basic operation in the image processing apparatus of FIG. 1 has thus been described. Referring now to FIG. 2, a basic operation of the ADF 200 is explained. FIG. 2 shows a longitudinal sectional view of a construction of the ADF 200 and the scanner unit 250 described above. In FIG. 2, numeral 201 denotes a document sheet tray for stacking document sheets, numeral 202 denotes a first mirror for directing a reflected light from the document sheet to the CCD 111, numeral 203 denotes a moving read document sheet read position, numeral 204 denotes a book mode scan read position, numeral 205 denotes a sheet feed unit, numeral 206 denotes a feed path to the moving read document sheet read position 203, numeral 207 denotes a feed path to eject a one-side document sheet read at the moving read document sheet read position 203, numeral 208 denotes a feed path to feed a rear side of the document sheet read in the moving read document sheet read position 203 to the moving read document sheet read position 203 and numeral 209 denotes a feed path to eject the document sheet after the rear side thereof is read in the moving read document sheet read position 203. The moving read document sheet reading is the system in which the document sheet fed from the document sheet tray 201 is moved past the moving read document sheet read position 203 while the mirror 202 is fixed at the moving read document sheet read position 203 to scan the image. The document sheet is fed along the arrow marked on the feed path. When the rear side of the document sheet is read, it is read as a mirror image to the image read from the front side of the document sheet. A process to correct the mirror image to a real image will be described in connection with an image processing unit 61. In the drawing, the solid line arrow indicates the feed direction of the moving read of the one-side document sheet and the broken line arrow indicates the feed direction of the moving read of the dual-side document sheet. Contrarily to the moving read document sheet read system, the book mode scan is the system in which the scan is made while the optical system such as the mirror 202 and a lamp 213 is moved without moving the document sheet mounted on the book mode scan read position 204. In any system, the read unit is moved relative to the document sheet to scan the document sheet. The reflected light by the exposure to the document sheet passes through a lens 210 and is projected to the CCD line sensor (hereinafter referred to as a CCD) 111 and it is photo-electrically converted. In the construction shown in FIG. 2, for the longitudinal feed (portrait feed), the feed path 206 has a length to accommodate two A4-size document sheets. For the longitudinal feed (portrait feed) along a short side of the document sheet, the feed path 208 has a length to accommodate two A4-size document sheets. For the lateral feed (landscape feed) to feed the document sheet along a long side, the feed paths 206 and 208 have a length to accommodate one A3-size document sheet. The document sheet mounted on the feed tray 201 are in a face-up leading-page process in which the document sheet front side faces up and the leading page is stacked at the top. In the one-side moving read, the document sheets are sequentially read along the solid line arrow, and in the dual-side moving read, the half-size document sheets (A4 longitudinal, B5 longitudinal, A5 longitudinal) assume a different sheet feed sequence. The half-size documents are fed two sheets at a time and the rear side reading is conducted through the feed path 208 for the two document sheets read at the moving read document sheet read position 203. Simultaneously with the completion of the reading of the two document sheets of the rear-side reading, the reading of the front sides of the next two document sheets is started. Namely, the reading is conducted in the sequence of the front side of the first document sheet, the front side of the second document sheet, the rear side of the first document sheet, the rear side of the second document sheet, the front side of the third document sheet, the front side of the fourth document sheet, the rear side of the third document sheet, . . . . The dual-side document sheet read operation is shown in FIG. 3. In FIG. 3, numerals 1A and 2A denote the document sheet images of the front side of the first and the front side of the second, respectively, numerals 1B and 2B denote document sheet images of the rear side of the first and the rear side of the second, respectively. numerals 3A and 4A denote document sheet images of the front side of the third and the front side of the fourth, respectively, and numerals 3B and 4B denote document sheet images of the rear side of third and the rear side of the fourth, respectively. In the ADF 200 shown in FIG. 2, a non-circulation type document sheet feed unit is used in which the document sheet mounted on the document sheet tray 201 is not returned to the document sheet tray 201 but returned to a return tray 231. The sheet feed unit 205 and the feed paths 206, 207, 208 and 209 shown in FIG. 2 assume an independently driven construction so that they may be individually driven, stopped and speed-controlled. The document sheet feed in the ADF 200 is controlled by the controller 123 (see FIG. 4A) based on the designation from the OCU 53 and the status of the PBM (print buffer memory) 65. In FIG. 2, numeral 211 denotes a waiting position in the feed path 206 and numeral 212 denotes a waiting position in the feed path 208. They are positions at which the document sheets are stopped in the feed paths in accordance with the status of the PBM 65 to be described later and the position control is conducted based on the sheet detection sensor pass time and the feed speed. In FIG. 2, numeral 230 denotes a feed path along which the document sheet is returned to the return tray 231. Referring to FIGS. 4A and 4B, the image processing unit 61 which conducts the image processing to the read image data is explained in detail. FIGS. 4A and 4B show a block diagram of a configuration of the image processing unit 61. In FIGS. 4A and 4B, the reflected light 111 of the document sheet reached to the document sheet read position is sensed by the CCD 111 and it is photo-electrically converted to generate RGB (red, green and blue) electrical signals. The generated image signals are amplified and then converted by an A/D (analog-to-digital) converter 112 to digital image signals. The digital RGB signals are black-corrected/white-corrected (shading-corrected) and color-corrected (masked) by a shading/color space conversion circuit 113 for normalization and standardization. The standardized RGB signals are brilliance/density converted and black/red two-color separated by a two-color separation circuit 114 to generate a black image data signal 115 and a red image data signal 116. The subsequent process is conducted by independent circuit configurations for the black image data signal and the red image data signal in parallel. Selector circuits 165 and 166 select the image data 115 and 116 inputted from the CCD 111 or the black image data signal 167 and the red image data signal 168 externally inputted from the PC. The selection is based on the setting of the OCU 53. In filter circuits 117 and 118, the filtering is conducted in order to recover the reduction of MTF during the reading of the image and weaken a moare pattern generated in reading a mesh document sheet. Each of page memories 119 and 120 has a capacity to store one page of up to A3 size image. In the image read by the bi-directional document sheet feeder, the image read in the opposite direction to the forward direction is in a mirror image. The image read in the mirror image is further mirror-image processed to convert it to a real image by using the page memories 119 and 120. A process to attain a cut and paste function to move a specified area of a document sheet image 610 as shown in (a) of FIG. 5 to other area to create an image 611 as shown in (b) of FIG. 5 and a reduction layout function to reduce input document sheet images of a plurality of sheets by a factor of 50% by succeeding stage variable magnification/resolution conversion circuits 125 and 126 to form four-sheet document image 610 as shown in (a) of FIG. 6 into an image 611 on one sheet as shown in (b) of FIG. 6 are also conducted on the page memories 119 and 120 by the memory control signal 124 from the controller 123. The variable magnification/resolution conversion circuits 125 and 126 conduct the reduction layout function as well as the conventional image size conversion. Image modification circuits 127 and 128 attain the functions to form an image 621 as shown in (b) of FIG. 7 negative-positive reversed by designating an area on the document sheet image as shown in (a) of FIG. 7, a meshed image 622 and a meshed image 623 by designating an area to the document sheet image 620. Density conversion circuits 129 and 130 conduct gamma conversion for correcting the linearity characteristic of the printer unit 51 and the process to reflect the density adjustment level inputted by the user to the image data. The image data heretofore are 8-bit 256-tone signals but tone conversion (error dispersion circuits 131 and 132 convert them to printable 4-bit 16-tone image signals that is, black image data signal 133 and red image data signal 134. In order to cancel the irregularity in the density caused by the conversion of the number of tones when viewed for a certain area, the error due to the tone conversion is dispersed (or diffused). The image signal processing operation conducted by the image processing unit 61 has thus been described. The PBM (print buffer memory) 65 for storing a large number of pages of image for printing is now explained. FIG. 8 shows the block diagram of a configuration of the PBM 65. In FIG. 8, the black image data signal 133 and the red image data signal 134 inputted from the image processing unit 61 to the PBM 65 are coded by a compression process of a variable length reversible compression system of compression circuits 150 and 153. The variable length reversible system has a property that the data amount after the compression differs from input image to input image but the image which is same as the input image can be restored after the decompression process and it is compared with a fixed length non-reversible compression system such as the JPEG. The variable length reversible compression system includes MH, Q-Coder and Lempel Ziv, and any one of them may be used. DRAMs 151 and 154 form a memory unit in the PBM 65 and comprise a semiconductor memory or a hard disk and a control unit for addressing it. When page rearrangement such as a pamphlet mode (page 1 and page N are recorded on front pages and page 2 and page N-1 are recorded on rear pages thereof. and other pages are arranged in the same manner) is conducted, it is attained by controlling the addressing in the DRAMs 151 and 154. The image to be printed out is read from the DRAMs 151 and 154 and it is restored to the original image data by decompression circuits 152 and 153. The read timing for the black image data signal 135 is that required to form the black image and the read timing for the red image data signal 136 is that required to form the red image and they are read independently. The DRAMs 151 and 154 store the image data relating to all jobs. Remaining capacity detection circuits 157 and 158 detect capacities of storable area of the DRAMs 151 and 154, respectively, and output the detection results as a black memory remaining capacity detection signal 198 and a red memory remaining capacity detection signal 199. The black image data signal 135 and the red image data signal 136 are outputted to a D/A converter and a laser driver. Referring to FIGS. 9A and 9B, an operation thereof is explained. FIGS. 9A and 9B show a conceptual view of the PBM 65. In FIG. 9A, numeral 5002 denotes a copy job (to record in accordance with the image read by the CCD 111) which is being printed and copies 100 sets of 150 pages of document sheets. The pages 1 to 150 are sequentially read, but each set, for print out and then finishing process is conducted. Numeral 5003 denotes a job which is withheld as the job to be executed next and it finishes 60 sets of 50 pages by a print job (to record in accordance with the image data inputted from the PC) requested from the external equipment such as the PC. Numeral 5004 denotes a copy job of 50 sets of 200 pages. It is in the course of reading the image for 200 pages. In this case, the PBM 65 becomes full before the completion of the storing of 200 pages of image data and the read operation is temporarily interrupted. The job 5002 prints out pages 1 to 150 of the last 100th set which has been continuously read and the image for the printed-out pages is no longer need be stored and it is replaced with the image of the withheld job 5004. When the job 5002 is completed, the printing of the withheld job 5003 is started. Numeral 8021 denotes status information of the PBM. In FIG. 9B, numeral 5005 denotes a vacant area in the PBM 15 to which other jobs may be inputted (stored) so long as the memory capacity permits. Referring to FIG. 4, compression factor prediction is described. The image data stored in the DRAMs 151 and 154 of the PBM 65 have been compressed by the compression circuits 150 and 153 and the compression factors thereof differ depending on the image data amount, the content thereof and the process to the image data. Thus, a compression prediction circuit 160 predicts the compression factor of the image stored in the page memories 119 and 120 which is to be stored in the PBM 65 based on the modification information (meshing in (b) of FIG. 7, partial movement in FIG. 12) of the image obtained from the controller 128 through a bus 161, the magnification information (reduction layout of FIG. 13) and the operations of the selected density conversion circuits 129 and 130 and the tone conversion circuits 131 and 132. Namely, the compression factor prediction circuit 160 applies a simple arithmetic operation to the statistics of the image information (a density means value of the image or an entropy which has a high correlation with the compression factor) to determine the prediction value. The arithmetic operation or the coefficient used therefor is changed in accordance with the processing information which indicates the processes applied to the image data. For example, density mean value of the image is used for the prediction and the following formula (1) is used to convert it to the prediction value. Compression factor prediction value=mean image density value*a+b(1) where a and b determined in accordance with the contents of the processes of the image. By referring a RAM table, not shown, a and b are determined and they are transmitted to the compression factor prediction circuit 160 through the bus 161. As an example, assuming that the means density value of the image area is 40, the coefficient a for the process is 0.01 and b is 0.1, the prediction value is determined by the following formula (2). Compression factor prediction value=40*0.01+0.1=0.5 (2) This represents that the data amount after the compression is 1/2 of the data amount before the compression. In this manner, the compression factor prediction circuit 160 predicts the compression factor of the image data stored in the page memories 119 and 120. Referring to FIG. 10, an operation of the ADF 200 in the image processing apparatus of the present invention is now explained. FIG. 10 shows a STD (status transition diagram) illustrating the status of the ADF 200 in the image processing apparatus of the present embodiment. In FIG. 10, in a step S1001, a power is turned on to initialize the apparatus and the apparatus assumes the normal operation mode in a step S1002. In the normal operation mode, if it is determined that some vacant area is available but it is not sufficient to store the image data for which the compression factor has been predicted, on the basis of the remaining capacity detection signals 198 and 199 (see FIG. 8), the prediction value by the compression factor prediction circuit 160 and the image data amount, an almost full status to be described later is assumed in a step S1003. In the almost full status, if it is determined that the vacant area in the PBM 65 is exhausted based on the remaining capacity detection signals 198 and 199, a PBM full status to be described later is assumed in a step S1004. In the PBM full status, if it is determined that a vacant area is available in the PBM 65 based on the remaining capacity detection signals 198 and 199, the almost full status is assumed in the step S1003. In the almost full status, if it is determined that a room to store the image data for which the compression factor has been predicted is available based on the remaining capacity detection signals 198 and 199, the normal operation mode of the step S1002 is assumed. Operations in the respective status are explained below. Normal Operation Mode! The normal operation mode is first explained with reference to a flow chart of FIG. 11. In the normal operation mode in the step S1002 in FIG. 10, whether a room to store the image data for which the compression factor has been predicted is present in the PBM 65 or not is determined in a step S1101 of FIG. 11 based on the remaining capacity detection signals 198 and 199. If there is no room, the process proceeds to the almost full mode (step S1003 of FIG. 10). If there is a room in the step S1101, the normal operation mode is maintained and the decision process of the step S1001 is again conducted. In this manner, when there is a room to store the image data for which the compression factor has been predicted in the PBM 65, the present apparatus repeatedly conducts the decision process in the step S1101. An operation timing of an image input signal 1405 inputted to the page memories 119 and 120 and an image output signal 146 outputted from the page memories 119 and 120 is now explained with reference to a timing chart of FIG. 14. The image input signal 1405 is linked to the document sheet feed. In FIG. 14, numerals 1, 2, . . . , n-1, n, n+1 denote the sequence of the read document sheet. From the document sheet scan start (1407), the document sheets fed by the ADF 200, one at a time, are sequentially read by the scanner unit 250 and the image signal from the CCD 111 passes through the filters 117 and 118 and stored in the page memory 119 or 120. Thereafter, the storing of one page of image data is completed (1401). The page memory 119 or 120 in this status is shown in FIG. 19. As shown in FIG. 19, when the document sheet is of A3-size, the entire area of the page memory 119 or 120 is occupied by the first page of data. Upon completion of one page of image input (1408), the controller 123 starts to output the image signal from the page memory 119 or 120 to the PBM 65. Upon the start of the image output (1409), the controller 123 commands to the ADF 200 to feed the next document sheet to the moving read position 203. In this manner, the storing of the document sheet data of the second page to the page memory 119 or 120 is started (1403). The page memory 119 or 120 in this status is shown in FIG. 20. As shown in FIG. 20, the areas of the page memory 119 or 120 from which the images have been outputted are sequentially released as an open area 2001. The second page of document sheet is written into the open area 2001, and at a time 1404 of FIG. 14, the page memory 119 or 120 assumes a status as shown in FIG. 21. In general, during the period of outputting the page (n-1) and inputting the page n (1405), two pages of image data as shown in FIG. 22 coexist in the page memory 119 or 120. Transition from Normal Operation Mode to Almost Full Mode! As described above, in the step S1101 FIG. 11, when the controller 123 determines a possibility of the full status of the PBM based on the image data amount for which the compression factor has been predicted and the remaining capacity detection signals 198 and 199, the almost full mode of the step S1003 of FIG. 10 is assumed. An operation of the transition is explained with reference to the timing chart of FIG. 15. In FIG. 15, n-1, n, n+1, n+2 denote the sequence of the read document sheets. Numerals 1501 and 1502 denote input and output of the document sheet data, respectively, for the page memory 119 or 120. In FIG. 15, the process operates in the normal operation mode of the step S1002 of FIG. 3, until the room to store one page of document sheet disappears in the PBM 65 (1504). After the time 1504 of FIG. 15, the PBM 65 does not have the room to store one page of image data so that whether the image data currently stored in the page memory 119 or 120 can be stored in the PBM 65 or not can be first determined by actually storing the image data in the PBM 65. This status is referred to as the almost full mode. In this status, since an operation to check whether the n-th image data has been actually stored in the PBM 65 or not is needed, the storing of the next page of image data to the page memory 119 or 120 cannot be executed until the check is completed. Accordingly, the ADF 200 shown in FIG. 2 is operated to limit the number of sheets per unit time fed by the fed unit 205. Namely, the document sheet interval is set longer than that in the normal operation mode (skip operation or step operation) so that the feed can be stopped at any time. When the mode is changed to the almost full mode, the controller 123 of FIG. 4 commands the operation of this sequence to the ADF 200 and the skip operation sequence is continued until the almost full mode is released. The sequence in the almost full mode may be conducted by controlling the number of sheets per unit time to be fed by the feed unit 205 of the ADF 200 of FIG. 2 as shown in the present embodiment, or by controlling the sheet feed speed and the feed speed in the feed path 206. Almost Full Mode! An operation in the almost full mode is explained with reference to a flow chart of FIG. 12. In the almost full mode of the step S1003 of FIG. 10, whether a room to store the image data for which the compression factor has been predicted is present in the PBM 65 or not is always monitored based on the remaining capacity detection signals 198 and 199, and if the room is available, the process is shifted to the normal operation mode. Further, whether a vacant area is present in the PBM 65 or not is monitored, and if no vacant area is available, the process assumes the PBM full mode as described above. When the mode is changed from the normal operation mode to the almost full mode, whether a room to store the image data for which the compression factor has been predicted is available or not in a step S1202, and if it is available, the process proceeds to the normal operation mode, and if it is not available, the process proceeds to a step S1201. In the step S1201, whether there is a vacant area in the PBM or not is determined, and if there is vacant area, the process proceeds to a step S1202 and if there is no vacant area, the process shifts to the PBM full mode. In the almost full mode, in the step S1003 of FIG. 10, the present apparatus alternately transits between the steps S1201 and S1202 of FIG. 12. An operation in the almost full mode is explained with reference to the timing chart of FIG. 15. In the normal operation mode in the step S1002 of FIG. 10, in response to the start of outputting of the image data of the previous document sheet n from the page memories 119 and 120 (1408 in FIG. 14), the next document sheet (n+1) is fed to the moving read position 203 as described above in connection with the normal operation mode by FIG. 14. In the almost full mode in the step S1003 of FIG. 10, since the image data of the document sheet n is not stored in the PBM 65, the next document sheet (n+1) cannot be read until the storing of the image data of the document sheet n has been stored in the PBM 65. Accordingly, in the almost full mode, the feed of the document sheet (n+1) is not started even if the outputting of the image data of the document sheet n is started. That is, in response to the completion of the image input of the page n (1509), the controller 123 starts the outputting of the image of the page n from the page memory 119 or 120 to the PBM 65. In response to the completion of the image output (1510), the controller 123 releases the areas of the page memories 119 and 120 and commands to the ADF 200 to feed the next document sheet (n+1) to the moving read position 203. In this manner, the storing of the document sheet data of the page (n+1) to the page memory 119 or 120 is started. Subsequently, the completion of the reading of the document sheet and the waiting of the completion of the outputting of the image data are alternately repeated and in the almost full mode in the step S1003 of FIG. 10, the sheet interval of the document sheets in the ADF 200 is increased and the productivity is reduced to approximately one-half of that in the normal operation mode in the step S1002 of FIG. 10. However. since the areas of the page memories 119 and 120 are released after the completion of the outputting of the image data, the read data is not broken. Transition from Almost Full Mode to PBM Full Mode! Referring to a flow chart of FIG. 12, a transition operation from the almost full mode to the PBM full mode is explained. When the controller 123 determines in the monitoring in the step S1201 of FIG. 12 that the PBM 65 is full based on the remaining capacity detection signals 198 and 199, it commands to the PBM 65 to discard the image data of the page which is being lastly stored in the PBM 65 and the management information thereof from the PBM 65 and then shifts the mode to the PBM full mode of the step S1004 of FIG. 10. The transition operation is explained with reference to a timing chart of FIG. 16. In FIG. 16, n-1 and n denote the sequence (pages) of the read document sheets. Numerals 1601 and 1602 denotes input and output respectively, of the document sheet data for the page memories 119 and 120. In FIG. 16, numeral 1603 denotes a time at which a vacant area is no longer available in the PBM 65 in the course of outputting the image data of the document sheet n to the PBM 65. The almost full mode operation in the step S1003 of FIG. 10 is conducted until a vacant area in the PBM 65 becomes unavailable (1603). After the time 1603 in FIG. 16, there is no space to store the document sheet data in the PBM 65 and the outputting of the image to the PBM 65 is interrupted. This status is referred to as the PBM full mode. The image of the document sheet n in the page memories 119 and 120 is maintained. In this status, since the reading of the document sheet is stopped until a vacant area to store the data becomes available in the PBM 65, the ADF 200 shown in FIG. 2 stops the feeding of the sheet by the sheet feed unit and waits for the command to start from the controller 123 of FIG. 4. Namely, at the time of shifting to the PBM full mode, the controller 123 of FIG. 4 commands to the ADF 123 of FIG. 4 to stop the moving read image read sequence operation. At the time of shifting to the PBM full sequence, the document sheet (n+1) in the feed path is stopped before it reaches the moving read image read position 203. The document sheet which is in the feed path but the reading therefor has been completed and located at a position which permits the ejection is not stopped but ejected. In FIG. 2, in the one-side read mode, the document sheets are withhold in the feed path 205 and the convey path 206. The document sheet on the convey path 207 is ejected. In the dual-side read mode, the document sheets are withhold in the feed unit 205 and the convey paths 206 and 208 and the document sheet in the convey path 209 is ejected. As described above, each of the convey paths can be independently driven, stopped and speed-controlled. Accordingly, as shown in FIG. 2, the feed unit 205 or the convey paths 206 and 208 are provided with independent wait positions 211 and 212 to attain the withholding of the document sheet in the PBM full mode. PBM Full Mode! An operation in the PBM full mode is now explained with reference to the flow chart of FIG. 13 and the timing chart of FIG. 16. In the step S1004 of FIG. 10, whether there is a vacant area in the PBM 65 or not is continuously monitored based on the remaining capacity detection signals 198 and 199, and if there is no vacant area, the process returns to the step S1301 of FIG. 13 to monitor whether a vacant area becomes available in the PBM 65 or not. If it is determined that a vacant area is available in the PBM 65, the mode is shifted to the almost full mode of the step S1003 of FIG. 10, and if it is determined that no vacant area is available, the process returns to the step S1301 to conduct the monitoring again. In the PBM full mode of the step S1004 of FIG. 10, the occurrence of a vacant area in the PBM 65 is waited (for a period from 1603 to 1604 in FIG. 16). The operation of the ADF 200 shown in FIG. 2 is in the stop status and waiting for a resume command from the controller 123. Recovery of PBM Full Mode! The recovery from the PBM full mode is explained with reference to the timing chart of FIG. 16. In the step S1301 of FIG. 13, if it is determined that a vacant area is available in the PBM 65 based on the remaining capacity detection signals 198 and 199, the controller 123 starts to output from the top of the image data stored in the page memories 119 and 120 (the image of the document sheet n outputted to the PBM 65 in the PBM full mode). As described above, the control mode of the controller 123 is in the almost full mode in the step S1003 of FIG. 10 from the start of the image output. If the vacant area of the PBM 65 available at that time is smaller than the capacity to store one page of document sheet and the vacant area in the PBM 65 is again exhausted, the PBM full mode of the step S1004 of FIG. 10 is again assumed and the expansion of the vacant area in the PBM 65 is waited. When a vacant area is available in the PBM 65 and the almost full mode is assumed and the storing of the image output from the page memories 119 and 120 to the PBM 65 is completed, the controller 123 of FIG. 4 commands to resume the operation of the ADF 200 shown in FIG. 2. When the ADF 200 receives the command, the ADF 200 resumes the feed of the document sheet (n+1) which is standing by in the stand-by positions 211 and 212 of FIG. 2 and the document sheet on the document sheet tray, and resumes the reading at the moving read image read position 203. Recovery from Almost Full Mode! As described above, when the present apparatus shifted from the normal operation mode in the step S1002 of FIG. 10 or the PBM full mode to the almost full mode in the step S1003 determines in the step S1202 of FIG. 12 that the image data for which the compression factor has been predicted may be stored in the PBM 65 based on the remaining capacity detection signals 198 and 199, it assumes the normal operation mode of the step S1002 of FIG. 10. A recovery operation from the almost full mode is now explained with reference to timing charts of FIGS. 17 and 18. FIG. 17 shows a status in which a storage space for the image of the page (n-1) document sheet is created in the PBM 65 by the reading of the image from the PBM 65 during the reading of the page (n-1) document sheet. In FIG. 17, n-1, n, n+1, n+2 denote the sequence of the read document sheets. Numerals 1701 and 1702 denote input and output of the document sheet, respectively, for the page memories 119 and 120. When a vacant area to store the one page of image data for which compression factor has been predicted is not available in the PBM 65, the almost full mode of operation in the step S1003 of FIG. 10 is conducted. After 1703 when the creation of a larger vacant area than predicted in the PBM 65 is detected during the reading of page n document sheet by a reason that the outputting of all of a large image data of other job is completed or other job coexisted in the PBM 65 is discarded, the almost full mode is released and the page (n+1) document sheet may be read without waiting the completion of the page n image data. FIG. 18 shows a status in which the almost full mode is released during the outputting of the page n image data. In FIG. 18, n-1, n, n+1, n+2 denote the sequence of the read document sheets. Numerals 1801 and 1802 denote input and output of the document sheet, respectively, for the page memories 119 and 120. FIG. 23 shows a conceptual view of the OCU 53. In FIG. 23, numeral 2301 denotes a CRT screen and a user selection is inputted by touch type input. The CRT screen 2301 may be substituted by an LCD or an FLC. Instead of the touch type input, the input by a pointing device such as a mouse or an input pen may be used. Numeral 2302 denotes a key pad, numeral 2303 denotes a numeric ten-key, numeral 2304 denotes a clear key, numeral 2305 denotes an enter key, numeral 2306 denotes a step key, numeral 2307 denotes a reset key and numeral 2308 denotes a start key. A basic configuration of the OCU 53 has been described above. FIG. 24 shows a display, a selection menu and settings on the display unit. In FIG. 24, numeral 2401 denotes a standard menu screen in the CRT screen 2301. Numeral 2402 denotes a selection area for a book mode (in which a document sheet a set on the platen and it is read by scanning the optical system), numeral 2403 denotes a selection area for a one-side copy mode of the moving read image read, numeral 2404 denotes a selection area for a dual-side copy mode of the moving read image read, numeral 2405 denotes a selection area for a number of copies, numeral 2406 denotes a selection area for a copy magnification factor, numeral 2407 denotes a selection area for function devices of the copying machine (sheet feed stacker, stapler, saddle switcher, group binder, mail box sorter, etc.) and numeral 2408 denotes a selection area for detail copy mode when detailed setting is to be conducted in the copy mode. FIG. 25 shows a display status when a device select is selected by the selection area 2407 for selecting the function device. In FIG. 25, numeral 2501 denotes a screen. The copying machine and all accessories of the copying machine are displayed to permit the selection of any function. In FIG. 25, numeral 2502 denotes a proof tray to which a test printed sheet on which the image after the copying is printed to test the finishing is ejected, numeral 2503 denotes a stapler, numeral 2504 denotes a stacker for accommodating the stapled output sheets, numeral 2505 denotes a saddle switcher, numeral 2506 denotes a stacker for accommodating the output sheets saddle-stitched by the saddle stitcher 2505, numeral 2514 denotes a group binder, numerals 2507 and 2508 denote a stacker for books processed by the group binder 2514, numeral 2509 denotes a mail box sorter, numeral 2510 denotes an output sort pin for sorting by the mail box sorter 2509 and numeral 2511 denotes a selection area to return to the screen 2501. Numerals 2512, 2513, 2517 and 2515 denotes sheet feed stages 1, 2, 3 and 4, respectively. The user set transfer sheets are accommodated in the sheet feed stages 1, 2, 3 and 4. Numeral 2516 denotes a screen area to display a flow of the feed of the output sheets to the function devices on real title basis. FIG. 26 shows a screen display status when a copy made detail is selected by the detail copy mode selection area 2408 of FIG. 24. The copy functions in the image processing such as the number of tones, the resolution, the multi-copying or the twin-color are selected. FIG. 27 shows a screen display status in the almost full mode. In this mode, since the image data is transferred to the PBM 65 while checking the vacant area of the PBM 65 as described above, the processing speed is low. Numeral 2701 in FIG. 27 denote display information for informing the status to the user and numeral 2702 denotes a selection area for releasing the job set by the user in that status. FIG. 28 shows a screen display status in the PBM full mode. In this mode, the image reading is temporarily stopped and the reading is withheld until the PBM full mode disappears. In FIG. 28, numeral 2801 denotes display information to inform that status, numeral 2804 denotes a display of wait time, numeral 2802 denotes a selection area for releasing the job set by the user in that status and numeral 2803 denotes a selection for waiting the start of the reading of the document sheet in the PBM full mode. Next, the lighting sequence of the document exposure lamp (document irradiation lamp) in almost full and PBM full modes will be described. FIG. 29 is block diagram for describing the document irradiation lamp of the image processing apparatus according to the present embodiment. In the figure, numeral 213 denotes a document irradiating lamp, numeral 1002 denotes a lamp control portion, which performs lighting, extinguishing, and adjusting of the document irradiation lamp. Numeral 111 denotes a CCD, numeral 112 denotes an A/D conversion circuit, numeral 160 denotes a compression prediction circuit, numeral 11 denotes an image processing portion, numeral 119 denotes a page memory, and numeral 123 denotes a controller. In FIG. 29, the image read by the CCD 111 of the reader section 1 is subjected to conversion processing by the A/D conversion circuit 112 and then sent to the compression prediction circuit 160, wherein the conversion percentage is predicted as described above at the compression prediction circuit 160, and the prediction data is sent to the controller 123 via the signal line 122. Also, the following the predetermined processing at the image processing portion 11, the image data is stored in the PBM 65, but the remaining capacity information calculated by the remaining capacity detection circuit 157 shown in FIG. 8 is sent to the controller 123 at this time. The controller 123 controls the lamp control portion 1002 with lamp control signals 803 using a control method described later. The lamp control portion 1002 performs actual control of the document irradiation lamp 213 using the control signal 1012. FIG. 30 is a diagram representing the capacity within the PBM 65 and the almost full and PBM full states. In the Figure, M1 indicates the amount for one page worth of image data, and the value at this time is described as a first threshold value Thr1. Here, the image processing apparatus according to the present invention is in the PBM full state. Also, the second threshold value for an image capacity M2 wherein the value is greater than the Thr1 and is dependent on the precision of prediction results of the compression prediction circuit 160 and it is not known whether storage to the PBM 65 is possible or not, is described as Thr2. At this time, the image processing apparatus according to the present invention is in the almost full state. FIG. 31 is a block diagram illustrating the construction which uses hardware circuitry to perform control of the document irradiation lamp 213 of the image processing apparatus according to the present invention. In the Figure, numeral 801 denotes a signal line which provides the first threshold value Thr1, numeral 802 denotes a signal line which provides the second threshold value Thr2, numeral 803 denotes a signal line which provides a control signal for controlling turning on and off of the document irradiation lamp 213 using the controller 123 shown in FIG. 4, and numeral 804 denotes a signal line which provides the presently remaining capacity of the PBM 65 as detected by the remaining capacity detection circuit 157. Also, numerals 805 and 806 each denote comparators, which compare the presently remaining capacity of the first threshold value Thr1 and the presently remaining capacity of the second threshold value Thr2, and in the event that the remaining capacity is greater than the threshold value, a "HIGH" signal is output. Numeral 807 denotes an AND gate, which creates signals for turning on and off of the document irradiation lamp 213, by means of taking the logical product of the signals of the signal line 803 and the comparators 805 and 806. Numeral 808 denotes a lamp control driver, and controls turning on and off of the document irradiation lamp 213 according to signals from the AND gate 807. FIG. 32 is a diagram which illustrates control performed at the lamp control portion 1002 when such is performed by means of software, i.e., a flowchart illustrating the lighting and extinguishing sequence so as to show the operation control procedures of the lamp lighting sequences, based on judgment of what state the PBM 65 of the image processing apparatus according to the present embodiment is in. In the Figure, the controller 123 judges whether or not the PBM 65 is presently in the almost full state or not, in step S3201. If the PBM 65 is judged to be presently in the almost full state, the lighting sequence of the document irradiation lamp 213 is performed in accordance with the almost full state in step S3202. This lighting sequence will be described later. If the PBM 65 is judged not to be presently in the almost full state, the controller 123 judges whether or not the PBM is presently in the PBM full state or not, in step S3203. If the PBM is judged to be presently in the PBM full state, the lighting sequence of the document irradiation lamp 213 is performed in accordance with the PBM full state in step S3204. This lighting sequence will be described later. Also, in the event that the PBM is judged not to be presently in the PBM full state in the aforementioned step S3203, normal lighting sequence of the document irradiation lamp 213 is performed in step S3205, i.e., the document irradiation lamp 213 is lit continuously. FIG. 33 is a flowchart illustrating the operation control procedures of the lamp lighting sequence of the document irradiation lamp 1001 performed in the almost full state in step S3202 in FIG. 32. In the Figure, the present document feeding interval time T calculated in step S3301 by the controller 123 (i.e., the time elapsing from the trailing edge of the preceding document passing over the read position to the leading edge of the next document passing over the read position) is compared with a certain predetermined threshold value Thr, and in the event that T>Thr, i.e., the present document feeding interval time T is longer than the certain threshold value Thr, then supplying of electricity to the document irradiation lamp 213 is terminated for the amount of time corresponding with the document feeding interval time T so as to turn off the lamp for that amount of time in step S3302, following which the document irradiation lamp 213 is supplied with electricity once more so as to turn it on in step S3304. Also, in the event that T<Thr in step S3301, i.e., the present document feeding interval time T is shorter than the certain threshold value Thr, lighting and extinguishing control of the lamp is not performed, and normal continuous lighting sequence of the document irradiation lamp 213 is performed in step S3303. Here, the document feeding interval time T is controlled having been calculated from the extended time of the image data of one page output from the PBM 65, and the like. Now, the certain threshold 213 is a value which is dependent on the document irradiation lamp 213, i.e., is a value which is dependent on the amount of time required from the document irradiation lamp 213 being off to reaching the quantity of light necessary for exposing the document, i.e., in the event that the document feeding interval time T is shorter than a certain threshold value Thr, the document irradiation lamp 213 is not turned off even if in the almost full state, i.e., is continuously lit. FIG. 34 is a flowchart illustrating the operation control procedures of the lamp lighting sequence of the document irradiation lamp 213 performed in the PBM full state in step S3204 in FIG. 32. In the PBM full state, the document feeding interval time T is longer than compared to the almost full state, so in the Figure, supplying of electricity to the document irradiation lamp 213 is terminated in step S3401. Next, in step S3402, the controller 123 judges whether the PBM full state has been resolved and an on signal of the document irradiation lamp 213 has been output. In the event that an on signal of the document irradiation lamp 213 has been output, electricity is supplied to the document irradiation lamp 213 in step S3403 once more, turning it on, in preparation for the document to be fed and read. According to the above control, the lamp is turned off when there is no document passing through the reading portion for a certain amount of time, thus preventing overheating of the reading portion due to the lamp. Although the lamp remains on in the normal mode, the documents passing over the reading portion in succession take the heat thereof and remove it, thus inhibiting rising of temperature. As described above, turning off the document irradiation lamp when the document feeding interval time of the document feeding means is to be long saves energy, and also prevents rising of temperature in one location due to the lamp being fixed for passing documents over and reading.
An original document reading apparatus includes a first control portion for performing a first control wherein documents are transported at a first document interval in the event that a detected occupying capacity is less than a detected unused capacity. The first control portion also performs a second control wherein documents are transported at a second document interval which is greater than the first document interval in the event that the detected occupying capacity exceeds the detected unused capacity. A second control portion continuously activates an exposure portion under the first control, and intermittently activates the exposure portion under the second control.
7
FIELD OF THE INVENTION [0001] This invention relates to an aluminium alloy suitable for use in aircraft, automobiles, and other applications and a method of producing such alloy. More specifically, it relates to an improved weldable aluminium product, particularly useful in aircraft applications, having high damage tolerant characteristics, including improved corrosion resistance, formability, fracture toughness and increased strength properties. BACKGROUND OF THE INVENTION [0002] It is known in the art to use heat treatable aluminium alloys in a number of applications involving relatively high strength such as aircraft fuselages, vehicular members and other applications. Aluminium alloys 6061 and 6063 are well known heat treatable aluminium alloys. These alloys have useful strength and toughness properties in both T4 and T6 tempers. As is known, the T4 condition refers to a solution heat treated and quenched condition naturally aged to a substantially stable property level, whereas T6 tempers refer to a stronger condition produced by artificially ageing. These known alloys lack, however, sufficient strength for most structural aerospace applications. Several other Aluminium Association (“AA”) 6000 series alloys are generally unsuitable for the design of commercial aircraft which require different sets of properties for different types of structures. Depending on the design criteria for a particular aircraft component, improvements in strength, fracture toughness and fatigue resistance result in weight savings, which translate to fuel economy over the lifetime of the aircraft, and/or a greater level of safety. To meet these demands several 6000 series alloys have been developed. [0003] European patent no. EP-0173632 concerns extruded or forged products of an alloy consisting of the following alloying elements, in weight percent: [0004] Si 0.9-1.3, preferably 1.0-1.15 [0005] Mg 0.7-1.1, preferably 0.8-1.0 [0006] Cu 0.3-1.1, preferably 0.8-1.0 [0007] Mn 0.5-0.7 [0008] Zr 0.07-0.2, preferably 0.08-0.12 [0009] Fe<0.30 [0010] Zn 0.1-0.7, preferably 0.3-0.6 [0011] balance aluminium and unavoidable impurities (each<0.05; total<0.15). The products have a non-recrystallised microstructure. This alloy has been registered under the AA designation 6056. [0012] It has been reported that this known AA6056 alloy is sensitive to intercrystalline corrosion in the T6 temper condition. In order to overcome this problem U.S. Pat. No. 5,858,134 provides a process for the production of rolled or extruded products having the following composition, in weight percent: [0013] Si 0.7-1.3 [0014] Mg 0.6-1.1 [0015] Cu 0.5-1.1 [0016] Mn 0.3-0.8 [0017] Zr<0.20 [0018] Fe<0.30 [0019] Zn<1 [0020] Ag<1 [0021] Cr<0.25 [0022] other elements<0.05, total<0.15 [0023] balance aluminium, [0024] and whereby the products are brought in an over-aged temper condition. However, over-ageing requires time and money consuming processing times at the end of the manufacturer of aerospace components. In order to obtain the improved intercrystalline corrosion resistance it is essential for this process that in the aluminium alloy the Mg/Si ratio is less than 1. [0025] U.S. Pat. No. 4,589,932 discloses an aluminium wrought alloy product for e.g. automotive and aerospace constructions, which alloy was subsequently registered under the AA designation 6013, having the following composition, in weight percent: [0026] Si 0.4-1.2, preferably 0.6-1.0 [0027] Mg 0.5-1.3, preferably 0.7-1.2 [0028] Cu 0.6-1.1 [0029] Mn 0.1-1.0, preferably 0.2-0.8 [0030] Fe<0.6 [0031] Cr<0.10 [0032] Ti<0.10 [0033] the balance aluminium and unavoidable impurities. [0034] The aluminium alloy has the mandatory proviso that [Si+0.1]<Mg<[Si+0.4], and has been solution heat treated at a temperature in a range of 549 to 582° C. and approaching the solidus temperature of the alloy. In the examples illustrating the patent the ratio of Mg/Si is always more than 1. [0035] U.S. Pat. No. 5,888,320 discloses a method of producing an aluminium alloy product. The product has a composition of, in weight percent: [0036] Si 0.6-1.4, preferably 0.7-1.0 [0037] Fe<0.5, preferably <0.3 [0038] Cu<0.6, preferably <0.5 [0039] Mg 0.6-1.4, preferably 0.8-1.1 [0040] Zn 0.4 to 1.4, preferably 0.5-0.8 [0041] at least one element selected from the group: Mn 0.2-0.8, preferably 0.3-0.5 Cr 0.05-0.3, preferably 0.1-0.2 [0044] balance aluminium and unavoidable impurities. [0045] The disclosed aluminium alloy provides an alternative for the known high-copper containing 6013 alloy, and whereby a low-copper level is present in the alloy and the zinc level has been increased to above 0.4 wt. % and which is preferably in a range of 0.5 to 0.8 wt. %. The higher zinc content is required to compensate for the loss of copper. [0046] In spite of these references, there is still a great need for an improved aluminium base alloy product having improved balance of strength, fracture toughness and corrosion resistance. SUMMARY OF THE INVENTION [0047] It is an object of the invention to provide a weldable 6000-series aluminium alloy wrought product having an improved balance of yield strength and fracture toughness. [0048] It is another object of the invention to provide a weldable 6000-series aluminium alloy wrought product having an improved balance of yield strength and fracture toughness, while having a corrosion resistance, in particular intergranular corrosion resistance, at least equal or better than standard AA6013 alloy product in the same form and temper. [0049] It is another object of the invention to provide a weldable 6000-series aluminium alloy rolled product having an improved balance of yield strength and fracture toughness, while having a corrosion resistance, in particular intergranular corrosion resistance, at least equal or better than standard AA6013 alloy product in the same form and temper. [0050] According to the invention there is provided a weldable, high-strength aluminium alloy wrought product, which may be in the form of a rolled, extruded or forged form, containing the elements, in weight percent, Si 0.8 to 1.3, Cu 0.2 to 1.0, Mn 0.5 to 1.1, Mg 0.45 to 1.0, Ce 0.01 to 0.25, and preferably added in the form of a Misch Metal, Fe 0.01 to 0.3, Zr<0.25, Cr<0.25, Zn<1.4, Ti<0.25, V<0.25, others each<0.05 and total<0.15, balance aluminium. BRIEF DESCRIPTION OF THE DRAWING [0051] FIG. 1 shows schematically a ratio of TS/Rp against yield strength DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0052] By the invention we can provide an improved and weldable AA6000-series aluminium alloy wrought product, preferably in the form of a rolled product, having an improved balance in strength, fracture toughness and corrosion resistance, and intergranular corrosion resistance in particular. With the alloy product according to the invention we can provide a wrought product, preferably in the form of a rolled product, having a yield strength of 340 MPa or more and an ultimate tensile strength of 355 MPa or more, in combination with an improved intergranular corrosion performance compared to standard AA6013 alloys and/or AA6056 alloys when tested in the same form and temper. The alloy product may be welded successfully using techniques like e.g. laser beam welding, friction-stir welding and TIG-welding. [0053] The product can either be naturally aged to produce an improved alloy product having good formability in the T4 temper or artificially aged to a T6 temper to produce an improved alloy having high strength and fracture toughness, along with a good corrosion resistance properties. A good balance in strength, fracture toughness and corrosion performance it being obtained without a need for bringing the product to an over-aged temper, but by careful selection of narrow ranges for the Ce, Cu, Mg, Si, and Mn-contents. [0054] The balance of high formability, improved fracture toughness, high strength, and good corrosion resistance properties of the weldable aluminium alloy of the present invention are dependent in particular upon the chemical composition that is closely controlled within specific limits in more detail as set forth below. All composition percentages are by weight percent. [0055] A preferred range for the silicon content is from 1.0 to 1.15% to optimise the strength of the alloy in combination with magnesium. A too high Si content has a detrimental influence on the elongation in the T6 temper and on the corrosion performance of the alloy. [0056] Magnesium in combination with the silicon provides strength to the alloy. The preferred range of magnesium is 0.6 to 0.85%, and more preferably 0.6 to 0.75%. At least 0.45% magnesium is needed to provide sufficient strength while amounts in excess of 1.0% make it difficult to dissolve enough solute to obtain sufficient age hardening precipitate to provide high T6 strength. [0057] Copper is an important element for adding strength to the alloy. However, too is high copper levels in combination with Mg have a detrimental influence of the corrosion performance and on the weldability of the alloy. Depending on the application a preferred copper content is in the range of 0.25 to 0.5% as a compromise in strength, fracture toughness, formability and corrosion performance. [0058] It has been found that in this range the alloy product has a good resistance against IGC. In another embodiment the preferred copper content is in the range of 0.5 to 1.0% resulting in higher strength levels and improved weldability of the alloy product. [0059] The preferred range of manganese is 0.6 to 0.8%, and more preferably 0.65 to 0.78%. Mn contributes to or aids in grain size control during operations that can cause the alloy to recystallise, and contributes to increase strength and fracture toughness. [0060] A very important alloying element according to the invention is the addition of Ce in the range of 0.01 to 0.25%, and preferably in the range of 0.01 to 0.15%. In accordance with the invention it has been found that the addition of cerium results in a remarkable improvement of the fracture toughness of the alloy product, in particular when measured via a Kahn-tear testing, and thereby improving in particular the relation between fracture toughness and proof strength and resulting in increased application possibilities of the alloy product, in particular as aircraft skin material. The cerium addition may be done preferably via addition in the form of a Misch Metal (“MM”) (rare earths with 50 to 60% cerium). The addition of cerium, mostly in the form of MM is known in the art to increase fluidity and the reduce die sticking in aluminium-silicon casting alloys. In aluminium casting alloys containing more than 0.7% of iron, it is reported to transform acicular FeAl 3 into a nonacicular compound. [0061] The zinc content in the alloy according to the invention should be less than 1.4%. It has been reported in U.S. Pat. No. 5,888,320 that the addition of zinc may add to the strength of the aluminium alloy product, but it has been found also that too high zinc contents have a detrimental effect of the intergranular corrosion performance of the product. Furthermore, the addition of zinc tends to produce an alloy product having undesirable higher density, which is in particular disadvantageous when the alloy is being applied for aerospace applications. A preferred level of zinc in the alloy product according to the invention is less than 0.4%, and more preferably less than 0.25%. [0062] Iron is an element having a strong influence on the formability and fracture toughness of the alloy product. The iron content should be in the range of 0.01 to 0.3%, and preferably 0.01 to 0.25%, and more preferably 0.01 to 0.2%. [0063] Titanium is an important element as a grain refiner during solidification of the rolling ingots, and should preferably be less than 0.25%. In accordance with the invention it has been found that the corrosion performance, in particular against intergranular corrosion, can be remarkably be improved by having a Ti-content in the range of 0.06 to 0.20%, and preferably 0.07 to 0.16%. It has been found that the Ti may be replaced in part or in whole by vanadium. [0064] Zirconium and chromium may be added to the alloy each in an amount of less than 0.25% to improve the recrystallisation behaviour of the alloy product. At too high levels the Cr present may form undesirable large particles with the Mg in the alloy product. [0065] The balance is aluminium and inevitable impurities. Typically each impurity element is present at 0.05% maximum and the total of impurities is 0.15% maximum. [0066] The best results are achieved when the alloy rolled products have a recrystallised microstructure, meaning that 80% or more, and preferably 90% or more of the grains in a T4 or T6 temper are recrystallised. [0067] The product according to the invention is preferably therein characterised that the alloy having been aged to the T6 temper in an ageing cycle which comprises exposure to a temperature of between 150 and 210° C. for a period between 1 and 20 hours, thereby producing an aluminium alloy product having a yield strength of 340 MPa or more, and preferably of 350 MPa or more, and an ultimate tensile strength of 355 MPa or more, and preferably of 365 MPa or more. [0068] Furthermore, the product according to the invention is preferably therein characterised that the alloy having been aged to the T6 temper-in an ageing cycle which comprises exposure to a temperature of between 150 and 210° C. for a period between 1 and 20 hours, thereby producing an aluminium alloy product having an intergranular corrosion after a test according to MIL-H-6088 present to a depth of less than 200 μm, and preferably to a depth of less than 180 μm. [0069] In an embodiment the invention also consists in that the product of this invention may be provided with at least one cladding. Such clad products utilise a core of the aluminium base alloy product of the invention and a cladding of usually higher purity which in particular corrosion protects the core. The cladding includes, but is not limited to, essentially unalloyed aluminium or aluminium containing not more than 0.1 or 1% of all other elements. Aluminium alloys herein designated 1xxx-type series include all Aluminium Association (AA) alloys, including the sub-classes of the 1000-type, 1100-type, 1200-type and 1300-type. Thus, the cladding on the core may be selected from various Aluminium Association alloys such as 1060, 1045, 1100, 1200, 1230, 1135, 1235, 1435, 1145, 1345, 1250, 1350, 1170, 1175, 1180, 1185, 1285, 1188, or 1199. In addition, alloys of the AA7000-series alloys, such as 7072 containing zinc (0.8 to 1.3%), can serve as the cladding and alloys of the AA6000-series alloys, such as 6003 or 6253, which contain typically more than 1% of alloying additions, can serve as cladding. Other alloys could also be useful as cladding as long as they provide in particular sufficient overall corrosion protection to the core alloy. In addition a cladding of the AA4000-series alloys can serve as cladding. The AA4000-series alloys have as main alloying element silicon typically in the range of 6 to 14%. In this embodiment the clad layer provides the welding filler material in a welding operation, e.g. by means of laser beam welding, and thereby overcoming the need for the use of additional filler wire materials in a welding operation. In this embodiment the silicon content is preferably in a range of 10 to 12%. [0070] The clad layer or layers are usually much thinner than the core, each constituting 2 to 15 or 20 or possibly 25% of the total composite thickness. A cladding layer more typically constitutes around 2 to 12% of the total composite thickness. [0071] In a preferred embodiment the alloy product according to the invention is being provided with a cladding thereon on one side of the AA1000-series and on the other side thereon of the AA4000-series. In this embodiment corrosion protection and welding capability are being combined. In this embodiment the product may be used successfully for example for pre-curved panels. In case the rolling practice of an asymmetric sandwich product (1000-series alloy+core+4000-series alloy) causes some problems such as banaring, there is also the possibility of first rolling a symmetrical sandwich product having the following subsequent layers 1000-series alloy+4000-series alloy+core alloy+4000-series alloy+1000-series alloy, where after one or more of the outer layer(s) are being removed, for example by means of chemical milling. [0072] The invention also consists in a method of manufacturing the aluminium alloy product according to the invention. The method of producing the alloy product comprises the sequential process steps of: (a) providing stock having a chemical composition as set out above, (b) preheating -or homogenising the stock, (c) hot working the stock, preferably by means of hot rolling (d) optionally cold working the stock, preferably by means of cold rolling (e) solution heat treating the stock, and (f) quenching the stock to minimise uncontrolled precipitation of secondary phases. Thereafter the alloy product can be provided in a T4 temper by allowing the product to naturally age to produce an improved alloy product having good formability, or can be provided in a T6 temper by artificial ageing. To artificial age, the product in subjected to an ageing cycle comprising exposure to a temperature of between 150 and 210° C. for a period between 0.5 and 30 hours. [0073] The aluminium alloy as described herein can be provided in process step (a) as an ingot or slab for fabrication into a suitable wrought product by casting techniques currently employed in the art for cast products, e.g: DC-casting, EMC-casting, EMS-casting. Slabs resulting from continuous casting, e.g. belt casters or roll caster, may be used also. [0074] Typically, prior to hot rolling the rolling faces of both the clad and the non-clad products are scalped in order to remove segregation zones near the cast surface of the ingot. [0075] The cast ingot or slab may be homogenised prior to hot working, preferably by means of rolling and/or it-may be preheated followed directly by hot working. The homogenisation and/or preheating of the alloy prior to hot working should be carried out at a temperature in the range 490 to 580° C. in single or in multiple steps. In either case, the segregation of alloying elements in the material as cast is reduced and soluble elements are dissolved. If the treatment is carried out below 490° C., the resultant homogenisation effect is inadequate. If the temperature is above 580° C., eutectic melting might occur resulting in undesirable pore formation. The preferred time of the above heat treatment is between 2 and 30 hours. Longer times are not normally detrimental. Homogenisation is usually performed at a temperature above 540° C. A typical preheat temperature is in the range of 535 to 560° C. with a soaking time in a range of 4 to 16 hours. [0076] After the alloy product is cold worked, preferably after being cold rolled, or if the product is not cold worked then after hot working, the alloy product is solution heat treated at a temperature in the range of 480 to 590° C., preferably 530 to 570° C., for a time sufficient for solution effects to approach equilibrium, with typical soaking times in the rang of 10 sec. to 120 minutes. With clad products, care should be taken against too long soaking times to prevent diffusion of alloying element from the core into the cladding detrimentally affecting the corrosion protection afforded by said cladding. [0077] After solution heat treatment, it is important that the alloy product be cooled to a temperature of 175° C. or lower, preferably to room temperature, to prevent or minimise the uncontrolled precipitation of secondary phases, e.g. Mg 2 Si. On the other hand cooling rates should not be too high in order to allow for a sufficient flatness and low level of residual stresses in the alloy product. Suitable cooling rates can be achieved with the use of water, e.g. water immersion or water jets. [0078] The product according to the invention has been found to be very suitable for application as a structural component of an aircraft, in particular as aircraft fuselage skin material. EXAMPLE [0079] Five different alloys have been DC-cast into ingots, then subsequently scalped, pre-heated for 6 hours at 550° C. (heating-up speed about 30° C./h), hot rolled to a gauge of 8 mm, cold rolled to a final gauge of 2.0 mm, solution heat treated for 15 min. at 550° C., water quenched, aged to a T6-temper by holding for 4 hours at 190° C. (heat-up speed about 35° C./h), followed by air cooling to room temperature. Table 1 gives the chemical composition of the alloys cast, balance inevitable impurities and aluminium, and whereby Alloy no. 3 is the alloy according to the invention and the other alloys are for comparison. The 0.03 wt. % cerium has been added to the melt via the addition of 0.06 wt. % of MM having 50% of cerium. [0080] The tensile testing has been carried out on the bare sheet material in the T6-temper and having a fully recystallised microstructure. For the tensile testing in the L-direction small euro-norm specimens were used, average results of 3 specimens are given, and whereby “Rp” stands for yield strength, “Rm” for ultimate tensile strength, and A50 for elongation. The results of the tensile tests have been listed in Table 2. The “TS” stands for tear strength, and has been measured in the L-T direction in accordance with ASTM-B871-96. “UPE” stands for Unit Propagation Energy, and has been measured in accordance with ASTM-B871-96, and is a measure for toughness, in particular for the crack growth, and whereas TS is in particular a measure for crack initiation. Intergranular corrosion (“ICG”) was tested on two specimens of 50×60 mm in accordance with the procedure given in AIMS 03-04-000, which specifies MIL-H-6088 and some additional steps. The maximum depth in microns has been reported in Table 4. [0081] FIG. 1 shows schematically the ratio of TS/Rp against the yield strength. [0082] From the results of Table 2 it can be seen that adding cerium in accordance with the invention results in a significant increase in strength levels, in particular the yield strength of the alloy product (see Alloy 1 and 3). From the results of Table 3 it can be seen that adding cerium results in a significant increase of the fracture toughness of the alloy product when tested in the L-T direction (see Alloy 1 and 3). Only a very small increase in fracture toughness can be found when adding zirconium instead of cerium to the alloy. The shown strength increase was expected for the addition of 0.11% of zirconium. Alloys 1, 2 and 3 have a somewhat lower strength and fracture toughness than standard 6056 and 6013 alloy, which is to a large extent due to a significantly lower copper content in the aluminium alloys tested. When the TS/Rp-ratio is plotted against the yield strength, see FIG. 1 , it can be seen that the addition of even small amounts of cerium results in a significant increase in the balance between fracture toughness and yield strength, which increase is a desirable property for various applications, in particular in aerospace constructions. [0083] From the results of Table 4 it can be seen that the addition of cerium in accordance with the invention has no significant influence on the performance against intergranular corrosion compared to aluminium alloy products having an almost similar chemical composition apart from the cerium addition while being in the same temper. However, the performance of Alloy no. 3 against intergranular corrosion is significantly better compared to standard 6056 and 6013 alloy products, whereas Alloy no. 3 has a yield strength and a TS/Rp-ratio close to the results of standard 6056 and 6013 alloy products in the same temper. It is believed that an increase of the Ti-content to for example 0.1 wt. % in the aluminium alloy product according to the invention would result in a reduction of the maximum intergranular corrosion depth. Furthermore, it is believed that optimising the T6 temper ageing treatment would also result in an improved resistance against intergranular corrosion. [0084] Having now described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made without departing from the spirit or scope of the invention as herein described. TABLE 1 Chemical composition of the alloys tested. Alloy Si Fe Cu Mn Mg Zn Ti Zr Ce 1 1.13 0.16 0.51 0.62 0.69 0.16 0.01 — — (comp) 2 1.20 0.18 0.52 0.72 0.69 0.15 0.04 0.11 — (comp) 3 1.17 0.16 0.48 0.67 0.69 0.15 0.01 — 0.03 (inv.) stan- 0.92 0.15 0.90 0.46 0.88 0.08 0.02 — — dard 6056 stan- 0.79 0.17 0.96 0.35 0.90 0.09 0.03 — — dard 6013 [0085] TABLE 2 Tensile properties in the L-direction in T6-temper sheet material. Alloy Rp [MPa] Rm [MPa] A50 [%] 1 330 358 8.5 2 336 364 7.0 3 361 379 6.5 standard 6056 362 398 12 standard 6013 369 398 9 [0086] TABLE 3 Fracture toughness results in the L-T direction. Alloy L-T TS [MPa] UPE [kJ] TS/Rp 1 552 207 1.67 2 564 208 1.68 3 595 211 1.65 standard 6056 590 215 1.66 standard 6013 593 184 1.66 [0087] TABLE 4 ICG corrosion results in the T6-temper. Alloy Depth of max. [μm] 1 137 2 127 3 (inv.) 134 standard 6056 190 standard 6013 190
The invention relates to a weldable, high-strength aluminium alloy wrought product, which may be in the form of a rolled, extruded or forged form, containing the elements, in weight percent, Si 0.8 to 1.3, Cu 0.2 to 1.0, Mn 0.5 to 1.1, Mg 0.45 to 1.0, Ce 0.01 to 0.25, and preferably added in the form of a Misch Metal, Fe 0.01 to 0.3, Zr<0.25, Cr<0.25, Zn<1.4, Ti<0.25, V<0.25, others each<0.05 and total<0.15, balance aluminium. The invention relates also to a method of manufacturing such an aluminium alloy product.
2
This application is a division of application Ser. No. 09/639,938, filed Aug. 17, 2000, now U.S. Pat. No. 6,599,874, which is a Division of application Ser. No. 08/793,047, filed Jul. 24, 1997, now abandoned, which is a 371 of PCT/SE94/00742, filed Aug. 16, 1994. DESCRIPTION Technical Field The present invention relates to a novel antibacterial protein and compositions, in the form of pharmaceutical compositions, human food compositions, and animal feedstuffs comprising said protein to be used in the therapeutic and/or prophylactic treatment of infections caused by bacteria, in particular Streptococcus pneumoniae and/or Haemophilus influenzae as well as a method for diagnosing infections caused by said bacteria. The object of the present invention is to obtain a protein and compositions containing said protein for prophylactic and/or therapeutic treatment of infections caused by bacteria, in particular Streptococcus pneumoniae and Haemophilus influenzae in the upper airways, ear-nose-and-throat infections, but also in the lower airways, e.g., the lungs by preventing adhesion of and/or causing a bactericidal effect on these bacteria. A further object is to be able to diagnose infections caused by these bacteria. BACKGROUND OF THE INVENTION Natural antimicrobial compounds exist in secreted form as well as in cells of immune and non-immune origin. Human milk has been used as a source for the purification of such compounds. These previously known compounds include specific antibodies to the micro-organism surface structure, casein, lysozyme, and oligosaccharides. The mechanism of action differs between the groups of antimicrobial molecules. Antibodies and receptor analogues prevent micro-organism adherence to mucosal surfaces. Lysozyme attacks the cell wall etc. The term bacterial adherence denotes the binding of bacteria to mucosal surfaces. This mechanic association is a means for the organism to resist elimination by the body fluids, and to establish a population at the site where relevant receptors are expressed. In most cases where the mechanisms of attachment have been identified it is a specific process. The bacterial ligands, commonly called adhesins bind to host receptors. For Gram-negative bacteria, the adhesins are commonly associated with pili or fimbriae, rigid surface organelles that help bacteria to reach the appropriate receptor in the complex cell surface. The fimbriae function as lectins, i.e. they show specificity for receptor epitopes provided by the oligosaccharide sequences in host glyco-conjugates (13). For Gram-positive bacteria, on the other hand, the adhesins are not expressed as a surface organell, but rather linked to cell wall components and lipoteichoic acids (21, 22). The receptor epitopes for Gram positive bacteria may consist of oligosaccharide sequences but can also be provided by peptides e.g. in connective tissue proteins (10). The functional consequences of adherence depend on the virulence of the bacterial strain, and on the form of the receptor. When cell-associated, the ligand receptor interaction facilitates colonization and tissue attack (8). When secreted the receptor molecule will occupy the adhesins, and competitively inhibit attachment to the corresponding cell-bound receptor. Human milk is a rich source of such competing soluble receptor molecules. The ability of specific antibodies to inhibit attachment is well established. This was first demonstrated for Vibrio cholera and oral streptococci. The anti-adhesive antibodies may act in either of two ways: 1) Antibodies to the receptor binding sites of the adhesin competitively inhibit receptor interaction or 2) antibodies to bacterial surface molecules which are not directly involved in adherence may agglutinate the bacteria and thereby reduce the number of organisms available for binding. In either of the above cases the anti-adhesive activity of the antibody is attributed to the specificity of the antigen-combining site. Recently an alternative mechanism of interaction between secretory IgA and E. coli based on lectin-carbohydrate interactions was identified. Human milk drastically inhibits the attachment of Streptococcus pneumoniae and Haemophilus influenzae to human nasopharyngeal epithelial cells. It contains antibodies to numerous surface antigens on these organisms. e.g., the phosphoryl choline and capsular polysaccharides of S. pneumoniae , the lipopolysaccharide and outer membrane proteins of H. influenzae . Accordingly, some of the anti-adhesive activity in milk resides in the immunoglobulin fraction. The remaining anti-adhesive activity in the non-immunoglobulin is fraction of milk may be explained by two types of molecules: free oligosaccharides and glycoproteins in the casein fraction. Human milk is unique with regard to its content of complex carbohydrates. The free oligosaccharide fraction of milk is dominated by the lactoseries and with improving methods of isolation and characterization of carbohydrates more than 130 oligosaccharides containing up to 20 monosaccharides per molecule have been identified. An anti-adhesive activity against S. pneumoniae in a low molecular weight fraction (<5 kDa) of milk was explained by the free oligosaccharides. In contrast there was no such effect against H. influenzae (15). An anti-adhesive activity of high molecular weight components of milk was localized to the casein fraction. Human casein drastically reduced the adherence both of S. pneumoniae and H. influenzae (15). This effect was species specific. Alpha-lactalbumin is a mettaloprotein, which shows some degree of heterogeneity depending on Ca(II) saturation and/or glycosylation (1). Alpha-lactalbumin acts as a specifier protein in the lactose synthase system. During lactation, alpha-lactalbumin is formed in the mammary gland and it alters the substrate specificity of the galactosyltransferase enzyme from N-acetyl glucosamine (GlcNAc) to glucose (Glc), enabling lactose synthesis to take place: Multiple forms of bovine, pig, sheep and goat alpha-lactalbumin have been isolated and well characterized (2, 3). These multiple forms differ in a few amino residues or the number of disulphide bonds (4, 5) but are all active in the lactose synthase system. The physiological relevance or functions of these different forms of alpha-lactalbumin are not known. Alpha-lactalbumin has undergone a high rate of evolutionary change and it shows homology with lysozyme (1). These two proteins are thought to originate from the same ancestral protein. Whereas lysozyme is known as an anti-bacterial agent, alpha-lactalbumin has not yet been found to have antibacterial functions. SUMMARY OF THE INVENTION The present invention describes the identification of a new anti-bacterial protein or group of proteins from milk. The protein comprises a multimeric form of alpha-lactalbumin. In the following this protein, or group of proteins, is abbreviated ALLP, Anti-adhesive. Lactalbumin Like Protein. The term antimicrobial or anti-bacterial protein used in the context of the present invention means here and in the following a protein which inhibits adherence of micro-organisms to tissue and/or exerts a bactericidal effect an microorganisms. Further characteristics of the invention will be evident from the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 . The ion-exchange fractionation profile of casein ( FIG. 1A ) and commercial human alpha-lactalbumin ( FIG. 1B ). The arrow represents the time point at which 1 M NaCl was applied. FIG. 2 . Gel chromatographic fractionation profiles of pool VI obtained from fractionation of case in ( FIG. 2A ) and human alpha-lactalbumin before ion-exchange chromatography ( FIG. 2B ). FIG. 3 . Ion-exchange fractionation profile of pool LA 2 obtained after ion-exchange chromatography of alpha-lactalbumin. FIG. 4 . Mass spectrometry of ALLP. DETAILED DESCRIPTION OF THE INVENTION. The present invention will be described more in detail with reference to the example given below. Experimental Purification of the Active Anti-Adhesive and Bactericidal Protein (ALLP) Milk samples from lactating women were screened for anti-adhesive activity against S. pneumoniae and H. influenzae . About 50 l of breast milk with high anti-adhesive activity was collected from one healthy donor and used for the purification of ALLP. About 5 l of milk was thawed at a time and centrifuged to remove fat. Casein was prepared from the defatted milk by acid precipitation at pH 4.6. ALLP was purified as outlined below: (i) Ion-Exchange Chromatography of Casein. Casein was fractionated using an ion-exchange column (14 cm×1.5 cm) packed with DEAE-Tris-acryl M (LKB, Sweden) attached to an FPLC (Pharmacia, Sweden) using a NaCl gradient: 100 mg of the lyophilized casein was dissolved in 10 ml of 0.01 M Tris-HCl, pH 8.5. After centrifugation, the sample was directly applied to the column and the run was under the following conditions: buffer A: 0.01 M Tris-HCl, pH 8.5; Buffer B: buffer A containing 1 M NaCl/l. Gradient program: from 0–3 ml 100% A, from 3–60 ml 15% B; from 60–85 ml 25% B; from 85–87 ml 100% B; from 87–89 ml 100% B for 2 min; from 89–120 ml 100% A. The gradient was not linear, but was interrupted at the elution of each peak for better separation. Flow rate: 1 ml/min, recorder 0.2 cm/min. The buffers were degassed and filtered through a 0.22 um filter before use. The peaks were monitored at 280 nm and the fraction size was 3 ml. Fractions were pooled as shown ( FIG. 1A ). The pools (I–VI) were then desalted by dialysis (membrane cut off 3.5 kD) against distilled water for at least 48 hrs, lyophilized and tested for anti-adhesive activity. (ii) Gel Chromatography of Pool VI 100 mg of the active pool VI obtained after repeated FPLC fractionations of casein, were dissolved in 7 ml 0.06 M sodium phosphate buffer, pH 7.0 and applied to a Sephadex R G-50 (Pharmacia, Sweden) column (93 cm×2.5 cm). Flow rate was 30 ml/hr, peaks were monitored at 280 nm, 3 ml fractions were collected and pooled as shown ( FIG. 2A ). The pools were desalted by dialysis, lyophilized, tested for composition and for anti-adhesive activity. Ion-exchange chromatography of commercial alpha-lactalbumin. 20 mg of commercial (Sigma) human or bovine alpha-lactalbumin were dissolved in 2 ml 0.01 M Tris-HCl, pH 8.5. The ion-exchange chromatography of alpha-lactalbumin was under similar conditions as described above for the fractionation of casein. The NaCl gradient was linear (not interrupted), flow rate was 1 ml/min, 3 ml fractions were collected and pooled as shown in FIG. 1B . The pools were dialysed. (membrane cut-off 3.5 kD), lyophilized, resuspended to the required concentration and tested for anti-adhesive activity. Gel Chromatography of Commercial Alpha-Lactalbumin Approximately 8–10 mg of commercial human or bovine alpha-lactalbumin (Sigma) were dissolved in 3 ml 0.06 M sodium phosphate buffer, pH 7.0 and fractionated on the Sephadex R G-50 column as described above. Flow rate was 30 ml/hr, peaks were monitored at 280 nm, 3 ml fractions were collected and pooled as shown ( FIG. 2B ). The pools were desalted by dialysis (membrane cut-off 3.5 kD) against distilled water for at least, 48 hrs, lyophilized, tested for composition and for anti-adhesive activity. 6–8 mg retained of the material retained and eluting after 1 M NaCl during ion-exchange chromatography of alpha-lactalbumin were dissolved in 5 ml 0.06 M sodium phosphate buffer pH 70 and subjected to gel chromatography on the G-50 column as described above. 3 ml fractions were collected and pooled ( FIG. 3 ). The pools were desalted, lyophilized, and tested for anti-adhesive activity. Polyacrylamide Gradient Gel Electrophoresis (PAGGE). Analytical PAGGE was performed using 4–20%-polyacrylamide pre-cast gels (Bio-Rad, Richmond, Calif.) on a Bio-Rad Mini Protean II cell. To 10/ul (5–10 mg/ml) each of the lyophilized fractions, an equal volume of sample buffer (13.1% 0.5 M Tris-HCl, pH 6.8, 10.5% glycerol, 1.2% SDS and 0.05% bromophenol blue) was added. 20/ul of each was then loaded on to the gel which was run in Tris-glycine buffer (pH 83) with 0.1% SDS at 200V constant voltage for about 40 min. Staining of the proteins was made by immersing the gel in Coomassie Blue solution (0.1% in 40% methanol; 10% acetic acid) for about 0.5 hr. Destaining was by several changes ire 40% methanol, 10% acetic acid until a clear background was obtained. Ion Desorption Mass Spectrometry ALLP and commercial alpha-lactalbumin were analyzed by ion-desorption mass spectrometry. Bacteria S. pneumoniae (CCUG3114 and 10175) and H. influenzae (Hi198) were used throughout the experiments. These strains were known to adhere well to human nasopharyngal epithelial cells in vitro. These strains were initially isolated from the nasopharynx of children with frequent episodes of acute otitis media. The strains were kept lyophilized and were transferred to blood agar (10175) or Levinthal medium agar plates (Hi 198) S. pneumoniae was cultured for 9 hrs at 37° C. in liquid medium (17), harvested by centrifugation and suspended in 1 ml of 0.9% NaCl with 1% choline H. influenzae Hi198 was cultured for 4 hrs in haemophilus medium (18), harvested by centrifugation and suspended in phosphate-buffer saline, (PBS). Adhesion Inhibition Adhesion and inhibition of adhesion was tested as previously described (15, 19). In brief, epithelial cells from the oropharynx of healthy donors ( 10 5 /ml) were mixed with the bacterial suspensions (10 9 /ml). After incubation of bacteria and epithelial cells, unbound bacteria were eliminated by repeated cycles of centrifugation and resuspension in NaCl with 1% choline (10175) or PES (Hi 198). The inhibitory activity of the different fractions was tested by preincubation with bacteria for, 30 min at 37° C. prior to addition of epithelial cells. The number of epithelial cells attached was counted with the aid of an interference contrast microscope (Ortolux II microscope with interference contrast equipment TE Leitz, Wetzlar). Adherence was given as the mean number of bacteria/cell for 40 epithelial cells. Inhibition was given in percent of the value of the buffer control. Results Properties of ALLP ALLP was purified from human milk by fractionation of casein by ion-exchange chromatography and fractionantion of the pool eluting after 1 M NaCl by gel chromatography. The ion-exchange fractionation profile of casein is shown in FIG. 1A . Eluted fractions were pooled as indicated and tested for anti-adhesive activity. Pool VI retained the anti-adhesive activity of casein; this pool inhibited the attachment of S. pneumoniae and H. influenzae by more than 80% of the control (Table 3). The remaining fractions were inactive and were not analyzed further. Pool VI was fractionated by gel chromatography on the Sephadex R G-50 column. The fractionation profile showed two distinct well separated peaks ( FIG. 2A ). Eluted fractions were pooled as shown, desalted, and tested for anti-adhesive activity. Pool K retained 98% of the anti-adhesive activity against S. pneumoniae and 91% of the activity against H. influenzae . Pool L was inactive (Table 3). Analytical PAGGE of pool K showed the presence of bands in the 14–15 kD region, one band in the 30 kD region, and two bands stained in the 100 kD region. Pool L showed the presence of only one band in the 14–15 kD region ( FIG. 2A , inset). The N-terminal amino acid sequence analysis showed that the bands of pool K were similar and were identical to the N-terminal sequence of human alpha-lactalbumin. The active anti-adhesive protein in pool K was designated as Anti-adhesive Lactalbumin Like Protein (ALLP). ALLP reduced attachment of both S. pneumoniae and H. influenzae by about 60% at a concentration of 1 mg/ml Mass Spectrometry of ALLP The results from analytical PAGGE suggested that ALLP might occur in a multimeric form. By ion laser desorption mass spectrometry. ALLP showed three distinct mass fragments (1, 2 and 3) at 14128.7 m/z, 28470.5 m/z and 42787.8 m/z, respectively ( FIG. 4 ). These fragments agreed with the monomeric (14 m/z), dimeric (28 m/z) and trimeric (42 m/z) mass ranges of the protein. Comparison of ALLP and Commercial Alpha-Lactalbumin When tested for anti-adhesive activity, commercial alpha-lactalbumin did not inhibit the adherence of S. pneumoniae or H. influenzae even at a concentration of 10 mg/ml (Table 4). ALLP showed stained bands in the 14–15 kD, 30 kD and the 100 kD regions, whereas the commercial alpha-lactalbumin stained only one band in the 14–15 kD region. The N-terminal amino acid sequence of ALLP showed complete homology with the sequence of human alpha-lactalbumin. The lack of anti-adhesive activity of commercial alpha-lactalbumin, as compared to ALLP, might be due to a difference in their molecular forms. Therefore commercial human aloha-lactalbumin was subjected to ion laser desorption mass spectrometry. The spectrum showed only one mass fragment at 14128.7 m/z corresponding to the monomeric form of alpha-lactalbumin (calculated molecular mass=14.079 kD). Thus commercial human alpha-lactalbumin was in the monomeric form and lacked anti-adhesive activity, whereas, ALLP was found to be multimeric and inhibited the attachment of S. pneumoniae and H. influenzae to human oropharyngeal cells in vitro. Ion-Exchange Chromatography of Human Alpha-Lactalbumin In order to test the effect of ion exchange chromatography on the anti-adhesive effect of commercial human alpha-lactalbumin, 20 mg of the commercial sample was applied onto the Tris-acryl column. The ion-exchange profile is shown in FIG. 1B . About 50% of the material applied was retained on the column and eluted after the application of 1 M NaCl (arrow, FIG. 1B ). The different fractions were pooled as shown. After desalting and lyophilization the fractions were reconstituted to a concentration of about 5–10 mg/ml and tested for anti-adhesive activity. Anti-Adhesive Effect of Human Alpha-Lactalbumin after Ion-Exchange Chromatography Before ion-exchange chromatography commercial human alpha-lactalbumin lacked anti-adhesive activity (Table 4). After it was subjected to ion-exchange chromatography, the pool which was retained and eluted with 1 M NaCl (pool LA 2 , FIG. 1B ) inhibited the attachment of both S. pneumoniae and H. influenzae by more than 95% of the value of the control (Table 4). The other pool (LA 1 ) obtained was inactive. Gel Chromatography of Human Alpha-Lactalbumin before and after Ion-Exchange Chromatography Since about 50% of the commercial human alpha-lactalbumin had become active after ion-exchange chromatography it was decided to check the mobility of the alpha-lactalbumin and pool LA 2 on gel chromatography. The G-50 gel chromatographic profile of human alpha-lactalbumin before ion-exchange chromatography is shown in FIG. 2B . The alpha-lactalbumin eluted as a single peak, which gave a single band (14–15 kD) on PAGGE analysis (inset, FIG. 2B ). This pool LA was found to be inactive when tested for anti-adhesive activity (Table 4). The gel chromatographic profile of the active pool LA 2 , obtained after ion-exchange chromatography of alpha-lactalbumin is shown in FIG. 3 . This pool eluted as two well separated peaks (1 and 2, FIG. 3 ) corresponding to the eluting volumes of peaks K and L of the casein ( FIG. 2A ). When tested for anti-adhesive activity pool 1 retained the activity against both S. pneumoniae and H. influenzae , whereas pool 2 was inactive (Table 4). When pool 1 was analysed by analytical PAGGE a pattern similar to that of ALLP was obtained, bands stained at 14–15 kD region, 30 kD region, and two bands at 100 kD region. Pool 2 gave a single band at the 14–15 kD region, corresponding to monomeric alpha-lactalbumin (inset, FIG. 3 ). Properties of Commercial Bovine Alpha-Lactalbumin. Since commercial human alpha-lactalbumin could be converted to the active multimeric form by ion-exchange chromatography it was decided to test the activity of bovine alpha-lactalbumin and to test its mobility on ion-exchange and gel chromatography. When tested for anti-adhesive activity, bovine alpha-lactalbumin was found to be inactive in inhibiting the attachment of S. pneumoniae and H. influenzae (Table 5). 20 mg of bovine alpha-lactalbumin were subjected to ion-exchange chromatography under similar conditions described above for human alpha-lactalbumin. 50% of the material applied to the column was retained and eluted after 1 M NaCl. The elution pattern was similar to that obtained for human alpha-lactalbumin ( FIG. 1B ). Pool BL 2 of bovine alpha-lactalbumin, corresponding to the elution volume of pool LA 2 of human alpha-lactalbumin ( FIG. 1B ) inhibited the attachment of S. pneumoniae by more than 95% and of H. influenzae by more than 80% of the value of the control (Table 5). When subjected to gel chromatography on the G-50 column as described above, bovine alpha-lactalbumin eluted as a single peak corresponding to the elution volume of human alpha-lactalbumin ( FIG. 2B ). In contrast, the material in pool BL 2 resolved into two distinct peaks corresponding to pools 1 and 2 obtained for human alpha-lactalbumin ( FIG. 3 ). The pool eluting just after the void volume of the column (corresponding to pool 1) retained the anti-adhesive activity, whereas, the other pool was inactive. The active pool had a PAGGE pattern similar to that of ALLP, whereas, the inactive pool stained only one band in the 14–15 kD region. Thus a portion of the commercial bovine alpha-lactalbumin was also converted to the active multimeric form by ion-exchange chromatography. Bactericidal Effect The present ALLP was tested with regard to bactericidal effect on different strains of S. pneumoniae being known to be resistant to antibiotics, and some other strains of Streptococcus, E. coli, H. influenzae and M. cath. Thereby the different bacterial strains were inoculated onto growth plates after incubation with ALLP in different concentrations. The viable counts (CFU) were determined at inoculation, 0.5 h, 2 h, and 4 h (hours), respectively after inoculation. Table 1 below shows the viable counts after incubation to a medium containing 10 mg/ml of ALLP compared with the control. TABLE 1 Viable counts (CFU) on S. pneumoniae strains after exposure to ALLP. Strain Viable counts (CFU) designation 0 h 0.5 h 2 h 4 h 10175 control 2 × 10 6 1 × 10 6 1 × 10 5 1 × 10 4 ALLP 2 × 10 5 — — — 15006-92 control 1 × 10 4 2 × 10 4 1 × 10 3 — ALLP 2 × 10 4 — — — 14060-92 control 2 × 10 6 1 × 10 5 1 × 10 4 — ALLP 2 × 10 5 — — — 15256-92 control 1 × 10 6 2 × 10 6 2 × 10 5 4 × 10 4 ALLP 2 × 10 6 — — — 14326-92 control 4 × 10 5 2 × 10 5 2 × 10 4 2 × 10 3 ALLP 7 × 10 4 — — — Prag 1828 control 5 × 10 6 2 × 10 6 5 × 10 5 — ALLP 5 × 10 6 — — — 14091-92 control 3 × 10 5 5 × 10 5 1 × 10 5 — ALLP 7 × 10 5 — — — 14117-92 control 2 × 10 6 2 × 10 6 2 × 10 6 — ALLP 2 × 10 6 — — — 14612-92 control 3 × 10 5 1 × 10 5 2 × 10 4 1 × 10 3 ALLP 3 × 10 4 — — — Dk 84/87 control 1 × 10 7 5 × 10 6 2 × 10 6 6 × 10 4 ALLP 3 × 10 5 — — — 14007-92 control 1 × 10 5 5 × 10 4 4 × 10 3 — ALLP 1 × 10 5 — — — 14030-92 control 5 × 10 6 2 × 10 6 2 × 10 5 — ALLP 5 × 10 6 2 × 10 1 — — 14423-92 control 6 × 10 5 6 × 10 6 1 × 10 6 6 × 10 5 ALLP 2 × 10 5 3 × 10 1 — — 4502-93 control 4 × 10 5 — — — ALLP 5 × 10 4 — — — SA44165 control 2 × 10 5 5 × 10 3 — — ALLP 3 × 10 5 — — — 1017-92 control 1 × 10 6 5 × 10 5 4 × 10 3 — ALLP 9 × 10 5 — —. — 317-93 control 4 × 10 4 1 × 10 4 5 × 10 3 — ALLP 2 × 10 3 — — — 760-92 control 2 × 10 7 2 × 10 6 1 × 10 4 1 × 10 4 ALLP 8 × 10 6 — — — Hun 859 control 6 × 10 5 3 × 10 5 2 × 10 5 2 × 10 5 ALLP 3 × 10 5 — — — Hun 963 control 1 × 10 7 4 × 10 6 1 × 10 5 — ALLP 5 × 10 6 — — — BN 241 control 4 × 10 6 5 × 10 4 2 × 10 4 — ALLP 2 × 10 5 — — — TABLE 2 Viable counts (CFU) on different bacterial species Strain Viable counts (CFU) designation 0 h 0.5 h 2 h 4 h S. mitis control 1 × 10 6 10 × 10 6   2 × 10 5 1 × 10 5 116 ALLP 1 × 10 6 — — — S. sanguis control 5 × 10 7 3 × 10 7 4 × 10 7 5 × 10 6 197 ALLP 3 × 10 7 2 × 10 5 2 × 10 2 — E. coli control 6 × 10 6 5 × 10 6 3 × 10 6 3 × 10 6 60 ALLP 7 × 10 6 5 × 10 6 1 × 10 7 2 × 10 7 4 control 5 × 10 6 5 × 10 6 5 × 10 6 7 × 10 6 ALLP 5 × 10 6 6 × 10 6 1 × 10 7 2 × 10 7 H. influenzae control 4 × 10 7 1 × 10 7 4 × 10 6 2 × 10 5 21594 ALLP 3 × 10 7 4 × 10 5 <1 × 10 3    <1 × 10 3    21300 control 4 × 10 7 2 × 10 7 5 × 10 6 3 × 10 5 ALLP 4 × 10 7 2 × 10 6 2 × 10 4 2 × 10 3 M. cath. control 4 × 10 5 3 × 10 5 5 × 10 4 2 × 10 4 71257 C+ ALLP 3 × 10 5 2 × 10 5 3 × 10 3 — 71295 C+ control 2 × 10 7 1 × 10 7 3 × 10 6 6 × 10 5 ALLP 2 × 10 7 5 × 10 6 2 × 10 6 3 × 10 5 C+ = beta-lactamase producing A dose response curve was made up based on the bactericidal effect on S. pneumoniae 10175 at different levels of administration of ALLP compared with control (no addition). thereby ALLP was administered at 0.1 mg/ml, 0.5 mg/ml, and 1.0 mg/ml, respectively. As little as 0.1 mg/ml of ALLP provides a bactericidal effect on S. pneumoniae. The viable counts were further determined using different control proteins, viz. bovine serum albumine (BSA), aiphalactal-bumine (bovine origin), lactoferrin (bovine origin) in a concentration of 10 mg/ml, and control (no protein). These proteins had no bactericidal effect on S. pneumoniae 10175. A new form of alpha-lactalbumin (ALLP) with anti-adhesive activity and bactericidal effect against the respiratory tract pathogens S. pneumoniae and H. influenzae was thus isolated and characterized from a human milk sample. Commercial human or bovine alpha-lactalbumin lacked anti-adhesive activity in the assay system. A portion of the commercial human and bovine alpha-lactalbumin was converted to active form by ion exchange chromatography. The active and non-active forms of alpha-lactalbumin showed different mobilities on gel chromatography and their staining patterns on gel electrophoresis were also different. By ion-desorption mass spectrometry analysis, ALLP was found to be in the trimeric form, whereas commercial alpha-lactalbumin was monomeric. The activated forms of commercial human and bovine alpha-lactalbumin showed gel pattern similar to the trimeric form. A portion of the monomeric form of alpha-lactalbumin was separated from the multimeric form and was found to be inactive in inhibiting the adherence of both S. pneumoniae and H. influenzae . The three forms of alpha-lactalbumin (mono, di and tri) existed in some sort of equilibrium after ion-exchange chromatography and could not successfully be separated from each other. This proposes that the active anti-adhesive alpha-lactalbumin (ALLP) is a multimeric form not previously identified in human milk. The identification of ALLP in a previous case in preparation was a result of its purification being monitored by the biological activity (16). It retained all of the anti-adhesive activity of casein and thus could be followed during the purification procedures. This form of alpha-lactalbumin has not previously been disclosed to be present in human milk. The early studies of the present inventors showed that the anti-adhesive effect of human milk against S. pneumoniae and H. influenzae was independent from the specific antibody activity and was concentrated in a casein fraction (15). Casein was, however, found to have both a bactericidal effect and an anti-adhesive effect. A bactericidal effect was present and was found to be more pronounced against S. pneumoniae than H. influenzae . The anti-adhesive activity remained intact after removal of the fatty acids from casein. The mechanism of adhesion inhibition of ALLP was found to be independent from its carbohydrate content. Carbohydrate analysis of ALLP showed the presence of only one monosaccharide unit associated with the molecule. Removal of this monosaccharide unit by glucosidase treatment did not alter the anti-adhesive effect of ALLP. Also since the commercial forms of human and bovine alpha-lactalbumin could be activated by ion-exchange chromatography, it is very unlikely that the carbohydrate play any role in the anti-adhesive or bactericidal effect of ALLP tested by the biological analysis system. Being predominantly a whey protein, alpha-lactalbumin is usually purified from the alpha-lactalbumin rich fractions of whey. Since the monomeric form and the multimeric forms have different mobilities on gel chromatography, the active multimeric forms are lost during the purification procedures. It is thus not surprising that the commercial preparations of alpha-lactalbumin lacked anti-adhesive properties in the present system. Genetic variants of alpha-lactalbumin have been isolated from milk of other mammals including bovine. Most of these forms consist of four disulphide bonds and a form of bovine alpha-lactalbumin with three disulphide bonds have also been isolated (5). The physiological role of these different forms of alpha-lactalbumin is not known. The present data demonstrate that the monomeric alpha-lactalbumin completely lacked biological activity in the present system. Aggregation and polymerization may therefore be an important event in the anti-adhesive activity of ALLP against S. pneumoniae and H. influenzae. The present data demonstrate that the multimeric alpha-lactalbumin is active in adhesion inhibition of the respiratory tract pathogens and can thus play a role in the protection against respiratory and gastro-intestinal infections. It is also active as a bactericide on at least S. pneumoniae , even those being resistant to antibiotics. Comments S. pneumoniae and H. influenzae are important causes of morbidity and mortality in all age groups. Respiratory tract infections, e.g., meningitis, otitis, and sinusitis are caused by bacteria which enter via the nasopharynx. Colonization at that site may thus be an important determinant of disease (18). The finding that a specific alpha-lactalbumin derived from human as well as bovine milk inhibits attachment of both species opens the possibility to prevent colonization by specific interference of attachment using these structures. The bactericidal effect is hereby of importance as well. The importance of the antimicrobial molecules is shown by the protection against infections which is seen in breast-fed babies. Breast-fed babies have a reduced frequency of diarrhoea, upper respiratory tract infections and acute otitis media (AOM). The bacterial species discussed in this application are the most frequent bacterial causes of AOM, viz. Haemophilus influenzae and Streptococcus pneumoniae. As evident from the data shown the alpha-lactalbumin obtained from the human or bovine milk inhibits the attachment of S. pneumoniae and H influenzae to human respiratory tract epithelial cells in vitro. TABLE 3 Bacterial adhesion to oropharyngeal cells after incubation with active human milk, casein, and casein fractions obtained after ion-exchange chromatography on DEAE-Trisacryl Adhesion S. pneumoniae H. influenzae Sample Mean (%) Mean (%) Saline control 150 (100) 200 (100) Human milk 25 (17) 70 (35) Casein 4 (3) 10 (5)  Pool VI 14 (9)  22 (11) Pool K 3 (2) 17 (9)  Pool L 159 (100) 178 (89)  TABLE 4 Bacterial adhesion to oropharyngeal cells after incubation with human alpha-lactalbumin and the fractions obtained after ion-exchange chromatography and gel chromatography. Adhesion S. pneumoniae H. influenzae Sample Mean (%) Mean (%) Saline control  138 (100)  130 (100) Human alpha-lactalbumin 124 (90) 110 (85) Pool LA 2  4 (3)  9 (7) Pool LA 123 (93)  76 (58) TABLE 5 Bacterial adhesion to oropharyngeal cells after incubation with bovine alpha-lactalbumin and the fractions obtained after ion-exchange chromatography and gel chromatography. Adhesion S. pneumoniae H. influenzae Sample Mean (%) Mean (%) Saline control 138 (100) 130 (100) Bovine alpha-lactalbumin 130 (94)  99 (76) Pool BL 2 3 (2) 18 (14) Applications The alpha-lactalbumin of the present invention can be administered in the form of an oral mucosal dosage unit, an injectable composition, or a topical composition. In any case the protein is normally administered together with commonly known carriers, fillers and/or expedients, which are pharmaceutically acceptable. In case the protein is administered in the form of a solution for topical use the solution contains an emulsifying agent for the protein together with an diluent which can be sprayed into the nasopharynx, or can be inhaled in the form of a mist into the upper respiratory airways. In oral use the protein is normally administered together with a carrier, which may be a solid, semi-solid or liquid diluent or a capsule. These pharmaceutical preparations are a further object of the present invention. Usually the amount of active compound is between 0.1 to 99% by weight of the preparation, preferably between 0.5 to 20% by weight in preparations for injection and between 2 and 50% by weight in preparations for oral administration. In pharmaceutical preparations containing a protein of the present invention in the form of dosage units for oral administration the compound may be mixed with a solid, pulverulent carrier, as e.g. with lactose, saccharose, sorbitol, mannitol, starch, such as potatoe starch, corn starch, amylopectin, cellulose derivatives or gelatine, as well as with an antifriction agent such as magnesium stearate, calcium stearate, polyethylene glycol waxes or the like, and be pressed into tablets. Multiple-unit-dosage granules can be prepared as well. Tablets and granules of the above cores can be coated with concentrated solutions of sugar, etc. The cores can also be coated with polymers which change the dissolution rate in the gastrointestinal tract, such as anionic polymers having a pk a of above 5.5. Such polymers are hydroxypropylmethyl cellulose phtalate, cellulose acetate phtalate, and polymers sold under the trade mark Eudragit S100 and L100. In the preparation of gelatine capsules these can be soft or hard. In the former case the active compound is mixed with an oil, and the latter case the multiple-unit-dosage granules are filled therein. Liquid preparations for oral administration can be present in the form of syrups or suspensions, e.g., solutions containing from about 0.2% by weight to about 20% by weight of the active compound disclosed, and glycerol and propylene glycol. If desired, such preparations can contain colouring agents, flavouring agents, saccharine, and carboxymethyl cellulose as a thickening agent. The daily dose of the active compound varies and is dependent on the type of administrative route, but as a general rule it is 1 to 100 mg/dose of active compound at peroral administration, and 2 to 200 mg/dose in topical administration. The number of applications per 24 hrs depend of the administration route, but may vary, e.g. in the case of a topical application in the nose from 3 to 8 times per 24 hrs, i.a., depending on the flow of phlegm produced by the body treated in therapeutic use. In prophylactic use the number may be on the lower side of the range given. The topical form can preferably be used in prophylactic treatment, preferably in connection with an infection caused by a rhinitis virus. The protein can also be used as an additive in infant food, particularly for prophylactic reasons, in order to supply the casein in an easy way to the child. Infants normally reject pharmaceuticals for different reasons. The food product can thus be in the form of a pulverulent porridge base, gruel base, milk substitute base, or more complex food product as of the Scotch collops type, comprising vegetables and meat pieces, often in disintegrated form. In the case of protein administration to animals they are normally added to the feedstuffs, which besides the protein contains commonly used nutrients. In accordance with a further aspect of the invention there is provided a process for determining the presence of S. pneumococci and H. influenzae in a sample taken from the respiratory tract of an animal or human. This process is based on the technique of determining the degree of interaction between the bacteria of the sample and a composition of the present invention. Such interaction may be determined by inhibition or induction or the adherence of the bacteria to cells or other surfaces. REFERENCES 1. McKenzie, H. A., White, F. H. Jr Adv. Protein Chem. 41:173, 1991 2. Hopper, K. E. and McKenzie, H. A. Biochim. Biophys. Acta 295:352, 1973 3. Schmidt, D. V. and Ebner, K. E. Biochim. Biophys. Acta 263:714, 1972 4. Maynard, F. J. Dairy Res. 59:425, 1992 5. Barman, T. E. Eur J. Biochim. 37:86, 1973 6. Readhead, K., Hill, T. and Mulloy, B. FEMS Microbiol Lett. 70:269, 1990 7. Gilin, F. D., Reiner, D. S. and Wang, C. S. Science 221:1290, 1983 8. Fiat, A.-M., and Jolles, P. Mol. Cell Biochem. 87:5, 1989 9. Matthews, T. H. J., Nair, C. D. G., Lawrence, M. K. and Tyrrell, D. A. J. Lancet, December, 25:1387, 1976 10. Andersson, B., Dahmén, J., Frejd, T., Leffler, H., Magnusson, G., Noori, G., and Svanborg, C., J. Exp. Med., 158:559, 1983 11. Svanborg, C., Aniansson, G., Mestecky, J., Sabharwal, H., and Wold, A. In Immunology of milk and the neonate, J. Mestecky ed. Plenum Press, New York, 1991 12. Svanborg-Edén, C. and Svennerholm, A.-M., Infect. Immun. 22:790, 1978 13. In Microbial lectins and agglutinins, properties and biological activity, Mirelman, D., Wiley, New York, 1986 14. Andersson, B., Porras, D., Hansson, L. {dot over (A)}., Lagerg{dot over (a)}rd, T. and Svanborg-Edén, C. J. Infect. Dis. 153:232, 1986 15. Aniansson, G., Andersson, B., Lindstedt, R., and Svanborg, C., Microbial Pathogenesis 8, 365, 1990 16. Sabharwal, H., Hansson, C., Nilsson, A. K., Saraf, A., Lönnerdahl, B., and Svanborg, C. 1993, submitted 17. Lacks, S., and Hotchiss, R. D. Biochim. Biophys. Acta, 38:508, 1960 18. Branefors-Helander, P. Acta Pathol. Microbiol. Immunol. Scand. (B), 80:211, 1972 19. Porras, O., Svanborg Edén, C., Lagerg{dot over (a)}rd, T., and Hansson, L. {dot over (A)}. Eur. J. Clin. Microbiol., 4, 310–15, 1985 20. Vanaman, T. C., Brew, K., and Hill, R. L. J. Biol. Chem. 245:4583, 1970 21. Beachey, E. H., J. Infect. Dis. 143, 325, 1981 22. Andersson, B., Beachey, E. H., Tomasz, A., Tuomanen, E., and Svanborg, C., Microbial Pathogenesis, 4, 267, 1988 23. Andersson, B., Eriksson, B., Falsén, E., et al Infect. Immun. 32, 311–17, 1981
The present invention relates to the use of alpha-lactalbumin in the preparation of preparations to be used in therapeutic or prophylactic treatment and/or for diagnostic use for infections, preferably of the respiratory tract, caused by bacteria, in particular S. pneumoniae and/or H. influenzae . The present invention further relates to essentially pure protein complexes comprising alpha-lactalbumin and the use of these protein complexes for therapeutically or prophylactically treating a bacterial infection, especially infections of the respiratory tract caused by S. pneumoniae and/or H. influenzae.
0
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to phase-lock loop systems and more particularly to phase-lock loop systems for frequency stabilizers. 2. Description of the Related Art Phase-lock loops (PLLs) find applications in a wide variety of devices including wireless communication systems, disk drive electronics, high speed digital circuits and instrumentation. A PLL is simply a servo system that controls the phase of an output signal so that the phase error between the output signal and a reference input signal are reduced to a minimum. PLL circuits include at a minimum a phase/frequency detector (PFD) and a voltage control oscillator (VCO). It is also common for these circuits to contain a charge pump which is used to convert the logic states of the PFD into analog signals suitable for controlling the VCO. Such circuits are known as charge-pump phase-lock loops. Charge-pump PPL's are commonly used to lock a local oscillating signal to a carrier frequency so that the carrier frequency can be removed, leaving an information signal of interest. Many of the devices which utilize charge-pump phase-lock loop systems operate in the microwave (900 MHZ-30 GHz) or millimeter wave (30-300 GHz) portion of the electromagnetic spectrum. As shown in FIG. 1, a prior art charge-pump PPL circuit 20 includes a VCO 22, which may be implemented as an LC tank circuit and which develops a local oscillating signal that is locked to a remotely received carrier signal. Both the local signal (whose frequency may be divided by a factor N) and the remote signal are applied to a PFD 24 which compares their phases and frequencies. The phase/frequency difference between the two signals results in a voltage output which is received by a charge pump 26. The charge pump, otherwise known as a transresistance amplifier, converts the voltage signal into a current signal which is provided to a fixed capacitor 28. The capacitor integrates the current, producing an output voltage which is supplied to the VCO to adjust the local signal. A low pass filter 30 is often utilized to remove unwanted harmonics generated by charge pump 26. The filter is commonly placed in the circuit prior to the VCO. The circuit may additionally contain a divider 32 between the VCO and the PFD to reduce the frequency of the local signal generated by the VCO. As the capacitance of capacitor 28 is fixed, the designer must make an initial decision as to its size. If a large capacitor is selected, integration is slow but the system finds the carrier signal much faster then it would with a small capacitor. This is primarily due to limited over- and under-shoot. However, the larger capacitor may lack sensitivity to accurately lock onto the carrier signal. A smaller capacitor, on the other hand, results in a more accurate lock onto the carrier signal but the process is much slower. This is primarily due to the large number of over- and under-shoots. However, a small capacitor permits a more accurate lock onto the carrier signal. Alternately, a conventional variable capacitor can be utilized. However, conventional variable capacitors only slightly improve the situation in that their tunability is only on the order of 2:1. These capacitors are also quite large in size and their tuning quite slow. Other smaller variable capacitors have been used, but they too had limited tunability range. See Darrin J. Young and Bernhard E. Boser, "A Micromachined Variable Capacitor for Monolithic Low-Noise VCOS," Technical Digest of the 1996 Solid-State Sensor and Actuator Workshop, Hilton Head, S.C., pp. 86-89. SUMMARY OF THE INVENTION In view of the above problems, the present invention provides a charge-pump phase-lock loop circuit that more rapidly and with greater precision determines the phase and frequency of a carrier signal so that it can be extracted, to obtain an information signal of interest. This is achieved by the use of a Micro Electro-Mechanical Systems (MEMS) adjustable capacitance device. The MEMS capacitance device could be a single tunable MEMS capacitor, a series of tunable MEMS capacitors, or a MEMS switched capacitor bank. Such MEMS devices have the added advantage of providing low insertion losses, higher isolation, high reliability, and linear capacitance. They run on low power and permit the entire circuit to be fabricated on a common substrate. Using the large tunability range of the MEMS device, an initial large capacitance is preferably set. The capacitance is reduced to rapidly converge the local signal to the carrier signal. This permits rapid and accurate lock of the local signal to the carrier signal. The use of MEMS tunable capacitance devices prevents large over- and under-shoots of the local signal in locking onto the carrier signal, thereby reducing unwanted harmonics generated by the charge pump and allowing the filtering requirements of the low pass filter to be relaxed and perhaps eliminated. Further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of a prior art charge-pump PPL circuit using a conventional fixed or variable capacitor; FIG. 2 is a block diagram of a new circuit in accordance with the invention utilizing a MEMS variable capacitance device; FIG. 3 is perspective view of a master-slave configuration for a tunable MEMS capacitor used in one embodiment; FIGS. 4a and 5a are plan views showing sequential steps in the integration of a MEMS tunable capacitor into a charge-pump PPL circuit; FIGS. 4b and 5b are sectional views taken along sectional lines 4b-4b and 5b-5b of FIGS. 4a and 4b, respectively; and FIG. 5c is a sectional view taken along section line 5c-5c of FIG. 5a depicting the raised bridge structure of the tunable MEMS capacitor. DETAILED DESCRIPTION OF THE INVENTION The invention uses a MEMS capacitance device, preferably a tunable MEMS capacitor or a MEMS capacitor bank, to implement a frequency synthesizer which not only has a better capacitance range then that provided by conventional fixed or adjustable capacitors, but can be monolithically integrated. The MEMS capacitor provides linear capacitance with low insertion losses, higher isolation, higher reliability, and requires less power since the device is operated by electrostatic force. FIG. 2 shows a block diagram of one implementation of the circuit. The objective is to match a locally generated signal to the carrier portion of a remotely generated signal at an input terminal 36 to remove the carrier signal and obtain its modulated information signal. The preferred embodiment shown in FIG. 2 is similar to the charge-pump PPL circuit 20 of FIG. 1, but a MEMS variable capacitor 38 is used. The frequency of the MEMS capacitor is preset to establish an initial input to the phase detector 24 with a frequency equal to the carrier signal to be received at input terminal 36. The MEMS tunable capacitor 38 integrates the current output from the charge pump 26 to determine how far off in frequency and in phase the VCO generated signal is from the carrier signal. The capacitance of capacitor 38 can be controlled either remotely or preferably by an output from charge pump 26. This can be handled in one of several fashions, with either the charge pump suppling a voltage signal to the master side of the MEMS capacitor, as described below, or by the use of a look up table that would provide a feedback signal to MEMS capacitor based on an initial signal received from charge pump 26. The MEMS capacitor is tunable over a range of approximately 10 to 1, or more. This allows for a large capacitance to be initially set, followed by a rapid reduction in capacitance to accurately match and remove the carrier signal. This approach not only provides for a rapid determination of the carrier signal, but also permits the signal to be accurately defined. In conventional circuits, the capacitance is normally fixed at a relatively large value in order to help assure that the locally generated signal approximates the carrier signal. This results in charge pump 26 producing a relatively large ΔI with an accompanying high level of detrimental harmonics, requiring the presence of a low pass filter 30 to remove them. The use of a MEMS capacitor 38 provides the unexpected advantage of allowing low pass filter 30 to be removed or at least be a less sophisticated, lower cost filter than is conventionally used. This is due to the fact that, for most of the circuit's operation, capacitor 38 has a small capacitance as the carrier signal is being honed in on. This results in a small ΔV being produced by phase detector 24, and likewise a small ΔI being produced by charge pump 26. As the current produced by charge pump 26 is quite small the unwanted harmonics generated by pump 26 also lessen. The filter 30 can therefore either be a less sophisticated filter, or preferably removed. FIG. 3 is a perspective view of the MEMS tunable capacitor 38 shown in FIG. 2. The capacitor 38 comprises a master-slave capacitor structure fabricated on a common substrate 40, preferably silicon. A master (control) capacitor 42 responds to a control voltage to set the capacitance of the slave (signal) capacitor 44. The capacitors 42 and 44 have respective contact 46M and 46S mounted to substrate 60, with respective sets of flat parallel fingers 48M and 48S extending from contact 46M and 46S parallel to and elevated above the substrate surface, with the flat fingers surfaces vertical. Capacitors 42 and 44 include respective second pairs of contacts 50aM, 50bM, and 50aS, 50bS with bridge structures 52M and 52S respectively connecting the two contact pairs. Bridges 52M and 52S carry respective second sets of flat fingers 54M and 54S which are substantially parallel and interdigitated with fingers 48m and 48S. Bridges 52M and 52S and their associated fingers 54M and 54S form a series of movable capacitor plates 56M and 56S and are connected to each other by a mechanical coupler 58. In the master-slave configuration, a signal voltage V sig (typically an RF signal in the MHZ to Ghz frequency range) is applied via contacts 46S and 50aS, 50bS across fingers 48s and 54s. A low frequency control voltage V c is applied across fingers 48M and 54M to produce an electrostatic force that attracts its movable capacitor plate 56M toward contact 46M causing a change in the capacitance of capacitor 44. The interdigitated configuration is preferred because it can be designed so that the force is independent of the displacement in the x direction. This is achieved by spacing the fingers evenly so that the force between them cancel and the fringing forces at the ends of the fingers in the z-direction dominate. The master and slave capacitors 42 and 44 respectively, are oriented so that the electrostatic force produced by the signal voltage is orthogonal to the motion of movable plate 56M of master capacitor 42 in the Z direction. In order to make the direction of force on the slave capacitor 44 perpendicular to the direction of motion so that the spring constant can be low in the direction of motion and high in the direction of force, the interdigitated fingers 48M, 48S and 54M, 54S are offset so that they are a symmetric. The force between the fingers dominates the much smaller fringing force such that the lateral spring constant can be relatively small thereby providing a large range of motion and a correspondingly large tuning ratio, presumably on the order of 10:1 or more. The invention can be implemented with a variety of substrate materials requiring several active device types. A monolithic microwave integrated circuit (MMIC is an I.C. in which microwave frequency active devices are integrated with passive components to perform a specific circuit function). A key advantage presented by the invention is the ability to integrate a series of microwave frequency active devices and their associated passive components (referred to herein as "MMIC components"), with a MEMS tunable capacitor on a common substrate, using MMIC fabrication processes. MMIC fabrication techniques are well known, and are discussed, for example, in C. T. Wang, Introduction to Semiconductor Technology, John Willy and Sons (1990), pp. 187-195 (active devices) and pp. 422-433 (passive components). When fabricating a conventional MMIC, the active devices are fabricated using MMIC fabrication processes, followed by the fabrication of the passive components and the concurrent deposition and patterning of metal interconnecting runs ("runs") which connect the circuit elements together. The invention utilizes the processing steps that create the runs to concurrently fabricate the preferred MEMS tunable capacitor and to interconnect the capacitor with the other circuitry. Plan views of a fabrication sequence showing the integration of an active device in a MEMS tunable capacitor are shown in FIGS. 4a and 5a and corresponding sectional views are shown in FIGS. 4b, 5b taken across section lines 4b--4b and 5b--5b respectively. FIG. 5c is a sectional view taken across section 5c--5c of FIG. 5a showing the free-standing capacitor structure. The steps described and shown are intended only to illustrate the process sequence, they're not intended to depict the implementation of a particular function or frequency synthesizer. However, the process of simultaneously building up both the MEMs tunable capacitor and the interconnecting runs shown in FIGS. 4a, 4b, 5a, 5b and 5c may be extended as necessary to produce functional circuits. FIGS. 4a and 5a fit one implementation of a MEMS tunable capacitor 38 shown in FIG. 2, integrated into a charge-pump phase-lock loop circuit 20 fabricated on a single crystal silicone substrate 60. Voltage control oscillator 22, phase detector 24, charge pump 26, low pass filter 30 and divider 32 are shown schematically fabricated on substrate 60, by known methods. Phase detector 24 furthermore has a series of pads 62 and 64 which the circuit receives and provides signals respectively. There are many possible ways of fabricating the MEMS tunable capacitor 38. One way is to use a silicon on insulator (SOI) wafer structure where the top silicon will be used as the capacitors structural material. A photo resist is first patterned forming contacts 46M, 46S, 50aM, 50aS, 50bM, 50bS and fingers 48M, 48S, 54M, 54S and bridges 52M and 52S. The pattern is then transferred to the top silicon 60 using reactive ion etching with an anisotropic sidewall profile that stops at a silicon dioxide layer 66 pattern on substrate 60. Next, a layer of Si 3 N 4 , suitably 0.5 to 2.0 microns thick to provide sufficient rigidity in the x-direction is patterned on the wafer to form mechanical coupler 58 that rigidly couples bridges 52M and 52S. Lastly, the wafer is subjected to a hydrofluoric acid (wet) etch to partially remove the underlying silicon dioxide layer 66, leaving the large structures still in tact with substrate 60 while the small geometry structures are free standing, as shown in FIG. 5c. Because all of the structure are formed in the top silicon, the control and signal capacitors are not, at this point, electrically isolated. Therefore, a deposition layer 68, suitably aluminum, covers the structure, specifically the capacitors fingers, to increase the conductivity of the master and slave capacitors with respect to the mechanical coupler 58 so that they are electrically isolated. The discontinuity between coupler 58 and bridges 52M and 52S create a discontinuity in the deposition layer that provides isolation. Additional details on the fabrication and use of the preferred MEMS tunable capacitor described above can be found in co-pending U.S. application Ser. No. 08/848,116 to Bartlett, et al. assigned to the same assignee as the present application and hereby incorporated by reference. For the reasons noted above, it is preferred that circuit be fabricated together on a common substrate. However it is not essential that the invention be implemented this way. For example, MEMS capacitor 38 could be fabricated on a separate substrate and interconnected to the remainder of the circuit via wire bonds. This approach permits the MEMS device and the remainder of the circuit to be fabricated using different substrate materials and processing steps. Though the integration of a MEMS tunable capacitor 38 and the series of active and passive devices of circuit was illustrated with a silicon substrate 60, other combinations of substrates are similarly contemplated. In an alternate embodiment of the charge-pump phase-lock loop circuit, the MEMS tunable capacitor 38 can be replaced by a series of MEMS tunable capacitors which can be individually controlled by the circuit itself or by an external device. In a second alternate embodiment, the MEMS tunable capacitor 38 can be replaced by a MEMS switched capacitor bank. Additional details on the fabrication and use of the MEMS switched capacitor bank can be found in co-pending U.S. application Ser. No. 08/848,116 to Bartlett, et al. assigned to the same assignee as the present application and hereby incorporated by reference. While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations in alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims.
A frequency stabilizer circuit in the form of a charge-pump phase-lock loop utilizing a MEMS capacitance device, preferably a tunable MEMS capacitor or a MEMS capacitor bank, which more rapid and with a greater precision determine the phase and frequency of a carrier signal so that it can be extracted, providing an information signal of interest. Such MEMS devices have the added advantage of providing linear capacitance, low insertion losses, higher isolation and high reliability, they run on low power and permit the entire circuit to be fabricated on a common substrate. The use of the MEMS capacitance device reduces unwanted harmonics generated by the circuit's charge pump allowing the filtering requirements to be relaxed or perhaps eliminated.
7
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS This application is an application claiming the benefit under 35 USC 119(e) of U.S. Application No. 60/599,283, filed Aug. 5, 2004, incorporated herein by reference in its entirety. FIELD OF THE INVENTION The present invention relates generally to correction codes in communication systems. More particularly, the present invention relates to the use of correction codes for reliably conveying information through channels having random events. BACKGROUND OF THE INVENTION Modern communication systems use Forward Error Correction (FEC) codes in an attempt to convey information more reliably through channels with random events. One such FEC error control system uses low density parity check (LDPC) codes. LDPC codes can have error correcting capabilities that rival the performance of “Turbo-Codes” and can be applicable over a wide range of statistical channels. In fact, some random irregular LDPC constructions based upon edge ensemble designs have error correcting capabilities measured in Bit Error Rate (BER) that are within 0.05 dB of the rate-distorted Shannon limit. Unfortunately, these LPDC code constructions often require long codeword constructions (on the order of 10 6 to 10 7 bits) in order to achieve these error rates. Despite good BER performance, these random code constructions often have poor Block Error Rate (BLER) performances. Therefore, these random constructions typically do not lend themselves well to packet-based communication systems. Another disadvantage of random constructions based on edge distribution ensembles is that, for each codeword length, a separate random construction is needed. Thus, communication systems employing variable block sizes (e.g. TCP/IP systems) require multiple code definitions. Such multiple code definitions can consume a significant amount of non-volatile memory for large combinations of codeword lengths and code rates. As an alternative to random LDPC constructions, structured LDPC constructions typically rely on a general algorithmic approach to constructing LDPC matrices which often requires much less non-volatile memory than random constructions. One such structured approach is based upon array codes. This approach can exhibit improved error performance (both BER and BLER performance) and a relatively low error floor for relatively high code rates (higher than 0.85). However, for code rates below 0.85, these code constructions have relatively poor performance with respect to irregular random constructions designed for lower code rates. One reason for this poor performance can be that their constructions are typically based on code ensembles that have poor asymptotic performances despite being an irregular construction. One challenge therefore is to design irregular structured LDPC codes that have good overall error performance for a wide range of code rates with attractive storage requirements. Such resulting LDPC codes would provide a better performing communication system with lower cost terminals. These factors can make such FEC attractive for applications over a wide range of products, including but not limited to, wireless LAN systems, next generation cellular systems, and ultra wide band systems. SUMMARY OF THE INVENTION Embodiments of the present invention provides for an irregularly structured LDPC code ensemble that has strong overall error performance and attractive storage requirements for a large set of codeword lengths. Embodiments of the invention offer communication systems with better performance and lower terminal costs due to the reduction in mandatory non-volatile memory over conventional systems. In contrast to conventional approaches, embodiments of the invention provide a structured approach to construction, offering reduced storage requirements and a simple construction. When used with seed matrices with good asymptotic performances and good girth properties, the irregularly structured LDPC codes used in embodiments of the present invention offer an improved overall level of error performance. Embodiments of the invention also offer a parity-check matrix that is lower in density than conventional array codes because there are fewer non-zero sub-matrices (i.e. there are more sub-matrices consisting of the all zeros matrix). These and other objects, advantages and features of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an overview diagram of a system within which embodiments of the invention may be implemented; FIG. 2 is a perspective view of a mobile telephone that can be used in the implementation of one embodiment the present invention; FIG. 3 is a schematic representation of the telephone circuitry of the mobile telephone of FIG. 2 ; FIG. 4 is a flow chart showing the implementation of one embodiment of the present invention; FIG. 5 is an example of a code rate 1/2 irregular parity-check matrix according to one embodiment of the present invention; FIG. 6 is an example of a code rate 2/3 irregular parity-check matrix according to one embodiment of the present invention; and FIG. 7 is an example of a code rate 3/4 irregular parity-check matrix according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Various exemplary embodiments of the invention are described below with reference to the drawing figures. One embodiment of the invention can be described in the general context of method steps, which may be implemented in one embodiment by a program product including computer-executable instructions, such as program code, executed by computers in networked environments. Embodiments of the invention may be implemented in either hardware or software, and can be placed both within a transmitter and/or a receiver. FIG. 1 shows a system 10 illustrating one embodiment of the invention, comprising multiple communication devices that can communicate through a network. The system 10 may comprise any combination of wired or wireless networks including, but not limited to, a mobile telephone network, a wireless Local Area Network (LAN), a Bluetooth personal area network, an Ethernet LAN, a token ring LAN, a wide area network, the Internet, etc. The system 10 may include both wired and wireless communication devices. For exemplification, the system 10 shown in FIG. 1 can include a mobile telephone network 11 and the Internet 28 . Connectivity to the Internet 28 may include, but is not limited to, long range wireless connections, short range wireless connections, and various wired connections including, but not limited to, telephone lines, cable lines, power lines, and the like. Exemplary communication devices of the system 10 may include, but are not limited to, a mobile telephone 12 , a combination PDA and mobile telephone 14 , a PDA 16 , an integrated messaging device (IND) 18 , a desktop computer 20 , and a notebook computer 22 . The communication devices may be stationary or mobile as when carried by an individual who is moving. The communication devices may also be located in a mode of transportation including, but not limited to, an automobile, a truck, a taxi, a bus, a boat, an airplane, a bicycle, a motorcycle, etc. Some or all of the communication devices may send and receive calls and messages and communicate with service providers through a wireless connection 25 to a base station 24 . The base station 24 may be connected to a network server 26 that allows communication between the mobile telephone network 11 and the Internet 28 . The system 10 may include additional communication devices and communication devices of different types. A communication device may communicate using various media including, but not limited to, radio, infrared, laser, cable connection, and the like. One such portable electronic device incorporating a wide variety of features is shown in FIG. 4 . This particular embodiment may serves as both a video gaming device and a portable telephone. The communication devices may communicate using various transmission technologies including, but not limited to, Code Division Multiple Access (CDMA), Global System for Mobile Communications (GSM), Universal Mobile Telecommunications System (UMTS), Time Division Multiple Access (TDMA), Frequency Division Multiple Access (FDMA), Transmission Control Protocol/Internet Protocol (TCP/IP), Short Messaging Service (SMS), Multimedia Messaging Service (MMS), e-mail, Instant Messaging Service (IMS), Bluetooth, IEEE 802.11, etc. FIGS. 2 and 3 show one representative mobile telephone 12 within which one embodiment of the present invention may be implemented. It should be understood, however, that the present invention is not intended to be limited to one particular type of mobile telephone 12 or other electronic device. The mobile telephone 12 of FIGS. 2 and 3 comprises a housing 30 , a display 32 in the form of a liquid crystal display, a keypad 34 , a microphone 36 , an ear-piece 38 , a battery 40 , an infrared port 42 , an antenna 44 , a smart card 46 in the form of a universal integrated circuit card (UICC) according to one embodiment of the invention, a card reader 48 , radio interface circuitry 52 , codec circuitry 54 , a controller 56 and a memory 58 . Generally, program modules can include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of program code for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps. Software and web implementations of the present invention could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various database searching steps, correlation steps, comparison steps and decision steps. It should also be noted that the words “component” and “module” as used herein, and in the claims, are intended to encompass implementations using one or more lines of software code, and/or hardware implementations, and/or equipment for receiving manual inputs. By taking into account the density evolution of messages passed in belief propagation decoding, random constructions of irregular LDPC codes can be developed that approach Shannon limits for an assortment of channels (e.g. Additive White Gaussian Noise (AWGN), Binary Erasure Channel (BEC), Binary Symmetric Channel (BSC)). These are typically described as ensembles with variable and check edge polynomials λ ⁡ ( x ) = ∑ i = 2 d l ⁢ λ i ⁢ x i - 1 and ρ ⁡ ( x ) = ∑ j = 2 d r ⁢ ρ j ⁢ x j - 1 , respectively, where λ i and ρ j are the fraction of total edges connected to variable and check nodes of degree i=2,3, . . . , d l and j=2,3, . . . , d l respectively. These random constructions sometimes require the relatively long codeword lengths to approach the capacity limit and do not always provide the strong BLER performance required by packet-based communication systems. In actual communication terminals, these random constructions can require storage of the entire parity-check matrix, and for systems employing variable packet-length, the storage of multiple random constructions is both necessary and costly. Alternatively, structured approaches to LDPC code designs that allow for reduced storage requirements and simple code description may be used. One such example is the LDPC code construction based upon array constructions. For code rates 0.85 and above, these code constructions can have acceptable performance with good error floors and BLERs. However, with respect to random constructions, these constructions sometimes suffer at lower code rates because they have edge distributions that result in relatively poor asymptotic performance and thus poor performance in general. It is desirable thus, to provide irregularly structured LDPC codes that have good overall error performance for a wide range of code rates with attractive storage requirements that make communication terminals cost effective. The result of such LDPC codes can do a better performing communication system with lower cost terminals. These factors can make such a FEC attractive for applications over a wide range of products including but not limited to wireless LAN, next generation cellular systems, and ultra wide band systems. As discussed herein, an irregular “seed” parity-check matrix can be used as the “seed” for irregular structured LDPC code some embodiments according to the present invention. One embodiment invention involves the construction of an irregular “seed” low-density parity check-matrix H SEED of dimension ((N SEED −K SEED )×N SEED ) derived from an edge distribution, λ SEED (x) and ρ SEED (x), with good asymptotic performance and good girth properties. In one embodiment, good asymptotic performance may be characterized by a good threshold value using belief propagation decoding and good girth may be characterized by having very few if no variable nodes with a girth of 4. This can be accomplished manually or via a software program once given the code ensemble and/or node degrees. Although there are no limits on the maximum values of K SEED and N SEED , which represent the number of information bits and the resulting codeword length, respectively in one embodiment, for the code defined by H SEED , these values can be relatively small in comparison to the target message-word and codeword length. This can allow for more potential integer multiples of N SEED within the target range of codeword lengths, reduced storage requirements, and simplified code descriptions. In one embodiment of the invention, the smallest possible value for H SEED can be used with edge distributions defined by λ SEED (x) and ρ SEED (x), while still maintaining good girth properties. One function of the seed matrix can be to identify the location and type of sub-matrices in the expanded LDPC parity-check matrix H constructed from H SEED and a given set of permutation matrices. The permutation matrices in H SEED can determine the location of sub-matrices in the expanded matrix H that contain a permutation matrix of dimension (N SPREAD ×N SPREAD ) from the given set. One selection within the given set of permutation matrices is defined below. As an example only, the given set of permutation matrices used herein can be finite and consist of the set {P SPREAD ∞ , P SPREAD 0 , P SPREAD 1 , P SPREAD 2 , . . . , P SPREAD p-1 } where p is a positive integer (a prime number in a preferred embodiment of the invention), P SPREAD 0 =I is the identity matrix, P SPREAD 1 is a full-rank permutation matrix, P SPREAD 2 =P SPREAD 1 P SPREAD 1 , etc. up to P SPREAD p−1 . One example embodiment of P SPREAD 1 is a single circular shift mutation matrix P SPREAD 1 = [ 0 1 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 1 1 0 0 0 0 ] ⁢ ⁢ for ⁢ ⁢ N SPREAD = 5 Another example embodiment of P SPREAD 1 is an alternate single circular shift permutation matrix P SPREAD 1 = [ 0 0 0 0 1 1 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 1 0 ] ⁢ ⁢ for ⁢ ⁢ N SPREAD = 5. For notational sake, P SPREAD ∞ denotes the all zeros matrix 0 of dimension (N SPREAD ×N SPREAD ) (i.e. P SPREAD ∞ =0 where every element is a zero), and the zeros in H SEED indicate the location of the sub-matrix P SPREAD ∞ =0 in the expanded matrix H. Thus, the expanded LDPC matrix H can be of dimension (N SPREAD (N SEED −K SEED )×N SPREAD N SEED ) with sub-matrices consisting of permutation matrices of dimension (N SPREAD ×N SPREAD ) raised to an exponential power from the set of {0,1, . . . , p−1, ∞}. Furthermore, the expanded LDPC code can have the same edge distribution as H SEED and hence can achieve the desired asymptotic performance described by λ SEED (x) and ρ SEED (x), provided both H SEED and the expanded matrix H have satisfactory girth properties. The following description concerns one embodiment of the invention that constructs a structured array exponent matrix that may be described as E ARRAY = [ E 1 , 1 E 1 , 2 … E 1 , p E 2 , 1 E 2 , 2 … E 2 , p ⋮ ⋮ ⋰ ⋮ E p , 1 E p , 2 … E p , p ] , where ⁢ ⁢ E i , j = ( i - 1 ) ⁢ ( j - 1 ) ⁢ ⁢ mod ⁢ ⁢ p using modulo arithmetic (but not limited to) of a number p. In one embodiment of the invention, p can be a prime number, but this is not necessary for the principles of the present invention. p can be at least the column dimension of the irregular “seed” parity check matrix and the column dimension of the spreading permutation matrix. In one embodiment, N SEED ≦p and N SPREAD ≦p. However, other values are also possible. Other embodiments of the present invention can use transformed versions of E ARRAY . In particular, one such transformation involves the shifting of rows to construct an upper triangular matrix while replacing vacated element locations with ∞, i.e. E SHIFT = [ E 1 , 1 E 1 , 2 E 1 , 3 … E 1 , p ∞ E 2 , 1 E 2 , 2 … E 2 , p - 1 ∞ ∞ E 3 , 1 … E 3 , p - 2 ⋮ ⋮ ⋮ ⋰ ⋮ ∞ ∞ ∞ … E p , 1 ] . Another embodiment of the present invention transforms E ARRAY by the truncation of columns and/or rows to select a sub-matrix of E ARRAY for implementation with a specified H SEED . Still another embodiment of the invention uses the combination of both shifting and truncation. For example, given N SEED +1≦p and N SPREAD ≦p (with p being a prime number in a particular embodiment of the invention) E TRUNCATE ⁢ ⁢ 1 = [ E 1 , 2 E 1 , 3 E 1 , 4 … E 1 , ( N SEED - K SEED ) … E 1 , ( N SEED + 1 ) E 2 , 1 E 2 , 2 E 2 , 3 … E 2 , ( N SEED - K SEED - 1 ) … E 2 , N SEED ∞ E 3 , 1 E 3 , 2 … E 3 , ( N SEED - K SEED - 2 ) … E 3 , ( N SEED - 1 ) ⋮ ⋮ ⋰ ⋰ ⋮ ⋰ ⋮ ∞ ∞ ∞ … E ( N SEED - K SEED ) , 1 … E ( N SEED - K SEED ) , ( K SEED + 2 ) ] For N SEED +2≦p and N SPREAD ≦p (with p being a prime number in a particular embodiment of the invention) E TRUNCATE ⁢ ⁢ 2 = [ E 2 , 2 E 2 , 3 E 2 , 4 … E 2 , ( N SEED - K SEED ) … E 2 , ( N SEED + 1 ) E 3 , 1 E 3 , 2 E 3 , 3 … E 3 , ( N SEED - K SEED - 1 ) … E 3 , N SEED ∞ E 4 , 1 E 4 , 2 … E 4 , ( N SEED - K SEED - 2 ) … E 4 , ( N SEED - 1 ) ⋮ ⋮ ⋰ ⋰ ⋮ ⋰ ⋮ ∞ ∞ ∞ … E ( N SEED - K SEED + 1 ) , 1 … E ( N SEED - K SEED + 1 ) , ( K SEED + 2 ) ] . Many shift and truncate embodiments can be used with the present invention, as well as column and row permutation transformations performed either prior to or after other individual transformations in a nested fashion. More generally, the transformation of the E ARRAY matrix can be described using the functional notation T(E ARRAY ) that represents a transformed exponent matrix of dimension ((N SEED −K SEED )×N SEED ). Yet another embodiment of this family of transformations may include an identity transformation. For example, in another embodiment of the invention, T(E ARRAY )=E ARRAY . In one embodiment of the present invention H SEED and T(E ARRAY ) can be used to construct the final exponent matrix in order to expand the seed matrix into H. The final exponent matrix may be defined as F FINAL = [ F 1 , 1 F 1 , 2 … F 1 , N SEED F 2 , 1 F 2 , 2 … F 2 , N SEED ⋮ ⋮ ⋰ ⋮ F ( N SEED - K SEED ) , 1 F ( N SEED - K SEED ) , 2 … F ( N SEED - K SEED ) , N SEED ] of dimension ((N SEED −K SEED )×N SEED ) by replacing each one in H SEED with the corresponding matrix element (i.e. the same row and column) in the transformed structured array exponent matrix T(E ARRAY ) and each zero in H SEED with ∞. Thus, the elements of F FINAL can belong to the set {0,1, . . . , p−1, ∞} if modulo arithmetic is used in the construction of E ARRAY . The following is a discussion of one embodiment of the expansion of H SEED using F FINAL to construct a final LDPC parity-check matrix H that describes the LDPC code. The matrix H SEED of dimension ((N SEED −K SEED )×N SEED ) can be spread or expanded using the elements of the permutation matrix set { P SPREAD ∞ , P SPREAD 0 , P SPREAD 1 , P SPREAD 2 , . . . , P SPREAD p-1 } with elements of dimension (N SPREAD ×N SPREAD ), where P SPREAD ∞ =0 is the all zeros matrix, P SPREAD 0 =I is the identity matrix, P SPREAD 1 is a permutation matrix, P SPREAD 2 =P SPREAD 1 P SPREAD 1 , P SPREAD 3 =P SPREAD 1 P SPREAD 1 P SPREAD 1 , etc.(but not limited to) to construct H = [ P SPREAD F 1 , 1 P SPREAD F 1 , 2 … P SPREAD F 1 , N SEED P SPREAD F 2 , 1 P SPREAD F 2 , 2 … P SPREAD F 2 , N SEED ⋮ ⋮ ⋰ ⋮ P SPREAD F ( N SEED - K SEED ) , 1 P SPREAD F ( N SEED - K SEED ) , 2 … P SPREAD F ( N SEED - K SEED ) , N SEED ] of dimension (N SPREAD (N SEED −K SEED )×N SPREAD N SEED ). Thus, this embodiment of the present invention can be used to describe an expanded LDPC code with sub-matrices of dimension (N SPREAD ×N SPREAD ) in the (i,j) th sub-matrix location consisting of the permutation matrix P SPREAD raised to the F i,j power (i.e. P SPREAD F i,j ). The following is one particular example of the implementation of one embodiment of the present invention. In this example, H SEED = [ 1 0 0 1 0 0 1 1 0 1 1 0 0 1 1 0 0 1 0 0 1 0 1 1 ] , thus ⁢ ⁢ N SEED = 6 , while P SPREAD 1 = [ 0 0 1 1 0 0 0 1 0 ] , thus ⁢ ⁢ N SPREAD = 3 , Therefore, p=11 is the smallest prime number that satisfies the example conditions N SEED +2 ≦p and N SPREAD ≦p. The interim and final exponent matrices as defined above can be: E TRUNCATE ⁢ ⁢ 2 = [ 1 2 3 4 5 6 0 2 4 6 8 10 ∞ 0 3 6 9 1 ∞ ∞ 0 4 8 1 ] ⁢ ⁢ and F = [ 1 ∞ ∞ 4 ∞ ∞ 0 2 ∞ 6 8 ∞ ∞ 0 3 ∞ ∞ 1 ∞ ∞ 0 ∞ 8 1 ] , and the corresponding expanded LDPC matrix can be: H = [ 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 1 0 0 0 1 0 0 0 0 0 1 0 0 0 1 0 0 0 0 1 0 0 0 1 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 1 0 ] . One embodiment of a method for constructing irregularly structured LDPC codes according to the present invention is depicted in FIG. 4 . At step 100 , an irregular “seed” parity check matrix H SEED of dimension ((N SEED −K SEED )×N SEED ) can be constructed, being derived from an edge ensemble, λ SEED (x) and ρ SEED (x), with good asymptotic performance. In one embodiment, good asymptotic performance can be characterized by good threshold value using belief propagation decoding and good girth properties such as by having very few if no variable nodes with girth of 4. At step 110 , a structured array exponent matrix can be constructed, as shown below: E ARRAY = [ E 1 , 1 E 1 , 2 ⋯ E 1 , p E 2 , 1 E 2 , 2 ⋯ E 2 , p ⋮ ⋮ ⋰ ⋮ E p , 1 E p , 2 ⋯ E p , p ] ⁢ ⁢ where ⁢ ⁢ E i , j = ( i - 1 ) ⁢ ( j - 1 ) ⁢ ⁢ mod ⁢ ⁢ p This matrix can be constructed using modulo arithmetic of a number p that can be at least the column dimension of the irregular “seed” parity check matrix and the column dimension of the spreading permutation matrix. In other words, N SEED ≦p and N SPREAD ≦p. At step 120 , the structured array exponent matrix can be transformed using a transform T(E ARRAY ) that may perform shifts, truncations, permutations, etc. operations to construct an exponent matrix of dimension ((N SEED −K SEED )×N SEED ) from E ARRAY . At step 130 , a final exponential matrix can be constructed, F FINAL = [ F 1 , 1 F 1 , 2 ⋯ F 1 , N SEED F 2 , 1 F 2 , 2 ⋯ F 2 , N SEED ⋮ ⋮ ⋰ ⋮ F ( N SEED - K SEED ) , 1 F ( N SEED - K SEED ) , 2 ⋯ F ( N SEED - K SEED ) , N SEED ] of dimension ((N SEED −K SEED )×N SEED ) by replacing each one in H SEED with the corresponding element in the transformed structured array exponent matrix T(E ARRAY ) and each zero in H SEED with ∞. Thus, the elements of F FINAL belong to the set {0,1, . . . , p−1, ∞}. At step 140 , the expanded parity check matrix can be constructed, H = [ P SPREAD F 1 , 1 P SPREAD F 1 , 2 ⋯ P SPREAD F 1 , N SEED P SPREAD F 2 , 1 P SPREAD F 2 , 2 ⋯ P SPREAD F 2 , N SEED ⋮ ⋮ ⋰ ⋮ P SPREAD F ( N SEED - K SEED ) , 1 P SPREAD F ( N SEED - K SEED ) , 2 ⋯ P SPREAD F ( N SEED - K SEED ) , N SEED ] of dimension (N SPREAD (N SEED −K SEED )×N SPREAD N SEED ) that describes the expanded LDPC code with sub-matrices of dimension (N SPREAD ×N SPREAD ) in the (i,j) th sub-matrix location consisting of the permutation matrix P SPREAD raised to the F i,j power, i.e. P SPREAD F i,j , where F i,j is the matrix element in the (i,j) th location of F FINAL . FIG. 5 is an example of one embodiment of a rate 1/2 irregular parity-check matrix. FIG. 6 is an example of one embodiment of a rate 2/3 irregular parity-check matrix. FIG. 7 is an example of one embodiment of a rate 3/4 irregular parity-check matrix. 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.
An error correction codeword. In one embodiment, an irregularly structured LDPC code ensemble possessing strong overall error performance and attractive storage requirements for a large set of codeword lengths. Embodiments of the invention can offer communication systems with better performance and lower terminal costs due to possible reductions in mandatory non-volatile memory over conventional systems.
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BACKGROUND 1. Field of the Invention The present invention relates generally to the field of holography. More particularly, the present invention relates to systems and methods for shearless digital hologram acquisition system suitable for use with “white light” (spectrally broadband) or laser illumination, or two-color illumination. For two-color (more than two colors is also possible) implementations, the two colors may either both be broadband (low or very low coherence) illumination or laser illumination. In one implementation, an LED (broadband light source) or laser is used for illumination, a diffractive or holographic optical element is used to create the required phase shift in a reference arm, and the hologram is recorded on a digital camera. In one implementation, advanced alignment and signal processing systems and methods, combined with the shearless geometry, afford a one-dimensional (1-D) FFT (Fast Fourier Transform) so that the processing time is substantially diminished compared to prior art systems that require a two-dimensional (2-D) FFT. 2. Related Art Prior methods of heterodyne (spatial carrier frequency) classical holography and of digital hologram acquisition have required both laser (coherent) illumination and that the reference and object (target) beams be combined at some angle (there is a shear between the two beams). Lasers have a number of problems, including high expense and generally requiring very extensive safety precautions, which makes them even more expensive. Additionally, since lasers have long coherence lengths (compared to broader band illumination sources), small reflections from optical surfaces will interfere with and make significant noise in the digital hologram. Previous methods have also required an angle (shear) between the two beams to create the spatially heterodyne fringe pattern that actually records the hologram. The shear is created by reflecting the reference beam from a mirror or beamsplitter so that it propagates at a different angle than the object (target) beam. For common path systems, such as a Michelson geometry, or the last leg of a Mach-Zender geometry to the digital recorder, this means that the beams separate spatially from one another, and in fact makes it impossible to use a Michelson geometry for systems with high magnification-the reference beam becomes so separated due to the shear that it is either clipped by the optics, does not overlay the object beam, or both. Even with the shorter common path Mach-Zender layout, shear between the two beams often causes problems in achieving adequate overlay of the beams. For low-coherence illumination source beams it is substantially impossible in either geometry to get an exact enough overlay to form fringes with the prior art sheared systems. Another problem with prior art digital hologram acquisition systems is that they require a two-dimensional (2-D) FFT (Fourier transform) and inverse FFT to separate the object wave phase and amplitude from the hologram. The 2-D FFT/inverse FFT requires large computational power or a long wait. Another considerable problem with prior art systems is that they have no method for measuring phase changes greater than one wavelength or two-pi radians in a shearless geometry. This is a substantial disadvantage for holographic metrology. FIG. 1 shows a prior art digital holography system with a Michelson geometry, where the shear angle between the two beams is indicated as a. Note that for this particular case, nominally a high-magnification case, the reference and object beams no longer have any overlap, as indicated, and therefore cannot form a hologram. There is therefore a particular need for systems and methods for 1) recording digital holograms in a shearless geometry, 2) recording digital holograms with broadband very short coherence length (both transverse and longitudinal) illumination, 3) recording digital holograms which extend the range of metrology substantially beyond one wavelength and 4) reducing the FFT computational requirements for separating the object wave phase and amplitude from the hologram. SUMMARY OF THE INVENTION This disclosure is directed to systems and methods for shearless hologram acquisition that solve one or more of the problems discussed above. The disclosed systems and methods may provide for single-beam or two (or more) color operation, and for separation of the object beam phase and amplitude from the hologram. The shearless geometry is highly suited for two (or more) color operation with either broadband or laser illumination, and systems and methods are introduced herein to enable this advanced metrology technique. The multi-color operation with shearless geometry extends the measurement capability of holographic metrology so that third-dimension measurements can be made without ambiguity over a much wider range with excellent overlay of the object and reference beams in Michelson, Mach-Zender, or other geometry in a shearless fashion. One apparatus for shearless recording of a spatially heterodyne hologram with broad-band or laser illumination includes: an illumination source or sources; a beamsplitter optically coupled to the illumination source(s); a reference beam phase-shaping optical element optically coupled to the beamsplitter; an object optically coupled to the beamsplitter; a focusing lens optically coupled to both the reference beam phase-shaping optical element and the object; and a digital recorder optically coupled to the focusing lens. A reference beam is incident upon the phase-shaping optical element, and the reference beam and an object beam are focused by the focusing lens at a focal plane of the digital recorder to form a spatially heterodyne hologram. This system and corresponding methods provide advantages in that the object and reference beams are unsheared and do not separate from one another as they travel a common optical path in space. Additionally, since the beams can be substantially perfectly overlapped with the shearless system and methods, no expensive and potentially dangerous laser is required for the illumination source, although the system is also perfectly compatible with laser illumination and also provides tremendous advantages for the case of laser illumination. The systems and methods provide advantages in that computer assisted holographic measurements can be more easily and less expensively made with higher quality results. Additionally, the advanced systems and methods allow substantially decreased computation time or computational power by allowing the FFT's to be 1-D rather than 2-D, and two-color operation with the shearless geometry and 1-D FFT/IFFT provides a greatly expanded measurement range. One particular embodiment comprises an apparatus to shearlessly record a hologram. The apparatus includes an illumination source configured to produce a first beam of light. The beam is split by a beamsplitter into a reference beam and an object illumination beam. The reference beam is directed onto a phase-shaping optical element which imparts a phase shift to the reference beam and returns the phase-shifted reference beam on itself to the beamsplitter. That is, the phase-shifted reference beam is returned in the same direction from which the non-phase-shifted reference beam was received, instead of being returned at an angle with respect to the received beam. The object illumination beam is directed onto an object, and a portion of the beam is reflected back to the beamsplitter. The beamsplitter receives the phase-shifted reference beam and object illumination beam and combines them substantially coaxially. The combined beams are passed through a focusing lens which focuses them at a focal plane. A digital recorder is positioned at the focal plane to record the spatially heterodyne hologram formed by the focused phase-shifted reference beam and reflected object illumination beam. The illumination source may, for example, be a laser, light emitting diode (LED), a spectrally filtered incandescent light source, or an arc lamp. The phase-shaping optical element may, e.g., be a diffractive optical element with a blaze grating or a holographic optical element which is configured to impose a phase shift, such as a linear phase shift or repetitively increasing and decreasing phase shift, on the reference beam. The apparatus may include conditioning optics, such as a beam expander or spatial filter, positioned between the illumination source and the beamsplitter to optically process the first beam of light before it is received by the beamsplitter. The digital recorder may be a CCD or CMOS camera, and a digital storage medium may be coupled to the digital recorder to store the hologram data. The beamsplitter, the phase-shaping optical element, and the digital recorder may be configured according to various geometries, such as a Michelson geometry. Another embodiment comprises a method for shearlessly recording a hologram. In this method, a beam of light is first provided. The beam is split into a reference beam and an object illumination beam. A phase shift is imparted to the reference beam, and an object is illuminated with the object illumination beam. The phase-shifted reference beam and a portion of the object illumination beam reflected from the object are then combined in a substantially coaxial manner. The phase-shifted reference beam and reflected object illumination beam are then focused at a focal plane, forming a spatially heterodyne hologram. Numerous other embodiments are also possible. BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of the invention may become apparent upon reading the following detailed description and upon reference to the accompanying drawings. FIG. 1 illustrates a schematic of a prior art high-magnification Michelson system indicating that shear has caused the reference and object beams to no longer overlap. FIG. 2 shows a schematic of a particular embodiment of the present invention using Michelson Geometry, illustrating unsheared beams with diffractive or holographic Phase-Shaping Element in the Reference Arm. FIG. 3 illustrates a schematic of a Two-Color Digital Holography System with shearless geometry suitable for 1-D FFT analysis. FIG. 4 shows an Example of Carrier Frequency Fringes suitable for separation of Object Waves using Two-Color Digital Holography. While orthogonal carrier frequencies in real and Fourier space are advantageous, all that is required for a 1-D FFT is the ability to mathematically rotate an axis perpendicular to the carrier frequency of interest. FIG. 5 depicts an example of a spectrally broadband illumination holography system with closely matched Reference and Object beam path lengths and reticle alignment target to allow precision overlay of the recombined beams at the digital camera. While the invention is subject to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and the accompanying detailed description. It should be understood, however, that the drawings and detailed description are not intended to limit the invention to the particular embodiment which is described. This disclosure is instead intended to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS One or more embodiments of the invention are described below. It should be noted that these and any other embodiments described below are exemplary and are intended to be illustrative of the invention rather than limiting. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the present invention in detail. As described herein, various embodiments of the invention comprise systems and methods for shearless hologram acquisition. Significant features of an apparatus for shearless digital hologram acquisition include the use of a phase-shaping optical element in the reference arm; using a broad-band illumination source with the optical paths, both longitudinal and transverse, matched to better than the longitudinal and transverse coherence lengths; arranging the system so that two (or more) colors can be used to record simultaneous holograms on the same digital camera exposure, or sequentially recording two (or more) colors on the same exposure by offsetting the direction of the carrier fringe recordation between the two (or more) colors; and building and aligning the system, or rotating the coordinate axes, so that the spatially heterodyne carrier frequency fringes are substantially aligned along either the x-axis or y-axis (or one color on the x-axis and one color on the y-axis for two-color recordation) of the system so that a 1-D FFT can be used rather than a 2-D FFT. The alignment can be replaced by axis rotations which make one axis of the coordinate system perpendicular to the carrier-frequency fringes of the object wave to be recovered from the hologram. The systems and methods for advanced digital holography disclosed herein allow for the use of simpler optical systems, for the use of less expensive apparatus, for improved quality of digital hologram acquisition, and for improved methods of analysis of the hologram for determining the amplitude and phase of the original object wave at every recorded pixel. By contrast, the prior art does not describe any method for shearlessly forming a heterodyne (spatial carrier frequency) hologram. Shearless formation allows the use of the simpler Michelson geometry even in high magnification applications, and also remains an advantage for beam overlay even using the more complex Mach-Zender geometry. Neither does the prior art teach how to use broadband light for recordation of holograms, how to simultaneously or sequentially record holograms with two (or more) colors (either broadband or laser illumination) in a shearless geometry on the same digital camera exposure, or how to analyze the hologram for the original object wave phase and amplitude using only a one-dimensional (and therefore much faster) Fourier transform and inverse Fourier transform. System Overview Shear between the reference and object beam makes it impossible for the previous embodiments of digital holography to use a Michelson geometry at high magnifications, and prevents good overlay of the two beams (which is necessary for creation of fringes with broadband illumination) even in a Mach-Zender geometry. This problem is overcome by introducing a phase-shaping optical element (which can be a diffraction grating, holographic element, birefringent optical element, wedged glass, or other phase-modifying element), which modifies the phase of the wavefront without requiring reflection of the wave at a non-normal angle. Thus, after recombination, both the reference and object/target beams travel the optical path at substantially the same angle and can be overlaid substantially exactly on one another. Additionally, prior-art embodiments of digital holography have not provided a shearless method for removing the ambiguity in phase measurements where the resolution-element-to-resolution-element difference in phase is greater than one wavelength. This problem is overcome by providing illumination at two or more different wavelengths or bands of wavelengths (“colors”) with a phase-shaping optical element for each color in the reference arm, and simultaneously or sequentially recording the digital hologram on the same exposure of the recordation device at two (or more) wavelengths where the required spatial carrier-frequency fringes are created by the phase shaping optical elements, rather than combining the beams at an angle. Use of the phase-shaping optical element allows the two beams to be combined in a co-linear fashion so that they can be exactly overlaid and form satisfactory carrier-frequency fringes even with low-coherence or spectrally broadband illumination. Additionally, this shearless method of forming the holograms greatly simplifies proper illumination of the recordation device with the best optical quality of each of the individual beams. In sheared geometries, it is often very difficult to properly illuminate the recordation device with both beams since the shear causes them to spatially separate. In order to separate the two unsheared holograms in Fourier-space (after an FFT), the fringes created in real space by the phase-shaping optical element for one of the colors are created with a significantly different x and y component of the carrier frequency, compared to the spatial carrier frequency fringes created by the other color, so that when the 1-D FFT is performed, the holograms are substantially separated from one another in Fourier space, and the object waves can therefore be reproduced without any interference or cross-talk between the colors. In general, one of the carrier frequencies will have a much higher x-component frequency and the other carrier frequency will have a much higher y-component frequency, thus allowing separation of the object waves in Fourier space. Aligning the carrier-frequency fringes of a single-color (for either broadband or laser illumination) hologram substantially parallel to either the x or y-axis allows a 1-D FFT to be used without axis rotation to retrieve the object beam phase and amplitude from the complex hologram by performing a 1-D FFT on the axis perpendicular to the fringes, translating the zero-frequency (0) axis location to the carrier frequency location, filtering around the new axis, and performing an inverse 1-D FFT. For two-color digital holography, if the fringes for one color are parallel to the x-axis and the fringes for the second color are parallel to the y-axis, then a 1-D FFT along the x-axis, axis-translation to the carrier frequency, filtering operation, and 1-D inverse FFT can be used to recreate the phase and amplitude of the second color object wave, and a 1-D FFT along the y-axis, axis translation, filtering operation, and 1-D inverse FFT can be used to recreate the phase and amplitude of the first color object wave. Similarly, rather than aligning the fringes parallel to either the x-axis or y-axis, it is possible to perform a mathematical coordinate rotation so that one of the axes is perpendicular to the carrier-frequency fringes. The axis rotation method of alignment of a coordinate axis to one set of carrier frequency fringes is in general useful when more than two holograms are recorded on the same digital recordation device, or when mechanically aligning the system (so that the fringes are created parallel to one of the system axes) is not convenient. This is another variation which allows use of the 1-D FFT rather than the 2-D FFT. More generally, a coordinate rotation allows use of the 1-D implementation even when the carrier frequencies cannot be made exactly orthogonal in real-space or Fourier space. The only requirement is that the difference in frequency components between the carrier frequencies is large enough that the undesired carrier frequency shows up as a substantially different frequency in the FFT transform of the. other carrier. Note that, if desired, the methods described above can also be used for illumination sources of the same wavelength to either simultaneously or sequentially expose a single frame of the digital recordation device, thus allowing differential measurements of the target in the shearless geometry. Detailed Description of Exemplary Embodiments Shearless Digital Holography System Referring now to FIG. 2 , a specific embodiment of a shearless holographic system is depicted. Light from an illumination source 210 passes through conditioning optics 220 , which may (or may not) include collimation, filtering, diffusion, or other optical conditioning of the light from the illumination source. The beam from illumination source 210 is split by a beamsplitter 230 into object and reference beams. The object beam strikes the target object 240 and returns through the beamsplitter 230 , while the reference beam is returned on itself by a phase-shaping optical element 250 (i.e., the returned beam is substantially coaxial with the original reference beam.) The phase-shifted reference beam is recombined with the object beam at the beamsplitter 230 . The combined beams (the phase-shifted reference beam and the returned object beam) are substantially co-linear and overlaid. A focusing lens 260 then focuses both beams simultaneously onto the recording array plane of a digital camera 270 , where the hologram and its spatial carrier frequency fringes created by the phase shift from the phase shaping optical element are recorded. Examples of phase-shaping optical elements include: a holographic optical element formed by interfering counter-propagating co-linear waves where the hologram recording material is at an angle to the two beams; a blaze grating used in the −1 (minus one) order; a glass wedge followed by a mirror perpendicular to the beam path; a linearly increasing and decreasing glass wedge (the wedge reverses slope in a periodic fashion so that the average glass thickness is constant when averaged over a complete period for the wedge). Two-Color Digital Holography System Referring now to FIG. 3 , a specific embodiment of a two-color digital hologram acquisition system is depicted. This method is not limited to just two colors. Colors may be added to the system as long as the spatial carrier frequencies are arranged so that the object wave frequencies do not overlap in Fourier space. In this embodiment, light from two illumination sources ( 310 , 315 ) is combined by a dichroic mirror 320 (which could also be a simple beamsplitter or other form of beam combiner). The light from the illumination sources then passes through conditioning optics 330 , which may (or may not) include collimation, filtering, diffusion, or other optical conditioning of the illumination sources. The substantially co-linear illumination beams (of both colors) are then split by a beamsplitter 340 into object and reference beams. The object beam strikes the target object 350 and returns through the beamsplitter 340 , while the reference beam is split into both of its colors by a dichroic mirror 325 or some other type of splitting element. Each individual color reference beam is returned on itself by a phase-shaping optical element ( 360 , 365 ), and the dichroic mirror 325 recombines the phase-shifted reference beams. Then, the combined reference beam is itself recombined with the object beam by the beamsplitter 340 . For the case where the phase-shaping optical element returns the beams substantially on themselves, the reference and object beams will be substantially co-linear and overlaid on one another after recombination. A focusing lens 370 then focuses both beams simultaneously onto the recording array plane of a digital camera 380 , which records the hologram and the spatial carrier frequency fringes created by the phase shift from the phase shaping optical element. In order for the phase and amplitude of each color object beam to be individually separable from the other beams in Fourier space, the carrier frequency fringes in the camera recordation plane must be created at substantially different frequency components. FIGS. 4A-4D show an example where the carrier frequency fringes of Color 1 are perpendicular to the carrier frequency fringes of Color 2 . It should be noted that the subject matter of the figures (e.g., carrier frequency fringes) comprise variations in intensity that are normally depicted by shades of gray. The figures are black and white representations of the subject matter, which is sufficient for the purposes of the following description. For example, FIG. 4A is presented for the purposes of illustrating the horizontal fringes formed by Color 1 . Similarly, FIGS. 4B and 4C are presented to illustrate the vertical fringes formed by Color 2 , and the combined fringes of both colors, respectively. FIG. 4D is presented to illustrate the 2-D FFT of the 2-color hologram in FIG. 4C . FIG. 4A illustrates the carrier frequency fringes achieved by arranging the Phase Shaping Optical Element (which could also be a mirror since this method is also compatible with sheared holography) for Color 1 , so that a linear vertical phase shift is created, resulting in horizontal fringes. FIG. 4B illustrates the carrier frequency fringes achieved by arranging the Phase Shaping Optical Element for Color 2 so that a linear horizontal phase shift is created, resulting in vertical fringes. FIG. 4C illustrates the simultaneous exposure of the digital camera to both fringe patterns. Finally, FIG. 4D shows the FFT of the image in FIG. 4C . Note that when the FFT is taken, the frequency component separation in x and y of the spatial carrier frequency fringe patterns from the two colors results in a total separation of the data in FFT space. The circles drawn on the figure indicate the separated sidebands for Color 1 and for Color 2 . While a 2-D FFT is used to illustrate the separation of the beams in Fourier space, only a 1-D FFT and Inverse Fast Fourier Transform (IFFT) are required to recover each of the Object Beams. Thus, a 1-D FFT perpendicular to the spatial carrier frequency fringes, translation of axes to the carrier frequency for Color 1 , filtering operation, and an inverse FFT results in the phase and amplitude of the Object Wave for Color 1 only. A similar procedure results in recovery of the phase and amplitude of the Object Wave for Color 2 only. Note that it is not necessary to use a 90-degree angle as the angle between the fringes of Color 1 and Color 2 . Other angles are entirely possible, but the advantage of using the 90-degree angle is that no axis rotation is required if the two carrier frequency fringe sets are parallel to the x and y axes. A 1-D FFT and IFFT can be used to recover the phase and amplitude of the object waves even for the case where the two sets of carrier frequency fringes are not orthogonal. In this case, an axis rotation must be carried out so that one of the axes is perpendicular to the carrier frequency under consideration. A 1-D FFT can then be carried out along this axis and the zero frequency location translated to the carrier frequency, the result filtered to only include the object beam frequencies under consideration, and then an inverse FFT produces the phase and amplitude of only that object wave. In the case where neither carrier frequency for either of the two colors is parallel to an axis, an axis rotation must be performed for each color to align one axis perpendicular to the carrier fringes for that color. Following this by a 1-D FFT, translation, filtering, and IFFT for each respective color returns the phase and amplitude of each of the respective colors. Once the complex Object Waves for Color 1 and Color 2 are recovered as described above, then without any further processing (other than possible coordinate rotations if necessary to place them both in the same coordinate system,) one of the Object Waves is divided by the other Object wave, corresponding pixel by corresponding pixel (e.g., the complex value of the Object Wave for Color 1 at pixel ( 1 , 1 ) is divided by the complex value of the Object Wave for Color 2 at pixel ( 1 , 1 )). Since there is an average wavelength difference between the two colors, the resulting phase value created by dividing the two complex object waves by one another unambiguously extends the phase measurement range of the system. For instance, if there is a 10% difference in wavelengths between the two colors, then the phase measurement range over which phase is unambiguously measured is extended to 10 wavelengths (average wavelength divided by the difference between the two measurement wavelengths times the wavelength). This feature thus tremendously extends the usefulness of digital holographic measurements and makes it available in the very advantageous shearless geometry with only a 1-D FFT required. One-Dimensional FFT for Object Wave Recovery The use of a one-dimensional FFT for recovery of the Object Wave is illustrated by examining just one of the colors illustrated in FIG. 4 . For instance, if the Phase-Shifting Optical Element is arranged so that a linear vertical phase shift is induced, as illustrated by the horizontal fringes in FIG. 4A , then only a 1-D FFT in the y-direction (vertical axis) is required to recover the object wave phase and amplitude. A one-dimensional FFT in the y-direction, followed by an axis translation to the carrier frequency, followed by a filtering operation, followed by a 1-D IFFT, extracts the phase and amplitude of the object wave only, using just a 1-D FFT and IFFT, not the 2-D FFT and IFFT required by all prior art. Note that the digital Fourier transforms need not be FFT and IFFT, many other digital Fourier transforms besides the Fast Fourier Transform (FFT) and Inverse Fast Fourier Transform (IFFT) will also work. Use of Broadband Illumination for Digital Hologram Acquisition It has been generally accepted that only highly coherent (laser) sources are suitable for holography, and digital holography has only been proposed using such sources in the prior art. In fact, although holography was invented in 1949, it languished on the shelf until the invention of lasers, followed by the invention of spatially heterodyne holography by Leith and Upatnieks. However, the use of laser illumination is not strictly required, and broadband (“white light”) illumination can be advantageous in many situations. In particular, not having laser illumination can greatly reduce the cost and complexity of a digital holography system, since many lasers are very expensive and require considerable safety precautions to prevent injury to users or bystanders. For systems that require extremely low noise, broadband illumination is also an advantage. In highly coherent systems, extraneous reflections from lens surfaces that reach the recording camera interfere coherently with the designed reference and object beams, creating noise in the carrier fringes. With broadband illumination, the reflections from the lenses have traveled a distance different by more than the coherence length from the path traveled by the designed beams, and therefore cannot interfere coherently with the reference and object beams. The carrier frequency fringe noise is thereby tremendously reduced. FIG. 5 provides an example of a system using broadband illumination. In this system, light is provided by an illumination source 510 , which in one embodiment may be a green LED. Light from illumination source 510 passes through conditioning optics 320 , which may, as noted above, perform collimation, filtering, diffusion, or other optical conditioning of the light. In this embodiment, the light from illumination source 310 is also passed through a reticle 530 and a lens 540 . The light beam is then split by a beamsplitter 550 into object and reference beams. In this embodiment, beamsplitter 550 is a split prism. The object beam strikes the target object 560 and returns through beamsplitter 550 , while the reference beam is returned on itself by a phase-shaping optical element 570 . The phase-shifted reference beam is recombined with the object beam at the beamsplitter 550 so that they are substantially co-linear and overlaid. A focusing lens 580 then focuses both beams simultaneously onto the recording array plane of a digital camera 590 , where the hologram and its spatial carrier frequency fringes created by the phase shift from the phase shaping optical element are recorded. In order to use broadband illumination, the path lengths for the reference and object beams must be very carefully matched, to a difference less than the longitudinal coherence length of the illumination: δ l<λ 2 /δλ, where δl is the path length difference between the reference and object paths, λ is the average wavelength of the illumination source, and δλ is the spectral bandwidth of the illumination source. As an example, for illumination with a green LED of wavelength 530 nm and spectral bandwidth of 5 nm, the path lengths of the reference and object beams must be matched to better than ˜56 microns. This is easily achievable by closely matching the design pathlengths and then providing a piezoelectrically driven longitudinal motion for the phase-matching optical element. Such piezoelectric stages can have motion resolution of 10 nm or less. Many other methods of precisely matching the path lengths are also available. Additionally, the object and reference beams must be exactly matched to one another in the transverse dimension, much more exactly than in any prior art implementation. The two beams must be recombined so that the exact areas that were split apart are joined back together to an accuracy better than the transverse coherence length (Born & Wolf, Seventh (expanded) Edition, p. 575, replace ρ, the source size, by Rδθ where R is the distance from the beamsplitter to the recombination plane): δ r <( Kλ avg )/(δθ), where δr is the allowable mismatch in overlay of the beams, K is a constant equal to 0.61 for no fringe contrast and smaller for good contrast, λ avg is the average wavelength of the broadband illumination source, and δθ is the divergence angle of the illumination source in radians. For instance, if the illumination source is a green LED with average wavelength of 530 nm, spectral bandwidth of 5 nm, and divergence angle after collimation of seven degrees, then the allowable error in overlay of the two beams is ˜6.5 microns if we use K=0.3 (˜33% spatial carrier frequency fringe contrast). Overlay of the two beams can be facilitated by passing the illumination beam through an alignment reticle 530 before splitting the beam, and arranging the optics such that the alignment reticle is also in focus at the digital recording plane. Clearly, in order to achieve this kind of overlay excellent optics and alignment must be used, but this is well within the actual state of the art. Flat-Field Correction The optical errors inherent in the system may be substantially removed by the method of flat-field correction. To make a flat field correction for reflection holography, the target is replaced by a flat reference surface which returns a plane wave. For a transmissive holography system, the object is simply removed from the system. A hologram is formed with the “perfect” target or with the target removed. The object wave from the “flat-field hologram” (reference hologram) is separated from the reference hologram by the standard methods of Fourier transform, axis translation, filtering, and Inverse Fourier transform. When a hologram is made of an object (target) to be analyzed, the complex object wave from the object under investigation may be divided by the complex object wave from the flat-field/reference hologram, and the optical wavefront errors and systematic noise are substantially removed from the measurement, greatly improving the accuracy of recreation of the object wave from the object/target under investigation. Advantages A shearless digital hologram acquisition system representing one embodiment of the invention is cost effective and advantageous for at least the following reasons. The shearless geometry allows a simpler Michelson geometry to be used for systems with arbitrary magnification, which is impossible with a sheared system, since the beams cease to overlap with one another (and therefore no hologram is created) for many implementations of the Michelson geometry. Even with a Mach-Zender geometry, the shear between the beams makes it difficult to adequately overlap the beams in many instances, and impossible for low coherence systems. For low coherence systems, the shearless geometry is a requirement, since it is otherwise impossible to overlap the beams so that they will interfere with one another-very low coherence illumination requires that the equivalent portions of the two beams overlap one another exactly. Use of the 1-D FFT, which is achieved by arranging the phase-shaping optical element so that the induced phase shift creates fringes parallel to either the x-axis or y-axis of the system or by rotating the coordinate system to have one axis perpendicular to the carrier frequency fringes, allows for substantially faster or less expensive (lower computational power) analysis of the holograms for separation of the object wave phase and amplitude from the raw spatially heterodyne hologram carrier frequency fringes. There are many variations of the embodiments described above which are within the scope of the present disclosure and the appended claims. These variations may include, for example, the elimination of the focusing lens (e.g., 260 ,) which is used to eliminate the effects of diffraction. This may not be necessary for testing very flat optical surfaces, so the lens may not be used in some embodiments. In another alternative embodiment, the system may be configured so that the object illumination beam is passed through the target object, rather than being reflected from it. In an alternative embodiment of a multi-color system, the holograms of the different colors could be recorded by the recording device on separate frames, rather than a single frame. In another alternative embodiment, digital Fourier transforms or other kinds of frequency transforms could be used instead of the FFT's described above. The benefits and advantages which may be provided by the present invention have been described above with regard to specific embodiments. These benefits and advantages, and any elements or limitations that may cause them to occur or to become more pronounced are not to be construed as critical, required, or essential features of any or all of the claims. As used herein, the terms “comprises,” “comprising,” or any other variations thereof, are intended to be interpreted as non-exclusively including the elements or limitations which follow those terms. Accordingly, a system, method, or other embodiment that comprises a set of elements is not limited to only those elements, and may include other elements not expressly listed or inherent to the claimed embodiment. While the present invention has been described with reference to particular embodiments, it should be understood that the embodiments are illustrative and that the scope of the invention is not limited to these embodiments. Many variations, modifications, additions and improvements to the embodiments described above are possible. It is contemplated that these variations, modifications, additions and improvements fall within the scope of the invention as detailed within the following claims.
Systems and methods for shearless digital hologram acquisition, including an apparatus incorporating an illumination source configured to produce a first beam of light, which is then split by a beamsplitter into a reference beam and an object illumination beam. The reference beam is directed onto a phase-shaping optical element which imparts a phase shift to the reference beam and returns the phase-shifted reference beam on itself to the beamsplitter. The object illumination beam is directed onto an object, and a portion of the beam is reflected back to the beamsplitter, which combines the phase-shifted reference beam and object illumination beam substantially coaxially. The combined beams are passed through a focusing lens which focuses them at a focal plane. A digital recorder is positioned at the focal plane to record the spatially heterodyne hologram formed by the focused phase-shifted reference beam and reflected object illumination beam.
6
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefits of U.S. 60/639,716 filed Dec. 28, 2004, which patent application is fully incorporated herein by reference. FIELD OF THE INVENTION The invention relates generally to a process for producing boron nitride using a borate mineral ore such as ulexite as a reactant material, and a boron nitride product thereof. BACKGROUND OF THE INVENTION Boron nitride (“BN”) is a thermally stable, highly refractory material of increasing commercial significance. Typically, boron nitride is produced by processes wherein boric acid is utilized as the boron source of reaction compositions. Suggested processes for producing boron nitride from boric acid are described in U.S. Pat. Nos. 2,922,699; 3,241,918; and 3,261,667 as well as in British Pat. Nos. 874,166; 874,165; and 1,241,206. U.S. Pat. No. 3,189,412 discloses a process to prepare boron nitride by passing nitrogen or ammonia or other nitrogen providing gas at 1200 to 1600° C. over a mixture comprising boric oxide, boric acid, or another boric oxide providing substance, carbon, and a catalyst, treating the reaction mixture with dilute mineral acid, and separating the boron nitride. JP Patent Publication No. 06-040713 discloses a process for producing boron nitride from colemanite, which is a hydrated calcium borate compound. It is thought that sodium compounds such as sodium borate can promote grain growth for BN particles in addition to the grain growth resulting from calcium borate compounds. Applicants have discovered a process to use ulexite, a hydrated sodium calcium borate compound, in the direct manufacture of boron nitride instead of or in addition to boric acid as a reactant material. Using ulexite as a reactant in the boron nitride making process inherently enhances the grain growth of boron nitride, since ulexite contains sodium borate, providing an improved and economical process for making boron nitride of high purity and excellent yield. SUMMARY OF THE INVENTION The invention relates to a process for producing a polycrystalline hexagonal boron nitride compound by reacting ulexite with ammonia for at least one hour at a processing temperature of at least 1000° C. DESCRIPTION OF THE INVENTION As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not to be limited to the precise value specified, in some cases. The term “processing temperature” may be used interchangeable with the term “process temperature,” refers to the temperature in the equipment/step in the process for making hBN in the invention. Generally in processes to produce boron nitride, a boron source and a nitrogen source are reacted to form a compound in which a boron atom and a nitrogen atom coexist. Instead of using boric acid as a boron source in the process of manufacturing boron nitride, applicants have discovered the use of ulexite as the boron source for excellent yields of high-purity, highly-crystalline hexagonal boron nitride. Starting Raw Materials: In one embodiment of the invention, the starting boron material comprises of ulexite. Ulexite is a hydrated sodium calcium borate of the formula (Na 2 O) 0.2 (CaO) 0.5 (B 2 O 3 ) 0.16 H 2 O, and it also contains magnesium, silica, aluminum, and iron impurities. As opposed to boric acid, ulexite is not soluble in water. Ulexite, also called “TV rock,” has a unique optical property is that is transmits light along the long axis of the crystal by internal reflections, very much in the same way as in fiber optics. In one embodiment, in addition to ulexite as the starting boron material, optionally up to 35 wt. % boric acid may be added as the boron source. In another embodiment, up to 50 wt. % boric acid may be added as the boron source. In yet another embodiment, alkaline earth metal salts of boric acid can be used instead of boric acid. In one embodiment of the invention, the nitrogen-containing compound comprises organic primary, secondary, and tertiary amines such as diphenylamine, dicyandiamide, ethylene amine, hexamethylene amine, melamine, urea, and mixtures thereof. In one embodiment, melamine is used as the nitrogen-containing compound. In a second embodiment, dicyandiamide is used as a nitrogen containing promoter. In a third embodiment, the nitrogen-containing raw material is ammonia for the ulexite boron-containing material to be fired in an ammonia atmosphere. In one embodiment of the invention, the nitrogen-containing compound in a powder form may be added to the ulexite-containing starting boron material in a ratio of about 30 to 55 wt. % of nitrogen-containing compound to starting boron material. In a second embodiment, the ratio of nitrogen-containing compound to starting boron material is about 40 to 50 wt. %. In a third embodiment, the ratio is about 30 to 55 wt. %. Process Steps: The process for making hBN of the invention may be carried out as a batch process, or as a continuous process, including the following process steps. Optional mixing/blending. In the initial step, the starting materials including the dopant are mixed or otherwise blended together in a dry state in suitable equipment such as a blender. The starting materials are used in powdery or compact form, whereby the grain size is not critical. If the starting materials comprise more than just ulexite (i.e., optional boric acid, optional nitrogen-containing promoters), the starting mixture is mixed in the dry state. Optional pre-heating/drying step After the optional mixing/blending step, the starting material is dried at temperatures of about 100 to 400° C., and in one embodiment, from 150 to 250° C., to drive off any moisture in the reactants and create porosity between the raw materials, forming aggregates of materials in the form of nuggets, chunks, or pellets. The drying operation can be carried out in air, or in a nitrogen or ammonia atmosphere. The drying time depends on the drying temperature and also whether the drying step is performed in a static atmosphere, or with circulating air or gas. In one embodiment, the drying time ranges from 4 hours at 200° C. to about 10 hours at 150° C. in a static environment. In a second embodiment, the drying time ranges from 1 to 15 hours. Optional Crushing of the Precursors: After the drying step, the starting material is crushed or ground using conventional milling equipment such as roller mills, cross beater mills, rolling discs, and the like. In one embodiment, the crushed materials are broken into pieces weighing between 10 mg to 10 g each. In yet another embodiment, the materials are broken into pieces weighing about 0.2 g each. Optionally in the next step, the crushed material is mixed with silica wherein the calcium in the ulexite reacts with the silica to give rise to calcium silicate to prevent the formation of 3CaO.B 2 O 3 which may otherwise be formed, thus giving a high yield of BN in the final reaction. In one embodiment, the total amount of silica to ulexite is maintained at a molar ratio of SiO 2 /CaO of less than 0.5. In a second embodiment, the molar ratio is maintained at a rate of less than 1.0. Optional Combined Preheating and Densification (“Pilling”) Step: In one embodiment after the mixing/blending step, the mixed precursors are dried/crushed, and then densified using a process known in the art such as tableting, briquetting, extruding, pilling, and compacting, among others. In this step, the crushed mixture is densified into pellets weighing from 0.1 g to 200 g each. In one embodiment, the pellets have an average weight of ˜10 g. in a second embodiment, the crushed mixture is densified into pellets with an average weight of about 2 g. In one embodiment, the densification/pelletizing steps are carried out in one extruding step, wherein the raw materials including ulexite and optional silica are fed in a twin screw extruder or similar equipment with a binder, such as polyvinyl alcohol; polyoxyethylene-based nonionic surfactants; polycarboxylic acid salts such as acrylic acid, methacrylic acid, itaconic acid, boletic acid, and maleic acid; polyoxazolines such as poly(2-ethyl-2-oxazoline); stearic acid; N,N′-ethylenebissteramide; sorbitan compounds such as sorbitan monostearate; and the like. The material is then subsequently dried and pelletized upon exit from the extruder. The exit pellets can be fed in a continuous process directly into the reaction vessel for the next step, or in yet another embodiment, processed through a furnace of 200° C. for additional drying prior to being fed into the reaction vessel. Calcinating Step: After drying and optional mixing with silica, the material is purged in a nitrogenous atmosphere such as ammonia at an elevated temperature of 700 to 1200° C. for an extended period of time of up to 18 hours to form an incompletely reacted boron nitride in the “turbostratic” form. In one embodiment, the material is maintained in ammonia while being fired at 1000 to 1200° C. for 1 to 24 hours. In a second embodiment, the material is fired at 1200° C. for about 4 hours. Heat Treating/Sintering Step: After calcinations, the turbostratic boron nitride is sintered at a temperature of at least about 1500° C. for at least 10 minutes. In one embodiment, the sintering is for about 1 to about 4 hours. In one embodiment, the heat treatment/sintering is carried out from about 1800° C. to about 2300° C. for 2 to 3 hours. In another embodiment, from 2000° C. to 2300° C. In yet another embodiment, from 2000° C. to about 2100° C. in inert gas, nitrogen, or argon. In one embodiment, the sintering is carried out in a vacuum. In another embodiment, the sintering is carried out under conditions of at least 1 atmosphere of pressure. Combined Single-step of Calcinating/Sintering: In yet another embodiment and instead of performing a two-step process of calcinations then heat-treating/sintering, the pellets are fired in a nitrogenous atmosphere in a reaction chamber, wherein the chamber is heated up from room temperature at a rate of 20 to 1200° C. per hour to at an elevated temperature of 1200 to 2300° C. The process temperature is then held for about 1 to 30 hours, wherein the nitrogen purge is maintained at a rate sufficient to sustain a non-oxidizing environment. In one embodiment of a single step process, the pellets containing the reactants including ulexite are fired in one single step at an elevated processing temperature forming BN crystals, for a high crystallinity boron nitride product. In one embodiment, the pellets are maintained in ammonia while being fired to 1200 to 1600° C. for 2 to 12 hours. In a second embodiment, the pellets are fired at 1400° C. for about 4 hours. In a third embodiment, the pellets are fired from room temperature to a temperature of 1800° C. at a rate of 500° C. per hour. The temperature is then held at 1800° C. for 5 hours, wherein a nitrogen purge is maintained. The single step reaction at high temperature is carried out using high temperature furnace equipment known in the art, for example, a plasma jet furnace. In one embodiment, the nitrogenous atmosphere is a mixture of ammonia and an inert gas. The process of the invention can be carried out as a batch process or continuously, whereby the reaction mixture is introduced as a loose powder, or as a compacted mass into a reaction vessel, which in one embodiment is made of graphite. Washing Step. After firing, the reaction product is cooled and the product is subject to a washing treatment. In one embodiment, the washing treatment is via leaching with an HCl solution of 26 vol. % to remove the impurities such as sodium borate and calcium borate, which come from ulexite. In a second embodiment, the leaching is via several cycles of HCl washing at an elevated temperature of at least 60° C., and then deionized water at room temperature. Applications of the BN Powder Made from the Invention: The high purity boron nitride powder of the present invention can be used as a filler or additives for polymer compositions. In one embodiment, the BN powder is used in thermal management applications, such as in composites, polymers, greases, and fluids. The boron nitride powder can also be used in hot pressing applications, or as a precursor feed stock material in the conversion of hexagonal boron nitride to cubic boron nitride. In another embodiment, the material is used for making a hexagonal boron nitride paste. As used herein, paste is a semisolid preparation. This method involves providing a boron nitride slurry and treating the slurry under conditions effective to produce a boron nitride paste including from about 60 wt. % to about 80 wt. % solid hexagonal boron nitride. EXAMPLES The invention is further illustrated by the following non-limiting examples: Example 1 200 grams of ulexite is placed in a crucible and dehydrated at 200° C. The material is then ground to granules of about 10 mm size. 150 grams of this material is then placed into a graphite tube, and ammonia gas is flowed through the tube. While ammonia gas is supplied at a rate of 0.5 litre/min. through the tube, it is heated to 1400° C. at the rate of 300° C. per minute. The temperature is maintained for 2 hours, and then the supply of ammonia is allowed to stop. The tube is allowed to cool naturally while argon gas is passed through. Powder x-ray diffraction analysis of the product confirms the presence of boron nitride. The reaction product obtained is then finally ground in a mill, placed in 400 cc of 3N HCl, and the impurities are allowed to be thoroughly leached into the acid. It is then filtered and washed repeatedly with deionized water 6 times. After drying at 80° C. for 24 hours, a white powder is obtained. X-ray diffraction of the powder shows only the presence of BN. The white powder is then weighed, giving greater than 90% of theoretical yield. Content of impurities such as calcium, silicon, and magnesium is insignificant, indicating that the final product is high purity BN. Example 2 The BN product of Example 1 is further heat-treated or sintered at 1700 to 2100° C. in a non-oxidizing gas atmosphere of nitrogen or argon. This treatment results in the progress of crystallization, yielding a BN product of improved crystallinity and purity. This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. All citations referred herein are expressly incorporated herein by reference.
A process for producing boron nitride using a boron containing ore as a starting material, by reacting naturally occurring ulexite with ammonia at high temperature, for a boron nitride with high impurity and at a high yield.
2
FIELD OF THE INVENTION [0001] The present invention relates to microelectrodes and to sensors and other electrochemical devices which contain them. BACKGROUND OF THE INVENTION [0002] It is known to make microelectrodes for use in electrochemical sensing. A non-conducting layer is provided over a conductive electrode material leaving small areas of the conductive material exposed which can be brought into contact with the fluid to be sensed. Typically the conductive material has been a metal, but more recently boron-doped diamond has been used. For example, P Rychen et al disclose applying a layer of Si 3 N 4 or similar non-conductive material to the surface of boron doped diamond and subsequently etching apertures into it to expose the diamond underneath (Electrochemical Society Proceedings vol 2001-23 pp 97-107). [0003] JP2009-128041 discloses a three-dimensional diamond microelectrode array. [0004] WO 2005/012894 A1 discloses a microelectrode in which pins or projections of electrically conducting diamond extend at least partially through a layer of non-conducting diamond so as to provide the conductive points on the analysis surface of a microelectrode. WO 2005/017514 A1 discusses the use of a similar microelectrode in sensors for monitoring the characteristics of a fluid such as those associated with wellbores. [0005] While such a diamond microelectrode is effective and reliable, it is costly to manufacture, requiring layers of both conducting and non-conducting diamond to be grown which requires a specialist manufacturer. [0006] There remains a need for a diamond microelectrode which is resilient and reliable but more easily and cheaply produced. SUMMARY OF THE INVENTION [0007] In accordance with the present invention there is provided a microelectrode having an analysis surface which comprises one or more regions of electrically conductive diamond material surrounded by electrically insulating diamond-like carbon material, the diamond-like carbon material having, [0000] (a) a hardness lower than that of the electrically conductive diamond material and (b) a resistivity of at least 1×10 9 ohmcm, and the microelectrode being provided with connection means for electrically connecting the one or more regions to an external circuit. [0008] Microelectrodes produced according to the present invention have the advantage that they are very stable and resilient because diamond-like carbon material adheres well to diamond material and has very similar physical properties such as thermal expansion coefficient. They are easier and cheaper to produce than existing microelectrodes such as those described in WO 2005/012894 because diamond-like carbon is relatively easy to deposit and does not require such specialist equipment and conditions. Further both diamond and diamond-like carbon are biocompatible so can be used for sensing applications inside the body. [0009] The microelectrodes of the present invention make use of electrically insulating diamond-like carbon material. Such materials have recently been developed and can be made with a varying range of physical properties according to the specific process conditions used for their fabrication, see e.g. research carried out at Brunel University, www.etcbrunel.co.uk/research_files/DLC.htm. Diamond is a crystalline material in which the carbon atoms are tetrahedrally arranged and bonded to each other with sp 3 bonds, diamond-like carbon material on the other hand contains both tetrahedral sp 3 bonded and graphitic sp 2 bonded carbon atoms, shows no long range order and may have significant amounts of hydrogen present. It can be deposited as a thin film coating that has useful properties being dense, inert, low friction and hard wearing. [0010] Hitherto diamond-like carbon material has generally been used as a competitor material for diamond exploiting its diamond-like properties so it can be used as an alternative to diamond for some applications. Here, on the other hand, the present inventors are surprisingly combining diamond together with diamond-like carbon using properties of both materials to produce a new product. [0011] For the purposes of the present invention the diamond-like carbon material should have a hardness less than that of the electrically conductive diamond. Diamond typically has a Vickers hardness of about 85 to 100 GPa (by definition it has a hardness of 10 on the Moh's scale). The diamond-like carbon material used in the present invention may typically have a hardness of 20 to 80 GPa. Where the method of fabricating the microelectrode is to include an abrasion step as discussed below, the diamond-like carbon may typically have a hardness of 60 GPa or less. For example, it may have a hardness of 0.75 or less times the hardness of the conductive diamond, alternatively between 0.55 and 0.65 times, alternatively less than or equal to 0.6 times. [0012] The electrically insulating diamond-like carbon material will have a resistivity of at least 1×10 9 ohmcm. In practice the resistivity may be higher than this, for example it may be at least 1×10 10 , alternatively at least 1×10 11 ohmcm or even more than 1×10 12 ohmcm. [0013] The person skilled in the art will understand that the particular electrically insulating diamond-like carbon material selected for use in a microelectrode according to the present invention will be one with physical properties such as to combine durability with ease of manufacture. Typically the electrically insulating diamond-like carbon material may have a density in the range 2.0 to 2.7 g/cm 3 , alternatively 2.2 to 2.6 g/cm 3 , alternatively 2.3 to 2.5 g/cm 3 . The density of natural diamond has been reported to be in the range 3.15 to 3.53 g/cm 3 , and is typically about 3.5 g/cm 3 , while that of synthetically produced electrically conductive diamond is likely to be in the region of 3.5 g/cm 3 . [0014] One of the useful properties of the diamond-like carbon material is that when it is deposited on to electrically conductive diamond material a strong bond is formed between the two materials. This means that a microelectrode comprising such layers has little tendency to delaminate during use. Further, the bonds remain stable at elevated temperatures up to 400° C. before the diamond-like carbon material starts to oxidise. [0015] The electrically conductive diamond material may be doped diamond, for example boron doped diamond, or diamond doped with another element that confers conductivity such as phosphorus. The electrically conductive diamond material may be naturally conductive diamond but in practice is likely to be synthetic diamond grown by a conventionally known process such as a high pressure high temperature process or a chemical vapour deposition process. The electrically conductive diamond material may either polycrystalline or single crystal diamond material. Chemical vapour deposition can be used to grow doped single crystal diamond having very controllable conductivity through the bulk of the material, so where it is desired to use diamond material having such properties this is a convenient source. Other methods for producing conductive diamond include doping by ion implantation. The electrically conductive diamond material for use in the present invention may for example have a resistivity less than 1×10 3 ohmcm, alternatively less than 10 ohmcm, alternatively, 1 ohmcm or less. Typically it will have a resistivity in the range 0.05 to 1 ohmcm. [0016] Microelectrodes used in electrochemistry utilise the relationship between current and voltage measured when immersed in a fluid to characterise properties of the fluid. The fluid may be a liquid, or a gas, and is typically a solution. Dependent on the application, one of the current or voltage may be fixed and the other parameter allowed to vary, for example as the composition of the solution varies. Alternatively the solution may be fixed and one of the current or voltage may be swept across a range of values and the response in the other parameter recorded in the form of a plot of time versus current, time versus voltage or voltage versus current (e.g. a cyclic voltammogram). [0017] Electrochemical measurements can be qualitative or comparative, or they may be quantitative. Quantitative measurements generally require that the system is amenable to mathematical modelling, and in both cases it is desirable that the signal to noise ratio in the system is maximised and that as much information as possible is extracted from the system, see Feeney R and Kounaves S P, “Microfabricated ultramicroelectrode arrays: developments, advances, and applications in environmental analysis”, Electroanalysis 2000, 12 no. 9 pages 677-684. These objectives can best be achieved by using small electrode points. [0018] The microelectrode according to the present invention has an analysis surface which comprises one or more regions of electrically conductive diamond material surrounded by electrically insulating diamond-like carbon material which provide the electrode points. These may conveniently present a circular profile on the analysis surface, but it will be understood that other shapes may be used dependent on the method of fabrication and intended application. Where the diameter of the regions is fairly small, species in the solution will diffuse under an applied electric field towards the regions according to an approximately hemispherical three-dimensional diffusion model. The diameter of the regions may, for example, range from 1 μm to 200 μm, typically the diameter of the regions may be in the range 10 μm to 50 μm, alternatively 15 μm to 30 μm. [0019] The simplest analysis surface according to the present invention will comprise only one region of electrically conductive diamond material. However, to increase the signal to noise ratio it may be desirable to use an analysis surface with two or more regions of electrically conductive diamond material surrounded by electrically insulating diamond-like carbon so as to provide two or more electrode points. The regions of electrically conductive diamond material will be electrically connected to each other at a position away from the analysis surface. Where the microelectrode is formed by deposition of a layer of diamond-like carbon material on to a substrate of electrically conductive diamond material, as described below, it will be understood that the regions will be electrically connected together by the substrate of electrically conductive diamond material. Further, that substrate may then provide connection means for electrically connecting the regions to an external circuit. [0020] If desired the analysis surface will comprise an array of three or more electrode points. In practice, the array may contain many more electrode points, depending on the intended application. The electrode points may conveniently each have a diameter in the range 15 μm to 30 μm and be separated from nearest neighbours by a distance of 5 to 15 times the average diameter of the electrode points. This geometry facilitates an efficient three dimensional diffusion model with, in use, each electrode point being surrounded by a hemispherical diffusion volume. [0021] The array of electrode points may be electrically connected together through the substrate of electrically conductive diamond material which acts as connection means for electrically connecting the array to an external circuit. The external circuit can be electrically connected to the substrate by a variety of means. For example, contact pads could be provided on an exposed surface of the electrically conductive substrate onto which individual wire bonds may be made or to which a ball-grid array substrate may be soldered. Alternatively, a metallised layer may be provided over the exposed surface and bonds made to that layer. [0022] According to the present invention it is also possible to manufacture a microelectrode which has an analysis surface which is subdivided into two or more arrays which are electrically separated from each other and adapted to connect to separate external circuits. Where the microelectrode is formed by deposition of a layer of diamond-like carbon material on to a substrate of electrically conductive diamond material, as described below, the electrical separation may be arranged by suitable geometry of the substrate of electrically conductive diamond material. For example a groove may be cut through the substrate of conductive material from below to separate it into two electrically separate portions each of which contains an array of electrically connected electrode points. Separate external circuits may then be connected to these separate portions. It will be understood that by suitable choice of geometry of electrode points and rear grooving it is possible to subdivide a microelectrode into any desired number of separately addressable arrays. [0023] It will be understood that the microelectrode described, including any additional bonding wires and contact pads, may be exposed to the fluid under analysis as it is or the structure may be fitted into an electrode holder, such as a polytetrafluoroethylene tube, or by some other means packaged to protect the structures behind the analysis surface before use. [0024] In a first embodiment the microelectrode of the present invention comprises a layer of electrically insulating diamond-like carbon material deposited on a substrate of electrically conductive diamond material, the substrate of electrically conductive diamond material having one or more protrusions projecting through the layer of diamond-like-carbon material so as to provide the one or more regions of electrically conductive diamond material for the analysis surface. In this embodiment the diamond-like carbon layer may typically have a thickness in the range 5 μm to 10 μm. [0025] In a second embodiment the analysis surface for the microelectrode of the present invention is provided by a layer of electrically insulating diamond-like carbon material deposited on a substrate of electrically conductive diamond material, the layer of electrically insulating diamond-like carbon material having apertures therein which expose the electrically conductive material below so as to provide the one or more regions of electrically conductive diamond material for the analysis surface. In this embodiment the diamond-like carbon layer may typically have a thickness in the range 1 μm to 3 μm. [0026] The apertures in the thin layer of diamond-like carbon material in this embodiment expose the electrically conductive diamond material below so that the electrode points are slightly recessed below the surface of the electrically insulating layer. For optimum performance of the microelectrode the recess depth should not be too great, but it can be larger when the electrode points have a larger diameter. For example, the electrode points may have an average diameter 15 to 20 times the thickness of the diamond-like carbon layer. Typically, the electrode points may have a diameter in the range 15 μm to 30 μm. [0027] If desired the electrically insulating diamond-like carbon can be deposited so that it surrounds and insulates the edges of the conductive diamond substrate as well as providing a layer thereon. This helps to ensure that the conductive substrate will be insulated from other parts when mounted in a housing, for example even if mounted through a brazed joint. [0028] The microelectrode of the present invention can be incorporated in a sensor for monitoring one or more characteristics of a fluid. The sensor will include at least one microelectrode which is connected to an external circuit adapted to convert electrical signals from the microelectrode into a qualitative or quantitative measure of the one or more characteristics of the fluid. [0029] Microelectrodes of the present invention can be used to measure a variety of characteristics of fluids in various environments. For example, they can be adapted to sense pH, to detect the presence or absence of certain chemical species e.g. hydrogen sulphide or to measure the resistivity of the fluid. As both diamond and the diamond-like carbon are biocompatible they can be used to measure or monitor characteristics inside the human body. An analysis surface for a microelectrode can be made as small as 20 μm diameter, particularly if only one region of electrically conductive diamond material is required, and in this case the microelectrode can be mounted within a medical needle, which may have an internal diameter of 1 mm, and so inserted into the human body to take a measurement. [0030] For some applications it may be desirable for the microelectrode to have an analysis surface which presents conductive regions of a particular material other than electrically conductive diamond, such as a metal like gold or platinum. The skilled person will appreciate that this can be achieved for the present invention by first providing an analysis surface having regions of electrically conductive diamond material and subsequently applying metal to the conductive regions by electroplating. [0031] Microelectrodes according to the present invention can be made by any suitable method. [0032] For example, one method suitable for making a microelectrode according to the first embodiment described above includes the steps of: [0000] providing a substrate of electrically conductive diamond material, selectively removing material from a face of that substrate so as to leave one or more protrusions projecting from the face, depositing on to the face a layer of diamond-like carbon material so as to cover the one or more protrusions projecting therefrom, said diamond-like carbon material having (a) a hardness that is lower than that of the electrically conductive diamond material, and (b) a resistivity of at least 1×10 9 ohmcm, and then, abrading the exposed surface of the layer of diamond-like carbon material until at least one of the previously-covered protrusions is exposed, thereby providing an analysis surface for the microelectrode which analysis surface comprises one or more regions of electrically conductive diamond material surrounded by electrically insulating diamond-like carbon material. [0033] Electrically conductive diamond material may be selectively removed from a face of the substrate by any suitable means, such as laser ablation using a UV laser or etching, for example by an argon chlorine etch such as that described in WO2008/090511. [0034] Deposition of the diamond-like carbon material may be carried out by plasma assisted chemical vapour deposition in a vacuum chamber. The substrate of electrically conductive diamond material is placed on a cathode in the chamber which is capacitatively coupled to a radiofrequency source. A gas which is a source of carbon and hydrogen, such as acetylene, is introduced into the chamber and ionised by the field. Positive ions of carbon and hydrogen are attracted to the cathode and so bombard the substrate and deposit the diamond-like carbon on it. Unlike chemical vapour deposition of diamond (which normally takes place at about 800° C.) this process can take place near room temperature without the need for heating. [0035] Abrasion of the diamond-like carbon material may be carried out by any suitable abrasive, such as diamond, silicon carbide or cubic boron nitride. By choosing an abrasive with a hardness between that of the diamond and the diamond-like carbon, the diamond-like carbon material will be fairly easily removed, but when the abrasive meets the electrically conducting diamond it will not be able to abrade that as effectively and so the rate of abrasion will slow providing the skilled person with a signal that enough material has been abraded away. [0036] The operation of a microelectrode can be modelled more easily when the electrode points are present in a substantially flat surface. Accordingly, when making the electrode by the method described above, the layer of diamond-like carbon will often be deposited sufficiently thickly over the undulating surface of the electrically conductive diamond material to fill completely the depressions between the protrusions so that, after abrasion to expose protrusions, the analysis surface produced is substantially flat. However, it is not essential that the depressions are always completely filled as some undulation in the finished analysis surface will not affect the useful operation of the microelectrode as will be understood by the skilled addressee. [0037] A microelectrode according to the second embodiment described above may be made, for example, by a method which includes the steps of providing a substrate of electrically conductive diamond material, depositing over that substrate a layer of electrically insulating diamond-like carbon material, the diamond-like carbon material having [0000] (a) a hardness that is lower than that of the electrically conductive diamond material, and (b) a resistivity of at least 1×10 9 ohmcm, and then, selectively removing material to form one or more apertures in the layer of diamond-like carbon material and so expose electrically conductive diamond material below, thereby providing an analysis surface for the microelectrode which comprises one or more regions of electrically conductive diamond material surrounded by electrically insulating diamond-like carbon material. [0038] In this method the electrically insulating diamond-like carbon material may be selectively removed by etching, laser ablation or any other suitable technique. Etching of the diamond-like carbon material may be carried out by known techniques. For example, plasma etching to selectively remove material to form apertures may be carried out through a lithography mask, resist or metal mask, which may be removed after the etch. Laser ablation of the diamond-like carbon material may be carried out by directly writing the laser onto its surface only in the regions where the apertures are desired. Alternatively a laser impermeable mask may be applied to the surface leaving apertures in the desired places so that when a laser scans the surface it can only remove diamond-like carbon material from those places. After the ablation step any mask may be cleaned from the surface. Conveniently the laser may be a UV laser but other light of other wavelengths may be also used. [0039] A microelectrode according to the second embodiment may also be made by providing a substrate of electrically conductive diamond, partially masking the surface of that material with one or more obstructions, depositing over the substrate a layer of electrically insulating diamond-like carbon material and then removing the one or more obstructions to expose electrically conductive diamond material below. [0040] The skilled person will appreciate that as the methods described for the second embodiment do not involve an abrasion step they can also be used for making a microelectrode which comprises any other type of electrically insulating material layer on a substrate of electrically conductive diamond material even one with a hardness equivalent to that of the electrically conductive diamond material, such as, electrically insulating diamond material. Accordingly in a third embodiment, the invention comprises a microelectrode having an analysis surface which comprises one or more regions of electrically conductive diamond material surrounded by electrically insulating diamond material having a resistivity of 1×10 9 ohmcm or more, and the microelectrode being provided with connection means for electrically connecting the one or more regions to an external circuit, wherein the analysis surface is provided by a layer of electrically insulating diamond material deposited on a substrate of electrically conductive diamond material, the layer of electrically insulating diamond material having apertures therein which expose the electrically conducting material below so as to provide the one or more regions of electrically conducting diamond material for the analysis surface. BRIEF DESCRIPTION OF THE FIGURES [0041] The invention will now be described by way of example with reference to the following drawings in which: [0042] FIGS. 1 a to 1 c show sectional views through a microelectrode according to a first embodiment of the invention at different stages of its manufacture; [0043] FIG. 1 d shows a sectional view though another microelectrode made in the same way; [0044] FIGS. 2 a to 2 c show sectional views through a microelectrode according to a second embodiment of the invention at different stages during its manufacture; [0045] FIGS. 3 a and 3 b show plan views of two stages in the production of an analysis surface of an example of a microelectrode according to the present invention which comprises four arrays; and [0046] FIG. 4 shows a plan view of the analysis surface of another example of a microelectrode according to the present invention which incorporates a reference electrode, counter-electrode and working electrode. DETAILED DESCRIPTION OF THE INVENTION [0047] Referring to the drawings, FIG. 1 a shows a substrate of electrically conductive diamond material 10 which has had material selectively removed from the face 12 so as to leave three protrusions 14 projecting forward from that face. In FIG. 1 b the same substrate 10 is shown after a layer of electrically insulating diamond-like carbon material 16 has been deposited thereon so that it covers the protrusions 14 . Subsequent abrasion to the exposed upper face of the layer of diamond-like carbon material 18 will remove material and this can be continued until the ends 20 of the previously covered protrusions 14 are exposed as shown in FIG. 1 c . The ends 14 thereby provide regions of electrically conductive diamond material 10 surrounded by electrically insulating diamond material 16 in an analysis surface 22 . The electrically conductive substrate 10 provides connection means for electrically connecting the regions together and to an external circuit. [0048] FIG. 1 d shows a microelectrode made in the same way but in which material was selectively removed to a greater depth in one section 24 of the electrically conductive substrate before the electrically insulating material was deposited. A channel 26 has also been cut through the electrically conductive substrate 10 into this section 24 , for example by laser cutting. This has the effect of electrically separating some electrically conductive regions 27 from other regions 28 . In such a way a microelectrode may be made in which the analysis surface is subdivided into two or more arrays which are electrically separated from each other. Each part of the divided conductive substrate 10 may be connected to a separate external circuit. If desired, before connection to the external circuit, the base of the substrate 10 may have been planarised to remove unnecessary back bulk. [0049] Typically before processing the substrate 10 of electrically conductive diamond material will have a thickness 0.5 mm or less. Material may then be removed by etching or laser ablation to leave protrusions 14 with a height of 10 μm or more, conveniently about 50 μm. If during processing it is desired to remove excess back bulk of the substrate 10 this may be planarised down to the desired thickness, which may be as little as 50 μm (measured from base of substrate to base of protrusions). [0050] FIG. 2 a shows a substrate of electrically conductive diamond material 30 with a thin layer of electrically insulating diamond-like carbon material 32 deposited on top and around the sides. Over this is laid a resist mask 34 with apertures 36 therein. Subsequent treatment with an etch selectively removes diamond-like carbon material to form corresponding apertures 38 in the layer 32 and expose electrically conductive diamond material below, see FIG. 2 b . The resist is removed from the layer 32 , for example using a resist remover such as sodium hydroxide solution, to leave an analysis surface 40 with slightly recessed regions of electrically conductive diamond material 42 surrounded by electrically insulating diamond-like carbon material, see FIG. 2 c. [0051] FIG. 3 a shows a plan view of a substrate of electrically conductive diamond material 50 which has been etched back so that pillars of electrically conductive diamond 52 protrude upwards from it. A circular channel 54 has been etched more deeply into the diamond material 50 to enclose the pillars 52 and this has been divided into four quarters 56 by two grooves 58 which are not etched quite as deeply as the circular channel 54 . [0052] After deposition of a layer of electrically insulating diamond-like carbon material 60 to cover the pillars, that layer is abraded to reveal electrode points 62 as shown in FIG. 3 b. [0053] The structure has been planarised from below until the circular channel 54 is reached thereby cutting the microelectrode away from surrounding material to leave a microelectrode disc 64 . Subsequent cutting of two grooves into the rear in the same positions as before has had the effect of electrically isolating the four quarters into four separate arrays. These arrays can then be electrically connected to separate electric circuits as desired. One convenient way to facilitate electrical connection to the arrays is to metallise the exposed surface of the layer of electrically conductive diamond material and then bond wires to the metallised surface. [0054] A further embodiment of the invention is illustrated in FIG. 4 . In electrochemical systems it is sometimes required to incorporate two or more types of electrode in the same microelectrode. These types of electrode may be differentiated for example by the voltage applied to them, by the use made of them in external circuitry, or by the geometry or size of the electrodes. FIG. 4 illustrates the analysis surface 70 of a microelectrode 72 that incorporates three electrodes: the reference electrode and positive and negative electrodes, generally known as the working electrodes (one of which may also be referred to as the counter-electrode). The analysis surface 70 comprises one crescent-shaped region of electrically conductive diamond material 74 which provides the reference electrode, a second crescent-shaped region of electrically conductive material 76 which provides the counter-electrode and an array of circular electrode points 78 located within the area enclosed by the crescent-shaped regions 74 , 76 and which are electrically connected together below the analysis surface to provide the other working electrode. Below the analysis surface the geometry of the microelectrode is such that the three electrodes are electrically separated from each other, for example by channels or grooves cut through into the layer of electrically conductive diamond material in similar manner to that discussed for FIG. 1 d . It will be understood that if desired the array of electrode points 78 in such a microelectrode may also be further subdivided into different addressable areas.
A microelectrode for electrochemical analysis having an analysis surface which comprises one or more regions of electrically conductive diamond material surrounded by electrically insulating diamond-like carbon material, the diamond-like carbon material having, (a) a hardness lower than that of the electrically conductive diamond material and (b) a resistivity of at least 1×10 9 ohm·cm, and the microelectrode being provided with connection means ( 10 ) for electrically connecting the one or more regions to an external circuit.
6
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention generally relates to providing interactive experiences to user of a mobile device . More specifically, the present invention relates to a method for physical surroundings to modify a user's interactive experience when playing an electronic game on a mobile device. [0003] 2. Description of the Related Art [0004] Wireless communications have become accessible to everyone. The types of devices used for wireless communications also have increased substantially. The variety of wireless telecommunication devices now includes cellular telephones, personal digital assistants (PDAs), pagers, two-way email devices, etc. Most of these devices are not only used for voice communications, but also used to provide entertainment to users. [0005] [0005]FIG. 1 depicts a prior art cellular telecommunication network 100 that supports not only voice communications but also data communications such as interactive games. The communication network 100 includes one or more communication towers 106 , each connected to a base station (BS) 110 and serving users with communication devices 102 . The communication devices 106 can be cellular telephones, pagers, personal digital assistants (PDAs), laptop computers, or other hand-held, stationary, or portable communication devices that use a wireless and cellular telecommunication network. The commands and data input by each user are transmitted as digital data to a communication tower 106 . The communication between a user using a communication device 102 and the communication tower 106 can be based on different technologies, such code division multiplexed access (CDMA), time division multiplexed access (TDMA), frequency division multiplexed access (FDMA), the global system for mobile communications (GSM), or other protocols that may be used in a wireless communications network or a data communications network. The data from each user is sent from the communication tower 106 to a base station (BS) 110 , and forwarded to a mobile switching center (MSC) 114 , which can be connected to a public switched telephone network (PSTN) 118 and the Internet 120 . The wireless subscribers can be identified by mobile identification number (MIN) or the wireless device's electronic identification number (EIN). [0006] The MSC 114 may be connected to a server 116 that supports different applications available to subscribers using the wireless communications devices 102 . The server 116 may also be connected to the Internet 120 and operated by a third party. The server 116 hosts many different games that can be accessed by users at desktop computers 122 or mobile devices 102 . [0007] Generally, the games, or the characteristics of the players at the games, do not change depending on the physical location of the players because the players generally are not mobile. Traditionally, the players are at their computer terminals 122 and do not change their location during the game. Even when a player moves his physical position, if he is using his mobile device to play the game, the game is not impacted by the changes in player's physical location. [0008] Many electronic games provided by the wireless devices are interactive multi-user games, i.e., games that are simultaneously played by several different players. An interactive multi-user game takes input from all participants and sends different screen updates to each participant. The game can also assign different properties to different players. For example, the screen displayed for player A may be different from the screen display for player B, and player A may have different attributes from player B. [0009] Most of the games are ported directly from a distributed computing environment, where individual computing devices are interconnected through the Internet to a server. The games are generally hosted by the server and distributed to the participants. The games and the players follow a set of predefined rules. The features or characteristics of a player during a game may change depending on the player's ability but generally not affected by the physical environment of the player. [0010] Another aspect of the development in wireless telecommunications has enabled new advertising venues. It is not uncommon for a user to receive an email advertisement on his wireless communications device. Generally, users consider these unsolicited emails as annoyance and discard them without reading. Consequently, advertisers cannot achieve their objective of attracting clients to their stores. SUMMARY OF THE INVENTION [0011] The present invention provides a way to attract users to a store by enhancing their interactive experience while executing applications on their wireless devices. The method enables special features in an application executed on a wireless device when the wireless device is within a predefined vicinity of a store. The method employs a server, which hosts applications and interacts with the wireless device through a wireless communications network. The server receives an application enabling request, sends an enabling signal to the wireless device, receives a device location from the wireless device, compares the device location with at least one predefined location, and if the device location is within a predefined range of the at least one predefined location, sends a feature enabling signal to the wireless device. [0012] The method also allows a wireless device that is in communication with the server through the wireless communications network to interact with a user through an application. To execute the application the wireless device sends an activation request for the application to the server, sends device identification to the server, sends location information to the server, receives application information from the server, receives a player feature from the server, wherein the player feature is dependent on the location information, and modifies a user feature according to the player feature. [0013] The invention also is a system for enabling special features in an application on a wireless device when the wireless device is within a predefined vicinity. The system includes a wireless device in communication with a wireless communications network and a plurality of satellites. The wireless device receives position information from the plurality of satellites and calculates a location information based on the position information received. The wireless device is also capable of displaying an electronic game that changes its behavior according to a signal from a remote server. The server, which is in communication with the wireless communications network, stores user information and a list of predefined locations. The server uses the location information received from the user and the list of predefined locations to alter the electronic game on the wireless device. [0014] Other features of the present invention will become apparent after review of the hereinafter set forth Brief Description of the Drawings, Detailed Description of the Invention, and the Claims. BRIEF DESCRIPTION OF THE DRAWINGS [0015] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below, are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention. [0016] [0016]FIG. 1 illustrates a prior art communications network. FIG. 2 illustrates a network. [0017] [0017]FIG. 3 illustrates architecture of a mobile device. [0018] [0018]FIG. 4 is a flow chart for a mobile device. [0019] [0019]FIG. 5 is a flow chart for a server. [0020] [0020]FIG. 6 is a flow chart for a mobile device that does not interface with a communications network. DETAILED DESCRIPTION OF THE INVENTION [0021] As required, detailed embodiments of the present invention are disclosed herein; [0022] however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. [0023] The terms a or an, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. The terms program, software application, and the like as used herein, are defined as a sequence of instructions designed for execution on a computer system. A program, computer program, or software application may include a subroutine, a function, a procedure, an object method, an object implementation, an executable application, an applet, a servlet, a source code, an object code, a shared library/dynamic load library and/or other sequence of instructions designed for execution on a computer system. [0024] In this description, the terms “communication device,” “wireless device,” “wireless telephone,” “wireless communications device,” “mobile device,” “mobile terminal,” and “wireless handset” are used interchangeably, and the term “game” as used herein is intended to encompass executable and nonexecutable software files, raw data, aggregated data, patches, and other code segments. Further, like numerals refer to like elements throughout the several views. [0025] With advent of 3 rd generation (3G) wireless communication technology, more bandwidth has become available for wireless communications, and wireless telecommunication devices, such as cellular telephones, pagers, personal digital assistants (PDAs) have increasing wireless capabilities. The wireless devices are increasingly being used not only for voice communications but also for entertainment. Now it is common for users to play electronic games on their handsets. [0026] The invention is an apparatus and method for improving the user interactive experience by allowing a user's physical location to affect the game that the user is playing. By being at a particular location, the user's strength in the game may increase significantly, or the game's scenario may change to offer more rewards. The invention also discloses a method to increase revenues for game developers by providing a venue for the game developers to get advertising revenues from merchants who want to make their stores part of the gaming experience for the users. For example, the game developer incorporates the coordinates of a merchant's store into the game, and the game also allows input of the user's physical location. When the user playing the game enters the store, the game awards extra strength to the user. The game learns about the user's physical location through the Global Positioning System (GPS) information received by the user's mobile device. [0027] [0027]FIG. 2 depicts a network architecture 200 that supports the invention. A server 116 is in communication with the Internet 120 and serves both users using a desktop computer 122 and a mobile device 202 . The user at the desktop computer 122 accesses directly the server 116 via the Internet 120 . The user at the mobile device 202 accesses the server 116 via a wireless communication network, i.e., the mobile device 202 sends and receives data from a communication tower 106 connected to a base station 110 . The base station 110 is connected to a mobile switching center 114 , which is in communication with the Internet 120 . The mobile device 202 also receives position information from a plurality of satellites 204 of the Global Positioning System (GPS). If the mobile device 202 is inside a store 208 when the user is playing a game, the server 116 compares the mobile device's 202 physical location with the store's 208 coordinates. If the server 116 detects the mobile device 202 is within a predefined vicinity of the store 208 , the server 116 sends a special feature enabling signal via the wireless network to the mobile device 202 , and the user's game is modified accordingly. [0028] The user's mobile device 202 has the capability to receive position information from the GPS satellites. FIG. 3 illustrates an architecture 300 for the mobile device 202 . The mobile device 202 has a transceiver 312 connected to an antenna 314 for communication with the BS 106 . The mobile device 202 also has a position locator 302 for receiving GPS information and calculating the current location information. The mobile device 202 is equipped with a display device 306 , an audio device 310 , and an input device 308 for interfacing with the user. A controller 304 generally controls the operation of the mobile device 202 . The input device may includes, besides a keyboard, a device interface for interfacing with disk drives and a network interface for interfacing with a land-based network. [0029] [0029]FIG. 4 is a flow chart 400 for a mobile device. After powering up the mobile device 202 , a user has the option of starting a new game or resuming an interrupted game on the mobile device 202 , step 402 , and the mobile device will send either the new game selection, step 404 , or a game resumption request, step 420 , to a server 116 . The mobile device 202 receives game and user information from the server 116 , step 406 . The game information may be a game applet that runs on the mobile device 202 , and the user information may be the information from the user's last game, if the game is of an accumulative type and was interrupted. For certain games, the user may interrupt the game at any time and the information is saved on the server 116 for later retrieval. [0030] The mobile device 202 displays the game, step 108 , and gets the location information from signals from the GPS satellites, step 410 . The mobile device 202 receives user input to the game, step 412 , and verifies whether the user input is a command for the game or a game ending input, step 414 . If the user input is to end the game, the mobile device 202 sends the user input to the server 116 , step 418 , and the game ends. If the user input is a command for the game, the mobile device 202 sends the user input and the location information to the server, step 416 , and the mobile device 202 repeats steps 406 - 416 . [0031] [0031]FIG. 5 is a flow chart 500 for the server 116 . The server 116 stores games and user information and interfaces with the mobile device 202 . The user can select a new game from a menu provided by the server or resume an interrupted game. After receiving the game request from the user, step 502 , the server checks whether it is for staring a new game or resuming an interrupted game, step 504 . If the user wants to resume an interrupted game, the server 116 retrieves the interrupted game information and related player information, step 508 and sends the game information and the player information at the point when the game was interrupted to the mobile device 202 , step 510 . If the user chooses to start a new game, the server 116 sends the game information to the user, step 506 . After sending the game and user information to the mobile device 202 , the server 116 monitors the user's game. The server receives the user input and the location information, step 512 , from the mobile device 202 and checks whether the user is ending the game, step 514 . If the user chooses to end the game, an option may be provided to the user to save the game information, and the server 116 will save the game and user information for later retrieval, step 526 . [0032] If the user input is not a game ending command, the server 116 checks the user location information to see if the user is within a predefined location, step 516 . A game may have many predefined locations and each predefined location may change the characteristics of each game differently. If the user and his mobile device 202 is within the vicinity of a predefined location, the server 116 retrieves a location record for that location, step 518 . The location record contains features and properties that can be assigned to the user, step 520 , when the user is at that particular location. The location features may include assigning special characteristics unique to that location to the user, and the location features change the user's properties. After changing the user property, the server 116 sends the new user property to the user, step 522 , and also sends the updated game information to the user, step 524 . The server 116 then repeats step 512 - 524 . [0033] The following is a use scenario for the invention. When developing a new game, a developer may sell advertising slots in the game to merchants who want to attract consumers to their stores. A merchant pays the developer to include his store as part of the game. The game developer incorporates the store's geographical coordinates into the game. The geographical coordinates preferably are in the same format as used in the GPS system and saved in a location database. After the store is integrated into the game, the store will affect the game's or user's characteristics. For example, in a dragon slaying game, the user may increase his character's physical strength in the game by the mere fact of being physically inside the store when playing the game. In another example, in the same dragon slaying game, a better sword may be available to the user's character when he steps into the store. The store may advertise these special game features and thus attract more people to the store. [0034] After the game is developed and placed on a server, the user may select the game for playing. The server may require the user to have a subscription for playing the game. The server provides a menu of available games to the mobile device and the user can select a game to play. After selecting the game, the selection and the user information is sent to the server, and the server may validate user information against a subscriber database before sending the game to the mobile device. The subscriber database may include user identification information and a password. The user identification information may also be the mobile device's electronic identification number (EIN) or mobile identification number (MIN). [0035] After verifying that the user is a subscriber, the server sends the game to the mobile device and enters into a monitoring mode. In the monitoring mode, the server receives user inputs, generates updated game information, and sends the update game information to the mobile device. [0036] The mobile device receives the game and displays it on a display screen. The mobile device also receives signals from the GPS system and calculates its own location information. The mobile device constantly sends user input and the location information to the server and receives the game information from the server until the user ends the game. [0037] When playing a game, the user notices a sport equipment store, for example, that provides special features to the game, and the user enters the sport equipment store. After entering the sport equipment store, the mobile device sends its new location information to the server. The server receives the new location information and checks it against the location database. When the server detects the mobile device is within a predefined location, i.e., the sport equipment store, the server retrieves a location record for the sport equipment store and enables special features listed for the sport equipment store on the mobile device. If the user leaves the sport equipment store when playing the game, the mobile device sends its new location information to the server, and the server takes away the special feature previously enabled for the mobile device. [0038] If the user interrupts the game, a game ending signal is sent to the server, and the server stores the current user and game information. When the user resumes the game, a game resumption request is sent to the server. After receiving the game resumption request, the server retrieves the user and game information, updates them according to the user's current location information, and sends the user and game information to the mobile device. [0039] In an alternative embodiment, the predefined location information may be embedded in the game that is downloaded to the wireless device. The wireless device, after receiving signals from the GPS satellites, calculates its own position and compares the position with the predefined locations embedded in the game. If the location matches one of the predefined locations, the game enables special a corresponding special feature for that location and sends the enabled special feature information to the server. The server receives the enabled special feature information and sends updates to other players in the game. [0040] In yet another alternative embodiment, the invention is a self contained apparatus that provides enhanced user interactive experience while the user is using a specific application as illustrated in FIG. 6. The user interface provided by the application changes according to the user's physical location. A list of predefined location information is embedded in the application that is downloaded to the mobile device. The user starts the application, step 602 , and the apparatus receives location information, step 604 , from outside sources such as GPS satellites or communications towers in a communications network. The mobile device, after receiving signals from the GPS satellites, calculates its current position, step 606 , and compares the position with the predefined locations embedded in the application, step 608 . If the location matches one of the predefined locations, the application modifies the application or enables special a corresponding special feature for that location, step 610 . While the user has not ended the application, step 612 , the apparatus repeats the steps of 604 - 610 . For example, if the user is visiting a science museum that provides this enhanced user interface experience, and he sees some previously unknown technical words. The user can request a dictionary application for his mobile device from an application server. [0041] When requesting this dictionary application, the mobile device provides the user's location information to the server. The server receives the request and the location information, matches the location information to the science museum, retrieves the dictionary application with a special feature provided by the science museum, and sends the dictionary application with the special feature to the mobile device. [0042] After receiving the dictionary application with the special feature, the user can look up special words, including technical acronyms, that are not included in a regular dictionary. [0043] In yet another alternative embodiment, the present invention is a self contained apparatus that receives an application through means other than wirelessly from an application server. The application is loaded via a data interface or a network interface and provides enhanced user interactive experience while the user is using the application. The application is equipped with a list of predefined locations that are used to compare with the apparatus' physical location. In this embodiment, the apparatus does not interface with any wireless network. An example of this embodiment is a compact disk based personal navigation application that runs on a personal navigation apparatus. The personal navigation application receives a map information from a compact disk provided by a third party vendor, and the map information includes a list of predefined locations. The compact disk with the map information is loaded into a disk drive connected to the personal navigation apparatus, and the map information is transferred to the personal navigation apparatus. The personal navigation apparatus also receives radio signals from either GPS satellites or other positioning systems. While using this navigation apparatus, if the user approaches an electronic store, a special coupon from the electronic store shows up on the display screen of the navigation device and invites the user to stop by. [0044] Although, the invention is described in terms of receiving signals from the GPS satellites, radio signals transmitted from other suitable navigation and positioning systems may be used as well. One example of the positioning system is Enhanced Observed Time Difference (E-OTD), which is a positioning system based on a wireless network. An E-OTD based device receives signals from neighboring communication towers, records the arrival time of these signals, and calculates its position using a triangulation technique. [0045] Furthermore, though, the invention has been extensively described in terms of playing games on a mobile device, the invention is equally applicable to other applications executed on the mobile device. [0046] In view of the method being executable on a server or a mobile device, the present invention includes programs resident in a computer readable medium, where the programs direct a server or other computer device having a computer platform to perform the steps of the method. The computer readable medium can be the memory of the server, or can be in a connective database. Further, the computer readable medium can be in a secondary storage media that is loadable onto a wireless communications device computer platform, such as a magnetic disk or tape, optical disk, hard disk, flash memory, or other storage media as is known in the art. [0047] In the context of the invention, the method may be implemented, for example, by operating portions of the wireless network to execute a sequence of machine-readable instructions, such as wireless communications device or the server. The instructions can reside in various types of signal-bearing or data storage primary, secondary, or tertiary media. The media may comprise, for example, RAM (not shown) accessible by, or residing within, the components of the wireless network. Whether contained in RAM, a diskette, or other secondary storage media, the instructions may be stored on a variety of machine-readable data storage media, such as DASD storage (e.g., a conventional “hard drive” or a RAID array), magnetic tape, electronic read-only memory (e.g., ROM, EPROM, or EEPROM), flash memory cards, an optical storage device (e.g. CD-ROM, WORM, DVD, digital optical tape), paper “punch” cards, or other suitable data storage media including digital and analog transmission media. [0048] While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail maybe made without departing from the spirit and scope of the present invention as set for the in the following claims. Furthermore, although elements of the invention may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated.
A system and method for enabling special features of an electronic game played on a mobile device 202 . The mobile device 202 receives GPS information to determine its location and transmits the location information to a server 116 . The server 116 uses the location information to alter the electronic game on the mobile device 202.
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BACKGROUND [0001] The field of the present invention is devices and processes for remote collection of bio-metric data using wireless mobile devices, and in some cases, the remote control of the wireless mobile device or a bio-metric sensor. [0002] The medical device industry has advanced to produce smaller and more effective biometric sensors. These sensors are used by a medical provider, such as a doctor or nurse, to collect important biological data regarding a patient. This data may include, for example, ECG, EKG, brain wave, temperature, pulse rate, hydration, blood chemistry, or glucose levels. In some cases, the provider is able to review the collected data and make an immediate therapeutic diagnosis, such as the case in finding an elevated temperature. In other cases, it is only by collecting data over an extended period of time that important medical results can be evaluated. In these cased, the medical provider may have to make several trips to the patient, or the patient will have to make several trips to the provider's office, before a meaningful result may be obtained. [0003] In other cases, patient data is only able to be monitored after an important event has occurred, for example, a mild heart attack. In these cases, the most critical data is never collected as the patient is not in their provider's office when the attack occurs. [0004] In one of the most challenge aspects of new drug development, a drug company typically pays for and orchestrates one or more human studies regarding safety and efficacy. These studies are time consuming and expensive, and rely on the voluntary participation of human subjects. These subjects must take their dosages according to predefined guidelines, and submit themselves for continual evaluation at a provider's office. Since the provider has only limited interaction with each subject, there is a substantial risk that the subject will forget of fail to follow the dosing regimen, will fail to participate in required follow-up and testing, or will have a negative reaction that is not detected in the short evaluation visit. [0005] Accordingly, there is a need for better collection and use of bio-medical data. SUMMARY [0006] Briefly, the present invention provides a wireless mobile device, typically in the form of a handset that is cable of providing voice and data communication using a wide-area wireless carrier system. The wireless handset has an associated bio-metric sensor, which may be integrally formed with the handset or spaced apart and connected with a wired or wireless connection. A patient uses bio-metric sensor to locally collect data, and then transmit that data to a medical server using the wireless handset. In some cases, the wireless handset may also process the data to transmit result or summary information. In other cases, the wireless handset may process the data to perform a local operation, such as signaling an alarm or displaying results to the patient, or to make an adjustment in the bio-metric sensor or other local medical device. In some cases the wireless handset may also receive commands from the medical server, and make an adaptation to the bio-metric sensor or other medical device, such as a medication pump. [0007] In one example, a patient uses a bio-metric sensor to collect glucose blood-chemistry data from time to time. The glucose sensor may be integral to a mobile wireless handset, or may connect using a wire or wireless communication. The mobile wireless handset may locally process the glucose level information, and present information or instructions to the patient. The wireless handset may also communicate the raw or processed data to medical server over a wireless communication channel, such as CDMA, GPRS, or UMTS. With greater computational and storage capability, the medical server may provide additional dosing or instructions to the patient. These messages may be delivered to the patient by voice or through a data message. In other cases, the medical server may send the data, or in a more critical case, an alert, to a medical provider or to an emergency responder. In some cases, the patient may have a local device for administering insulin or other medication, which may be activated or adapted from a command sent from the wireless mobile handset. This command may be locally generated responsive to a timer or to collected data, or may be a command received from a medical provider to from a medical server. [0008] Advantageously, the disclosed patient handset enables high quality medical care to be more efficiently provided. For example, a patient is able to collect bio-metric data at almost any location, and at any time, allowing for more frequent and consistent data collection, with minimal interruption to the patient's schedule. Medical providers are able to more closely monitor patient conditions and progress, and communicate with those patients using voice or data channels. For example, a doctor may talk to a patient while viewing data results in near-real time, even though both the doctor and the patient are hundreds of miles apart. Due to the ubiquitous nature of mobile handsets, such patient handsets may be readily deployed, and used in almost every geographic location. BRIEF DESCRIPTION OF THE DRAWINGS [0009] The invention can be better understood with reference to the following figures. The components within the figures are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. It will also be understood that certain components and details may not appear in the figures to assist in more clearly describing the invention. [0010] FIG. 1 is a simplified block diagram of a system for remote bio-medical data collection and device control in accordance with the present invention; [0011] FIG. 2 is a diagram of a patient handset constructed for use in a bio-medical data collection system in accordance with the present invention; [0012] FIG. 3 is a diagram of a patient handset constructed for use in a bio-medical data collection system in accordance with the present invention; [0013] FIG. 4 is flowchart of a process of using a biomedical sensor that is associated with a wireless mobile handset in accordance with the present invention; [0014] FIG. 5 is flowchart of a process for enabling a medical provider to receive data from a remote data collection device, and to issue commands to the control the device or sensor in accordance with the present invention; and [0015] FIG. 6 is a block diagram of processes, algorithms, and data structures used in a medical server in accordance with the present invention; DETAILED DESCRIPTION [0016] Referring now to FIG. 1 , a distributed biometric system is illustrated. System 10 advantageously enables the remote collection of biometric data, the automated communication of the biometric data to medical personnel, and the ability of medical providers to react to and control the biometric collection devices. In system 10 , data collection, communication, and control are provided in an authenticated and secure manner, assuring patient privacy as well as safely assisting the delivery of quality medical care. [0017] Biometric system 10 uses commercially available mobile voice and data communication systems 12 . Mobile communication system 12 may be operated by a telecommunication provider, and may use communication standards promulgated by national or international standards bodies. For example, mobile communication system 12 may comply with CDMA, CDMA 2000, WCDMA, EVDO, EVDV, GSM, GPRS, EDGE, PHS, PCS, or other telecommunication standards. The telecommunication system may also include or rely upon other communication protocols such as WiFi, 802.11, Bluetooth, WiMax, or other local or wide area data network. However, the reach and ubiquitous nature of the mobile telephone systems make the mobile telephone system the network of choice. Accordingly, the descriptions provided herein will describe the invention operating using a mobile telecommunications system, however it will be appreciated that other communication and data networks may be used. [0018] Mobile communication system 12 enables remote voice and data communication with mobile handsets, such as mobile handsets 14 , 21 , and 28 . The communication of voice and data between a mobile communication system and its associated mobile handsets is well known, so will not be described herein. In a similar way, the construction and deployment of mobile handsets is well known, so will not be described in detail. In one example, patient handset 14 allows voice communication to human medical providers, as well as data communication with a medical server 31 . In some cases, medical providers 42 and 44 may use medical server 31 to send device control commands to the patient handset 14 . [0019] Patient handset 14 couples to a medical or biometric sensor 16 . In one example, the medical sensor connects using a cable or line, and in another example, medical sensor 18 connects using a wireless communication, such as Bluetooth. The medical sensors 16 and 18 may be any kind of biometric or medical sensor useful for collecting patient data. For example, the sensors may provide an audio signal for hearing heart, lung, or breathing activity; may sense temperature, heart rate, blood pressure, glucose level, or other blood chemistry information; or may measure skin hydration, environment data, exercise data, or location information. It will be appreciated that the biometric or medical sensors may be constructed and configured to collect a wide range of useful information regarding patients and their environment. [0020] In another example, patient handset 21 has a medical sensor 23 integrally formed with the handset. In this way, the patient uses a single device for voice and data communication, as well as collecting medical data. Although this structure may provide a particularly efficient housing, the integrally formed medical sensor handset provides less flexibility then the discrete sensors discussed with reference to patient handset 14 . The patient handset 14 or 21 may operate local application software for controlling the handset's respective sensor or sensors. For example, the patient handset may determine when data is collected and when data is transferred to the medical server 31 . This determination may be done according to a time schedule; may be responsive to data collected at one or more medical sensors; or may be initiated by a local command given by the patient or a medical provider. It will be appreciated that other processes and triggers may be used to start or stop data collection and transfer data to medical server. [0021] The collected data may be sent to medical server 31 . The data may be sent in near real time, or may be collected and processed in the patient handset and then communicated to the medical server 31 from time to time. The medical server 31 is preferably stationed within the control of the mobile communication system 12 . In this way, enhanced security may be established between patient handsets and the medical server 31 . If the medical server is outside the protected environment of the mobile communication system, then additional authentication processes 33 must be used to assure the private and secure transmission of data, as well as to authenticate access to the medical server. A robust and flexible association and authentication process has been fully described in co-pending U.S. patent application Ser. No. 11/296,077 filed Dec. 7, 2005 and titled “Wireless Controller Device”, which is incorporated herein in its entirety. It will be appreciated that other authentication, association, and security processes may be used. Once the medical server 31 has received data from the patient handsets, that data may be processed or made available for use by medical providers, such as medical provider 42 and 44 . It will be appreciated that medical server 31 may operate automated processes for monitoring received data, and may automatically generate alarms or messages responsive to analyzing patient data. [0022] In some cases, a medical provider may also be operating remotely, and may use a provider handset 28 for both voice communication and for receiving data from the medical server 31 . Advantageously, biometric system 10 enables secure collection of medical data for patient, the transmission of that medical data to a medical server, and distribution and use of the data by distributed medical providers. Further, data collection and transmission may occur simultaneously with voice communication with the patient. In this way, a medical provider may be in voice communication with a patient while monitoring near real time medical data. [0023] To this point, the distributed biometric system 10 has been described as a data collection and distribution network. As an extension, system 10 also allows medical providers, such as medical providers 42 , 44 , and 28 to control and adjust the data collection process. For example, the authenticated medical providers may cause commands to be sent to patient handsets 14 and 21 for changing the way data is collected. These commands may be used with in the patient handset for adjusting the timing of data collection and transmission, or may be used with in medical sensors 16 , 18 or 23 for adjusting sensor configurations. [0024] The biometric system 10 may be advantageously used in several practical applications. For example, system 10 may enable the automated and remote monitoring of patients. In this way, medical data is collected according to predefined triggers, and that data may be locally or centrally processed to evaluate patient condition. Responsive to processing the medical data, the medical server or medical providers may determine when a patient needs more direct contact with a medical facility, or in some cases may even initiate or adapt medical treatment by sending commands to a local medical device. In this way, patients may be closely monitored with less intrusion into their lives, and a more advanced medical treatment sought before conditions become critical. More effective medical treatment may thereby be delivered to patients in a more comfortable and timely manner. [0025] In another example of use, clinical trials may use system 10 for controlling clinical studies. A medical server may be used to notify patients when to take a medication, or may even send commands to local medical devices to administer local doses. The medical server may also interrogate the patient with text messages, and solicit current medical information from the patient, or may call the patient using a voice capability the handset, and have the patient give an oral report. Since the patient handset has one or more local sensors, the medical server may also receive real-time or processed data from patients. In this way, more complete and accurate information may be obtained for trial studies, and patients having complications may be more quickly identified and removed from the study. Further, the cost of managing human clinical studies has skyrocketed, with some studies costing more than $30,000 per patient per year of study. Accordingly, a more efficient way of monitoring patients and collecting data could dramatically reduce study costs and increase the study's reliability, allowing beneficial drugs to come to market more quickly. [0026] In other examples, system 10 may be used to monitor athletes to assess performance and stress levels, or may be used to monitor military personnel or police. Also, even though the patient handset has been described as being associated with a single patient, in some cases the patient handset may be a handset used by a medical provider, such as an emergency responder. In this way, the emergency responder moves to the location of the patient, and then uses the patient handset to collect the patient's medical data, and transmit the patient data to a nearby hospital or other medical provider. In this way, the local hospital or medical provider may better understand patient condition, and either be prepared for the patients arrival, or even direct the patient to an alternative facility. With the efficient and accurate transmission of medical data, time may be saved in moving the patient to a preferred medical treatment location. [0027] Referring now to FIG. 2 , a patient handset system 50 is illustrated. Mobile handset 50 is similar to patient handset 21 described with reference to FIG. 1 , and is intended to operate within a distributed biometric system 10 . Handset 50 has a housing 52 holding a standard mobile handset. Typically, a mobile handset 52 will include a textual or graphical display 58 , input keys 60 , as well as internal circuitry for operating local programs as well as wide area communication. The mobile handset 52 may operate according to one or more wide area connection 54 , such as CDMA, WCDMA, UMTS, GSM, WiFi, or other wide area voice and data network. Typically, these wide-area connections are operated by a communication carrier, and the mobile handsets are particularly constructed to operate in a specific carrier's network. In some cases, mobile handset 52 also has a local area connection such as Bluetooth or 802.11. The local area connection 56 may be useful for connecting to other medical sensors, or to other peripheral devices such as headsets, medical devices, or hands-free car kits. Handset 52 also has an integrated medical sensor 62 . The medical sensor 62 may be constructed as a stethoscope, a heart rate monitor, a blood pressure monitor, a glucose monitor, or other biometric sensor. The mobile handset 52 may also have control keys 69 for allowing the patient or a medical provider to directly interact with medical sensor 62 . A speaker 64 may also be provided for sounding alarms or giving instructions. It will also be appreciated that the handsets regular speakerphone or earpiece may be used in this capacity. The mobile handset may also have alerts or alarm lights 66 associate with the medical sensor 62 . For example, lights 66 may indicate that a glucose level is dangerously low, or that the medical sensor is no longer receiving a required signal. The display 58 may also be used to display instructions on use of the medical sensor 62 , or may be used for outputting results or alarm information. [0028] Medical sensor 62 may initiate its data collection responsive to a manual local control, as when a patient or medical provider interacts with control buttons 69 . The medical sensor 62 may also operate responsive to an application running within the mobile handset itself, and thereby may periodically begin data collection, or take data collection responsive to some other application or trigger provided by the mobile handset. In another example, and other local medical sensor provides trigger data for medical sensor 62 . The mobile handset may also receive a command from a medical provider or from a medical server, and responsive to receiving the command, initiate or a just medical sensor 62 . The sensor data may be displayed locally to the patient or local medical provider, or the data may be logged in the memory of the mobile handset. The data may also be sent continuously to an associated medical server in near real time, or may be stored locally and periodically transmitted. Mobile handset 52 may also provide local analysis of data, and present local results to the patient or local medical provider. For example, medical sensor 62 may collect blood glucose information, process the data locally, and process and present the results locally. The raw data or resulting blood level data may then be transmitted to a medical server. [0029] Referring now to FIG. 3 , patient handset system 100 is illustrated. Patient handset 100 is similar to patient handset 21 described with reference to FIG. 1 and has many similarities with patient handset system 50 described with reference to FIG. 2 . Accordingly, mobile handset system 100 will be described with less detail. Patient handset system 100 has mobile handset 102 having a wide area connection 104 for transmitting and receiving data and voice. Mobile handset 102 also has a local area connection such as Bluetooth, Zigbee, or 802.11. The local area connection may be used to connect to a medical sensor 108 , or to a medical control device 113 , for example. The medical sensor 108 may include various control keys, alarms, and displays. The medical sensor 108 may be, for example, an EKG, ECG, blood pressure, thermometer, pulse, hydration, blood analysis, or glucose sensing device. It will be appreciated that other types of sensors may be used, or that multiple sensors may be connected. In operation, medical sensor 108 is positioned on or adjacent patient, and collects data responsive to a local or remote trigger. From time to time or in real time the medical sensor 108 communicates data back to the mobile handset 102 , which periodically transmits the data back to a medical server. The mobile handset will too may also receive commands from a medical provider or from the medical server for adjusting medical sensor 108 . In this way, a remote medical provider may interact with medical sensor 108 or the application interacting with the medical sensor operating on mobile handset 102 . In another control example, a medical control device 113 also uses the local area connection to interact with the mobile handset 102 . This medical control device 113 may be a pacemaker, IV drip, or medication pump, for example. This medical control device 113 may receive the command directly from mobile handset 102 , or the command may have been initiated from a medical server or a human medical provider, and communicated to the mobile handset via the wide area connection 104 . [0030] In one specific example, mobile handset 102 is used by a patient having a pain medication administered using a medication pump. The medication pump has a medical control device 113 which sets the flow rate or duty cycle or period of operation. A medical sensor 108 may be attached to the patient to monitor pulse rate, skin hydration, or other biometric indicator of pain. Further, the patient may use mobile handset 102 to communicate verbally to a medical provider. Responsive to receiving data that pain has increased, or responsive to a verbal communication from the patient, a medical provider may send a command to medical control device 113 to increase pain medication. In this way, a medical provider is able to accurately evaluate the patients condition, including speaking with the patient, and enable a change in medication delivery from a remote location. Accordingly, patient system 100 facilitates the timely and efficient delivery of high quality medical care. [0031] Referring now to FIG. 4 , a process for using a wireless medical sensor with a mobile handset is illustrated. In process 150 , a medical sensor is placed on or near a patient as shown in block 152 . This sensor may be a discrete sensor that connects or couples to a handset, or may be a sensor integrally formed in a wireless mobile handset. The sensor is configured as shown in block 154 . Configuring the sensor may include using local buttons or local commands from the mobile handset, and may include further instruction or commands from a medical server or remote medical provider. Data collection is triggered as shown in block 156 . Data collection may be triggered by a local command received at the sensor or on the handset, may be provided by an application operating on the mobile handset, or may be responsive to a command received from the medical server or remote medical provider. The collected data may be locally logged into memory as shown in block 161 , and may be locally processed as shown in block 163 . In some cases, the data logging and data processing steps may not be used, with raw data being transmitted to the medical server in near real time. In other cases, the logged data and processed data may be sent to the medical server as shown in block 167 . The data may also be locally displayed, as well as local results on display at 169 . The command may be received at the mobile handset from the wide area connection as shown in block 172 . This command may come directly from the medical server, from a medical provider connected to the medical server, or even from a medical provider operating a mobile handset. [0032] In another example, a command may be generated locally as shown in block 177 . This local command may be from an application operating on the mobile handset, or may be responsive to a patient or medical provider pressing a key. Any of these instructions may then be used to make adjustments in the data collection process. For example, the instruction may affect how the sensor is configured, what triggers the data collection, the amount of data logged, the type of data processing performed, or the timing of data transmissions. In this way, process 150 facilitates the secure and flexible collection of medical data, the use of the medical data by medical providers irrespective of their location, and the adaptation of the sensor and patient handset. Of course, the patient handset may facilitate voice communication 179 between the patient and medical providers, even while medical data is being collected and transmitted. [0033] Referring now to FIG. 5 , a process for a medical provider to access and control a biomedical sensor is illustrated. Process 200 allows a remote medical provider to access medical data, evaluate medical data, and control one or more devices associated with a patient. Although the medical provider may be connected to a medical server, in some cases the medical provider may be operating using a wireless mobile device, such as a portable computer or wireless handset. In these cases, the wireless mobile device provides a secure process for authenticating the medical provider to the medical server as shown in block 202 . Once the medical provider has been authenticated to the medical server, then the medical provider has to be associated with particular patients and their associated remote medical devices as shown in block 204 . In this way, a particular medical provider is only able to access data and control devices for that provider's set of patients. [0034] Once the medical provider has been authenticated and associated with their set of patients, the medical provider may select a particular patient, and receive data collected by that patient's medical sensor or medical sensors. As previously discussed, this data may be real-time, batch transmitted, and may include summary or processed results. The medical practitioner then may view and store this medical data or may provide additional analytic tools as shown in block 211 . Responsive to viewing the data, the medical provider may send a command to remote medical device at the patient's location as shown in block 213 . This command may be used to further adapt the medical sensor, or may provide control for another device, such as an IV pump, at the patient location. [0035] In another example, the medical provider may stand messages or data information to other medical providers for collaboration as shown in block 217 . In this way, multiple remote medical providers may cooperate in assisting a single patient, and all providers will be using the same medical data information. While receiving and analyzing medical information from the patient, the medical provider may also be in voice communication with the patient as shown in block 221 . Of course, the medical provider may also use forced vacation 221 to discuss the patient with other medical providers. [0036] Referring now to FIG. 6 , medical server processes 225 are illustrated. The connection of a medical server to a mobile communications system, as well as the operation of a general computer server, are well known, so will not be described in detail. Instead, the general processes operating on a medical server are described. Medical server 227 has processes 232 for authenticating and associating mobile devices with the medical server. The authentication and association processes are simplified when the medical server operates with in the controlled environment of the mobile communications system, but the medical server may also be connected on a more general network system such as the Internet. The server has mobile handset authentication information 241 , which is useful for authenticating patient handset to the medical server. The mobile handset authentication information 241 may include the mobile identification number for the handset, a serial number for the handset, IP address for the handset, or other identification information. The authentication information may also have carrier information, and password requirements for the user. Once a handset has been authenticated to the server, the server may then associate a particular patient handset with that handsets authorized biometric sensors, and may provide sensor configuration and interface information as shown in block 243 . This information may be specific to the particular sensor at a patients handset, or may be global to a class of products. In another example, sensors may be configured according to the particular medical requirements of the patient. [0037] The server 227 also maintains information for authorizing medical personnel 244 . Some medical personnel may login through existing server client processes, while others may access the server using their mobile handsets. For those using the mobile handsets, a mobile handset authentication information system to 46 is provided. In this way, a particular medical provider's handset may be authenticated to the server, and the medical provider associated with an authorized set of patients and patient records. Logging and legal requirements 248 may also be set on a global basis, a provider bases, or a patient basis. In this way, appropriate records may be maintained as to patient care. [0038] Processes 232 enable server 227 to communicate with a patients handset and its associated sensors, as well as access rules specific to that patient. For example rules 234 may include rules for when the server initiates data collection as shown in block 251 . Alternatively, authorized medical personnel may initiate data collection as shown in block 253 , or a patient may be allowed to initiate the collection as shown in block 255 . In other cases, other remote devices may be allowed to trigger or initiate data collection as shown in block 257 . The data collection rules also may include information as to the trigger for initiating data collection, how much data to store locally, then to transmit data to medical server, and what type of local display and processing may be allowed. In some cases, the collected medical data may be processed locally and used for further adapt in the medical sensor or local application. [0039] In other cases, server analytics 236 are applied to the received medical data by server 227 . Processing routines 262 may be applied to incoming data, and provided certain thresholds or patterns are seen, notifications may be sent to medical providers 264 or alarms may be generated 266 . The medical provider notifications 264 may include messages, automated phone calls, or other forms of notification. The alarm may also be used to notify medical providers, or may be set as a sound, illumination, or display on the patients handset. For example, if the processing routines 260 to determine that a heart rate is too high, a local alarm may be sounded at the patient's handset to warn the patient to reduce their level of exertion. In another example, responsive to the processing routines to 62 , the server may send commands to the patient's handset to 68 . These commands may then be used to adapt or configure the medical sensor, or may be used to set operation of another local medical device. [0040] While particular preferred and alternative embodiments of the present intention have been disclosed, it will be appreciated that many various modifications and extensions of the above described technology may be implemented using the teaching of this invention. All such modifications and extensions are intended to be included within the true spirit and scope of the appended claims.
A wireless mobile device is provided, typically in the form of a handset that is cable of providing voice and data communication using a wide-area wireless carrier system. The wireless handset has an associated bio-metric sensor, which may be integrally formed with the handset or spaced apart and connected with a wired or wireless connection. A patient uses bio-metric sensor to locally collect data, and then transmit that data to a medical server using the wireless handset. In some cases, the wireless handset may also process the data to transmit result or summary information. In other cases, the wireless handset may process the data to perform a local operation, such as signaling an alarm or displaying results to the patient, or to make an adjustment in the bio-metric sensor or other local medical device. In some cases the wireless handset may also receive commands from the medical server, and make an adaptation to the bio-metric sensor or other medical device, such as a medication pump.
7
BACKGROUND OF THE INVENTION The present invention relates generally to a seat suspension protection device and, more particularly, to a mechanical ride zone protection device for a pneumatic seat suspension having a swivel arm which pivotally moves with the seat and includes a cam which alternatively allows and prevents vertical seat adjustment. Many vehicle seats today are vertically adjustable using an air suspension. In such suspension systems, compressed air allows the seat to be raised or lowered vertically when actuated. These seat suspension systems generally include scissors linkage or parallelogram-type mechanical connections between the seat and the vehicle frame as generally described in U.S. Pat. Nos. 3,826,457; 3,339,906; 4,125,242; and 5,125,631; all incorporated herein by reference. As such, the seats are vertically adjustable only within a defined range, called the ride zone. The air suspension system allows the seat to be lowered to its lowest vertical position and raised to its maximum vertical height. A problem with such systems occurs when the seat occupant raises the seat to its maximum height or lowers the seat to its lowest point. At such extreme positions, the seat may provide little suspension and comfort for the seat occupant. As such, the seat is uncomfortable and may cause back ailments because the seat suspension is not working to provide suitable shock absorption. One way to prevent such problems from occurring is to prevent the seat from being positioned to its lowest and highest positions, i.e. to prevent or regulate the air suspension system from completely charging or discharging the air spring. The present invention provides for a mechanical apparatus which prevents the air compressor from working to charge the air spring to adjust the seat to its maximum height or completely discharge the air spring to "bottom out" the suspension. The present invention provides a mechanical apparatus which ensures that the seat remains within the intended ride zone, i.e. that the air suspension system operates to raise or lower the seat to maximum or minimum height levels that insure adequate shock absorption and comfort during normal operating conditions. SUMMARY OF THE INVENTION Many different types of vehicle seat suspension systems are used today. A popular type of vehicle seat suspension is a pneumatic air spring used in conjunction with a scissors arms or parallelogram linkage assembly. In such systems, the linkage assembly provides the rigid support structure while the air spring provides an actuation and suspension means to vertically adjust the seat height. In these types of seat suspension systems, a need has been found to exist to confine the vertical travel of the vehicle seat within a specified range--the ride zone. The ride zone is generally established to be that range of vertical adjustment within which the mechanical linkage assembly will work to provide comfortable support and shock absorption to the seat occupant. It will be appreciated, therefore, that the pneumatic adjustment mechanism and the mechanical suspension device are two independent systems working together to provide seat suspension and adjustment. As such, a need has developed for a device or system to allow these two independent systems to operatively associate to prevent the pneumatic adjustment system from causing the seat to be extended above or below its maximum or minimum intended positions. The present invention solves this problem. The present invention provides a mechanical swivel arm connected to a seat bottom which pivotally travels with the seat bottom, and a cam connected to the swivel arm which, based on the positioning of the cam relative to the seat bottom, alternatively permits or prevents the pneumatic seat suspension system to operate to raise and/or lower the seat. A primary object of the present invention is to provide a mechanical, ride zone protection device which is connected to the air suspension system actuation means and to the seat to allow or prevent seat height adjustment depending on the vertical position of the seat. A further object of the present invention is to provide an inexpensive ride zone protection apparatus adaptable for use with any air suspension system and easy to install and maintain to prevent vertical seat travel outside of the intended ride zone. Therefore, according to the present invention, a ride zone protection device is provided for use with a pneumatic seat suspension, comprising a cam connected to the seat in communication with the air suspension actuation means to alternatively permit and prevent actuation of the air suspension system based on the positioning of the vehicle seat. DESCRIPTION OF THE DRAWINGS The novel features which are characteristic of the present invention are set forth in the appended claims. However, the invention's preferred embodiments, together with further objects and attendant advantages, will be best understood by reference to the following detailed description taken in connection with the accompanying drawings in which: FIG. 1 is a side cross-sectional view of the present invention; FIG. 2 is a top cross-sectional view of the present invention. FIG. 3 is a side view of the present invention showing the seat in its uppermost intended position. FIG. 4 is a side view of the present invention with the seat in an intermediate position. FIG. 5 is a side view of the present invention showing the seat in its lowermost intended position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT One preferred embodiment of the present invention is shown in FIGS. 1 and 2 and designated generally 10. The depicted apparatus has a swivel arm 15 pivotally connected to a seat bottom 20 adjacent air suspension actuation means 25 and carrying a cam 41 cooperating with air suspension actuation means 25. Air suspension actuation means 25 includes a knob 26, a link 27, a valve 28 having an inlet 29 and an outlet 30, and a plunger 31. While many suitable valves are well known to those of ordinary skill in the art, one such valve used in the industry is manufactured by GT Development of Seattle, Wash. and used by Sears Manufacturing of Davenport, Iowa, part no. 6450113. Extending rearward from valve 28 is plunger 31 which terminates at a free end, and in this preferred embodiment has attached thereto a roller 33. Roller 33 is disposed within an aperture 40 in cam 41. Valve 28 operates to allow air to charge the air suspension system to raise the seat or to discharge the air suspension system to lower the seat. Valve 28 is operated by movement of knob 26 and link 27. As is common in many pneumatic valves, valve plunger 31 remains in a neutral, non-actuated position unless acted upon. Valve 28 may be actuated by either pushing or pulling plunger 31 relative to valve 28. When plunger 31 is retracted (i.e., valve 28 moves rearward relative to plunger 31), air is charged into the suspension system to raise the seat. When plunger 31 is extended (i.e., valve 28 moves forward relative to plunger 31), air is discharged from the suspension system, which lowers the seat. Actuation of the preferred embodiment of the present invention will now be described. Knob 26 is pivotally connected to link 27 which is pivotally connected to valve 28 which is operatively connected to plunger 31. Raising knob 26 causes link 27 to move rearward which exerts a similar force on plunger 31. If roller 33 attached to plunger 31 contacts rear surface 43 of cam aperture 40, plunger 31 retracts relative to plunger 31. Plunger 31 retracting within valve 28 opens valve 28 allowing air into the suspension system to raise the seat. On the other hand, lowering knob 26 causes link 27 to move forward with valve 28. Movement of valve 28 tends to cause plunger 31 and roller 33 to also move forward. If roller 33 contacts forward surface 45 of aperture 40, however, movement of plunger 31 is prevented, thus causing plunger 31 to extend from valve 28 which causes air to be discharged from the suspension system to lower the seat. It will be appreciated, therefore, that aperture 40 of cam 41 is designed such that as the position of cam 41 changes relative to seat bottom 20, movement of roller 33 is restricted or unrestricted permitting or preventing extension or retraction of plunger 31 relative to valve 28. Only when valve 28 moves relative to plunger 31 (i.e. valve 28 moves and plunger 31 is prevented from so moving) will valve 28 operate to allow air into or out of the air spring suspension system. It will be appreciated that as seat 20 is raised or lowered, the angle Θ between the swivel arm 15 and seat bottom 20 will change. As angle Θ changes and swivel arm 15 pivotally rotates, the position of roller 33 within aperture 40 will change. As seen in FIG. 5, when seat 20 is in its lowest intended position, swivel arm 15 will be substantially parallel to seat 20 (angle Θ thus being minimized). When in this position, roller 33 will be in the lowermost portion of aperture 40. Aperture 40 is thus designed to allow forward movement of roller 33, and thus plunger 31 with valve 28, when seat 20 is in this position. Allowing forward movement of plunger 31 with valve 28 when seat 20 is in this position prevents further discharge of air from the suspension assembly which prevents seat 20 from being lowered further. On the other hand, in this position, aperture 40 prevents rearward movement of plunger 31 which permits retraction of plunger 31 relative to valve 28 to charge the suspension system to raise the vehicle seat. Conversely, when seat 20 is in its uppermost intended position as seen in FIG. 3 (Θ will be maximized), roller 33 will be in the uppermost portion of aperture 40. When in this position, the contours of this portion of aperture 40 work to allow rearward movement of roller 33, and, thus, plunger 31 with valve 28. Allowing rearward movement of plunger 31 with valve 28 prevents the seat occupant from charging the suspension assembly which prevents further raising of seat 20. On the other hand, in this position aperture 40 prevents forward movement of plunger 31 which allows valve 28 to discharge the system to lower the vehicle seat. In the third scenario as shown in FIG. 4, the seat is in any position between its lowest intended position and its highest intended position. In this scenario, roller 33 will be disposed in any possible position within aperture 40. When the seat is within this range, the air suspension system must be actuatable to both raise and lower the seat. As such, plunger 31 must be prevented from extension or retraction relative to valve 28. Aperture 40 is designed such that, when the seat is anywhere within this range, fore or aft movement of plunger 31 is prevented. Preventing both fore and aft movement of plunger 31 ensures that valve 28 can charge or discharge the system to raise and lower the seat. It will be appreciated by those of ordinary skill in the art that many variables will affect the shape and contours of aperture 40, including but not limited to the size and shape of roller 33 and aperture 40, the length of plunger 31, the intended ride zone, the placement of swivel arm 15, and the placement of cam 41. The present invention thus provides a reliable, mechanical system which ensures ride zone protection for a vehicle seat using a pneumatic seat suspension system. The present invention provides a communicative bridge between a mechanical seat support system and the pneumatic seat suspension system used to adjust the height of the seat. Of course, it should be understood that various changes and modifications to the preferred embodiments described herein will be apparent to those skilled in the art. Other changes and modifications, such as those expressed here or others left unexpressed but apparent to those of ordinary skill in the art, can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is, therefore, intended that such changes and modifications be covered by the following claims.
According to the present invention, a ride zone protection device is provided for use with a pneumatic seat suspension, comprising a cam in communication with the air suspension actuation means to alternatively allow and prevent actuation of the air suspension based on the positioning of the vehicle seat.
1
This is a continuation-in-part of application Ser. No. 07/534,376, filed June 7, 1990, which in turn is a continuation-in-part of application Ser. No. 07/306,304, filed Feb. 3, 1989, both applications being now abandoned. BACKGROUND OF THE INVENTION This invention relates to oxide superconductive materials and a method of preparing such materials. Recently, YBaCuO system materials have been reported as superconductives materials, and various tests and studies are being carried out on such materials. As a result, these materials have been reported as being very unstable and low in the critical current. Besides, the cost of such materials is high because rare earth elements are used in significant quantities, and the cost is susceptible to market fluctuations. It is desired to be improve upon these points. More recently, new materials of an SrBiCuO system have been reported, but details are not known at the present time. SUMMARY OF THE INVENTION It is a primary object of this invention to present a material free from the above problems in respect to the critical current values, stability, and economic aspects of such materials. The material of this invention is characterized firstly in the, the orientation of the C-plane of oxide superconductive materials and secondly resides in the use of ABiCuO as the principal constituents of the superconductive material (in which A comprises at least one kind of element composed of alkaline earth group metals). This material is almost free from erosion by water or the like probably due to the nature of the orientation, since the oriented C-plane surface prevents the undesirable progress of erosion and further it does not contain rare earth elements and alkaline earth elements that causes instability as being in an unstable form. In addition, the solid solution range is estimated to be broad, and probably owing to this property, the material is stable in always containing a high temperature superconductor phase. Furthermore, since the C-plane orientation has a specific intra-plane Cu chain arrangement, it seems to contribute to the enhancement of the critical current. It seems that further excellent characteristics are obtained because a proper element-to-element distance is realized by mixing alkaline earth elements larger than and smaller than 1 Å in ion radius. As a result, the materials of the present invention excels in economy because the materials have a high critical current and do not contain the expensive and marketably unstable rare. While the novel features of the invention are set forth in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description. DETAILED DESCRIPTION OF THE INVENTION As a result of follow-up tests on general recent YBaCuO system materials, the transition temperature was about 90° K., according to the investigation by the present inventors, even in the optimum composition of the so-called 123 (the ratio of Y/Ba/Cu). When the composition was slightly varied, an impurity phase was generated, and the characteristics fluctuated. This material was fabricated into a wire by hot extrusion at 950°, and the critical current was measured at 50° K. This value is called reference value 1 of this invention. By contrast, according to the investigation of the present inventors, the new material possesses stable and excellent characteristics as follows. Oxides containing at least one type each from a group of Mg, Ca of which the ion radius is 1 Å or less, and a group of Sr, Ba, and also Bi and Cu were weighed so that the ratio of the three A/Bi/Cu might be nearly 5/3/5, 3/2/3, 2/1/2 or in their vicinity, and were uniformly mixed, and temporarily sintered at 800° to 850°, crushed, formed and baked at 830° to 870°. A sintered polycrystalline material was thus-produced. The material was extruded at 800° C. A nozzle with a rectangular section having an axial ratio of 5/1 was used. It is known that the better results are obtained when this ratio is higher, but according to the experiment by the present inventors, if the ratio was 3/1 or over, a high C-plane orientation was obtained radiographically. In the X-ray diffraction diagram, the rate of (00n) intensity of the total of the oriented oxide superconductive materials is approximately over 80%. The obtained results are shown in Table 1. TABLE 1__________________________________________________________________________Composition Transition Current Zero-resistanceSr Ca Ba Mg Bi Cu temperature ratio Phase temperature__________________________________________________________________________ 1 3.3 1.7 0 0 3 5 105 3 Single 101 2 3.8 2.2 0 0 4 5 108 4 Single 100 3 3.5 2.5 0 0 4 5 110 6 Single 106 4 4.5 1.5 0 0 5 4 113 2 Single T 5 3.0 3.0 0 0 3 5 102 5 Single 99 6 0.5 0.5 0 0 1 1 82 1 Plural 78 7 1.5 1.5 0 0 2 2 81 2 Plural T 8 1.0 1.0 0 0 1 2 101 9 Plural T 9 2.0 2.0 0 0 2 3 84 2 Plural 8310 2.0 2.0 1 1 4 5 106 4 Single 10111 2.0 2.0 1 3 5 101 4 Single 9012 4.0 0.5 1 0.5 4 5 110 8 Single T13 2.0 1.0 0.5 0.5 2 3 101 8 Plural 9514 2.0 2 2 3 23 0 Plural 1215 1.5 1.5 2 3 105 4 Single 10316 0.5 0.5 0 0 1 1 82 2 Plural T17 1.5 1.5 0 0 2 1 81 1 Plural T18 1.0 1.0 0 0 1 1 101 6 Plural 9519 2.0 2.0 0 0 2 1 84 2 Plural T20 2.0 1.0 0.5 0.5 2 1 101 3 Plural T21 0.5 0.5 0 0 0.2 1 103 4 Single T22 0.5 0.5 0 0 1/3 1 101 4 Single 9423 0.5 1.0 0 0 0.2 1 110 9 Single T24 0.5 1.0 0 0 1/3 1 106 3 Single T25 0.5 1.0 0 0 1/4 1 113 7 Single 10826 0.5 0.5 0.2 0.2 0.3 1 105 7 Single 9627 0.3 0.6 0.2 0.1 0.3 1 101 2 Single 9028 0.2 0.9 0.1 1/4 1 102 6 Single T29 0.4 0.9 1/4 1 113 7 Single 106__________________________________________________________________________ As obvious from the table, the transition temperature was stable in all examples. Moreover, by mixing the elements of the two groups, the transition temperature was over 80° K. as compared with 20° to 30° K. in the case of a single group composition. In the humidity resistance test performed by subjecting the materials to high temperature and high humidity (60°, 60%) for a month, the so-called YBaCu system materials were whitened on the whole and were considerably decayed, whereas the new materials were only slightly whitened on the surface and were very stable. As known from Table 1, in spite of single phase and plural phases, basically, the ratio of the critical current to the reference value was remarkably improved in all materials (except for material 14), and excellent characteristics were found. In respect to the superconductor material in Example 14 of Table 1, Sr and Ba are contained therein and have ionic radiuses larger then 1 Å. On the other hand, the other examples of this table were mixed, i.e. contained ions with a smaller ionic radius than 1 Å. Accordingly, it is presumed from the results shown therein that mixtures of components having different ionic radiuses were more effective in improving the properties of the final product than the individual components. More precisely, a careful examination of the table shows that in the mixed states (wherein the ratios of A with a radius of 1 Å or larger in combination with an A component with an ionic radius of less than 1 Å was between 5/1-1/3) excellent results are obtained. Further, when examining the data in Table 1, it is noted that when the averages of the ratio of Bi and Cu where computed, the ion ratio of Bi to Cu is 2/3. Further, it is noted that preferable ranges of the ion ratios are represented by 2≧A/Bi≧1.5, Bi/Cu<1, and A/Cu≦2, where A represents the sum of Sr and Ca. When such ratio exists, excellent characteristics are found within the broad scope of the materials of Table 1 in that compositions falling within this range exhibit remarkable effects as a super-conductor. Also, it is noted that excellent characteristics are found where A/Bi>4.5. As the X-ray analysis results show, a crystal phase in a composition ratio in the vicinity of the single 3/2/3 or 5/3/5 is formed in a considerably wide range (it is estimated, as presently investigated, to be composed of a superlattice of a pseudotetragonal system with a unit cell of 5.4 Å, considering together with the results of transmission electron microscopic findings, as being nominally expressed as an orthorhombic system with lattice constants of a=5.4 Å, b=5.4×5=27.0 Å and c=15.3×2=30.6 Å), and it is known that it is very easy to cleave on the C-plane. It is assumed that the high orientation of more than 80% is due to the cleaving characteristics of the materials. Therefore, this technology of extension can be applied to other oxide superconducting materials which shows clear cleaving characteristics. According to the invention, materials excelling in humidity resistance, broad in the solid solution range, large in critical current, and superior in safety and reproducibility may be produced, which may be widely applied in superconductive appliances. While specific embodiments of the invention have been illustrated and described herein, it is realized that other modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all modifications and changes as fall within the true spirit and scope of the invention.
An oxide superconductive material comprising constituent elements mainly composed of ABiCuO in which A comprises at least one element of alkaline earth metals, and having a C-plane orientation, and a method of orienting such superconductive materials by hot extrusion from a rectangular nozzle.
8
FIELD OF THE INVENTION The Present invention describes a process of setting stone in jewelry by using computer aided numerically controlled (CNC) system. OBJECTIVE The objective of this invention is to invent an easy and automated process of setting stone in jewelry. Another objective is to invent a process of stone setting which produces lesser residual stress in precious metal. Yet another objective is to invent process of stone setting which results in minimum rejection due to stone damage BACKGROUND OF THE INVENTION Use of stones as decorative elements of jewelry is prevalent since ages. Various precious and semiprecious stones are used which are fixed in precious metals. Conventional method of stone setting comprises of manually bending of metal around stone using a hammer and chisel. Thus the stone gets entrapped in the metal groove. However, the quality of product thus produced depends on attention and skill of the operator and therefore inconsistent products are produced. Another Method of manual setting is the use of pressing machine with pre-made hardened tool which presses the precious metal around the stone as described in Patent W09829005A1 (Publication Number) However this Process is dependent on the length of the stroke which operator applies. In other words, the dependence on operator remains, though of a lower order. U.S. Pat. No. 6,095,256 and U.S. Pat. No. 3,747,692 describe the process of manual stone setting where oscillating pneumatic hammer is used for pressing metal against stone; Here too, the dependence on operator's skill in pressing of the metal sheet obliquely against the Precious stone remains important. Patent US20070204464 A1 describes use of machines for cutting jewelry items. This method may not result in operator fatigue but still depends on his skills in operating machine. Thus all the known processes of setting stone eventually depend on mechanical skill. Even a skilled operator cannot produce consistent output depending on the various constraints. Our Invention overcomes these problems and improves productivity. STATEMENT OF INVENTION Our invention uses CNC machine for setting stone in precious metal. By using a master-stone, which is referentially equivalent of the stone to be set, and which is made of any metal or substantially equivalent hard material, the boundary dimensions of the stone are captured by manual X and Y direction movement of the dual purpose pressing tool, mounted on CNC machine. The dimensions thus captured are converted to computer language by the converter and fed to computer. With reference to dimensions thus fed, instructions are released from computer to Converter which converts and releases instructions in machine language to produce desired X, Y and Z direction movement in CNC machine, with or without rotation as desired. CNC machine caries out pressing of the metal sheet obliquely against the Precious stone in micro-steps and simultaneously smoothens the metal surface thereby folding the edge of metal for securing the stone in precious metal. By virtue of the above process being gradual & consistent, it thereby produces lesser residual stress in metal. Probability of stone damaging is also minimized. BRIEF DESCRIPTION OF DRAWINGS FIG. 1 shows the Computer aided numerically controlled system comprising of interconnected CNC machine, Convertor and Computer. FIG. 2 shows CNC machine with master-stone held in fixture. FIG. 3 shows the illustrative master-stones with depressions used for setting reference. FIG. 4 shows pressing tool and cutting tool deployed for the embodiment. FIG. 5 shows illustrative progressive stages of stone setting. FIG. 6 shows calibrating referencing relationship. FIG. 7 shows illustrative trajectory of movement of tool. DETAILED DESCRIPTION OF INVENTION Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description or drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. FIG. 1 shows our invented system ( 3 ) of stone setting, comprising a computer aided numerically controlled (henceforth called CNC) Machine ( 1 ), Converter ( 2 ) and computer system ( 25 ) with display ( 5 ) and input devices ( 13 ). The system is electrically interconnected such that computer instructions are converted in machine language which is received by the CNC machine and it accordingly produces linear and rotary movements. It is possible that computer system has integral converter and therefore directly transacts in machine language compatible with CNC machine. CNC machine ( 1 ) comprises of: (a) Motor-Gear mechanism ( 18 ) which provides X and Y axis linear movement to Fixture ( 10 ) and which pro vides Z axis movement to pressing tool ( 11 ) or Cutting tool ( 14 ) and which provides rotary movement around Z axis to Cutting tool ( 14 ); (b) Fixture ( 10 ) for holding master-stone ( 16 ) or ( 16 A), or Jewelry ( 23 ) wherein the stone ( 21 ) is to be set, (c) Tool holder ( 12 ) for holding tool ( 14 / 11 ). (d) Relays (not explicitly shown) which switch ON or OFF as per commands received and thereby produce correspondingly desired movement. The Converter ( 2 ) converts the computer language into machine language and vice versa. Display ( 5 ) of the computer ( 25 ) is used for visually relating & monitoring; and input devices ( 13 ) facilitate keying in inputs. FIG. 3 describes herein two kinds of shapes of master-stone ( 16 ) and ( 16 A) used for setting reference, and they relate to corresponding shapes of stone to be set in jewellery. Description provided in this embodiment is with respect to master-stone ( 16 ) but the invention is not limited to shapes ( 16 ) and ( 16 A). Master-stone has depression ( 31 ) in the centre known as a central depression and ( 27 , 28 , 29 , 30 ) at the extremes known as a plurality of extreme depressions for setting up reference. Pressing tool ( 11 ) has bottom tip ( 11 A) of such shape that when pressing tool is made to firmly seat over any of the plurality of extreme depressions ( 27 , 28 , 29 , 30 , 31 ); its axis ( 11 C) aligns substantially with the centre of any of the plurality of extreme depressions ( 27 , 28 , 29 , 30 , 31 ). Thus, the bottom tip ( 11 A) is used for setting reference while side of the tool is used for pressing the metal and thus the tool serves two or dual purpose. To set references, Master-stone ( 16 ) is held in the fixture ( 10 ). Pressing tool ( 11 ) is manually lowered and made to firmly seat over the central depression ( 31 ). Correspondingly on the screen some value of the X and Y co-ordinates appears forming a first reference point. By input device ( 13 ), the value of co-ordinates corresponding to the central depression ( 31 ) is changed to X=0 and Y=0. Thus is set the calibrating reference point. FIG. 6 facilitates this understanding. Further, the pressing tool ( 14 ) is manually made to firmly seat over the plurality of extreme depressions ( 27 , 28 , 29 and 30 ) and correspondingly now the computer calculates and registers their X and Y co-ordinates i.e. other reference points, taking co-ordinates of the central depression ( 31 ) as X=0 and Y=0, which is calibrating reference point. This way, overall configuration of the shape of the stone to be fixed in jewellery e.g. ( 16 ) or ( 16 A) etc. is set. Next, the master-stone ( 16 ) is replaced by item of jewellery ( 20 ). Corresponding to this item of jewellery ( 20 ) and with details of reference points ( 27 , 28 , 29 , 30 , 31 ), the computer ( 25 ) computes required movement of the tools ( 11 / 14 ) to achieve desired shape, based on instructions previously stored in its memory. Computed output from computer ( 25 ) generates sequence of instructions to converter ( 2 ) which issues instructions in machine language to CNC machine ( 1 ) to carry out following as shown in FIG. 5 : (a) Removing of irregularity ( 22 A) and achieve dimensions corresponding to limits set by the plurality of extreme depressions ( 27 , 28 , 29 and 30 ) by using cutting tool ( 14 ) by issuing command so as to generate rotary movement causing cutting action, generate movement in Z axis and progressive and incremental movement in X and Y axis, one axis at a time. (b) Progressive inward bending of vertical wall ( 22 B) by using pressing tool ( 11 ) by issuing command so as to generate movement in Z axis and progressive and incremental movement in X and Y axis, as per trajectory described in FIG. 7 . After completing operation as in (a) above, the stone is manually placed in the socket ( 20 ). Also, cutting tool ( 14 ) is removed and pressing tool ( 11 ) is mounted in the tool holder ( 12 ). For operation as in (b) above, the pressing tool is made to firmly touch the vertical wall ( 22 B) from outside. It then follows the trajectory ( 41 to 42 , 42 to 43 , 43 to 44 , 44 to 45 ). Since the required inside dimension is known due to prior setting of other references points ( 27 , 28 , 29 and 30 ), the computer computes the total incremental movement (point 40 to point 45 )+(point 45 to point 50 )+ . . . needed to achieve required bend and therefore, the process is independent of variation in thickness ( 22 C) in the vertical wall. Various shapes of master-stones can be used depending upon the jewelry. The tool movement trajectory i.e. the path of the movement of tool as shown in FIG. 7 varies and is calculated by CNC system depending upon the referencing points, through which the CNC system gets inputs of shape of stone. The least count of the X, Y movement, (on which depends the setting of distance from point 40 to point 45 , point 45 to point 50 , . . . ) of this system is as low as less than 0.1 mm and therefore the process of setting stone is more gradual than any manual process, since the incremental movements are small. This results in minimal residual stress in the metal. The system computes required incremental X and Y movement to the accuracy of less than 0.1 mm Thus there is no possibility of stone getting excessively pressed or getting damaged.
A process of setting stone in jewelry by using computer aided numerically controlled (CNC) system. Precious metal is cut and bent around stone using CNC machine. The process exploits capability of CNC machine by achieving gradual and consistent bending which results in minimum residual stress in precious metal and eliminates possibility of damage to stone.
8
RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Patent Application No. 61/143,407 filed Jan. 8, 2009 entitled “Probe Apparatus for Recognizing Abnormal Tissue”, the entire contents of which is incorporated by reference herein. [0002] This application is related to co-pending U.S. patent application Ser. No. 11/604,653 filed Nov. 27, 2006, entitled “Method of Recognizing Abnormal Tissue Using the Detection of Early Increase in Microvascular Blood Content”, the disclosure of which is incorporated in its entirety by reference, which application claims priority to U.S. Application No. 60/801,947 entitled “Guide-To-Colonoscopy By Optical Detection Of Colonic Micro-Circulation And Applications Of Same”, which was filed on May 19, 2006, the contents of which are expressly incorporated by reference herein. [0003] This application is also related to co-pending U.S. patent application Ser. No. 11/604,659 filed Nov. 27, 2006 and entitled “Apparatus For Recognizing Abnormal Tissue Using The Detection Of Early Increase In Microvascular Blood Content,” the contents of which are expressly incorporated by reference herein. [0004] This application is also related to co-pending U.S. patent application Ser. No. 11/261,452 entitled “Multi-Dimensional Elastic Light Scattering”, filed Oct. 27, 2005, the contents of which are expressly incorporated herein by reference. [0005] Some references, which may include patents, patent applications and various publications, are cited and discussed in the description of this invention. The citation and/or discussion of such references is provided merely to clarify the description of the present invention and is not an admission that any such reference is “prior art” to the invention described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference. FIELD OF THE INVENTIONS [0006] The present invention relates generally to light scattering and absorption, and in particular to probe apparatuses and component combinations thereof that are used to screen for possibly abnormal living tissue BACKGROUND [0007] Optical probes are known that detect optical signals. Simple optical probes will transmit broadband or a laser light to a target with one optical fiber, and receive the light such as light that is elastically scattered from a specimen, fluorescent light, Raman scattered light, etc., with another optical fiber. The received backscattered light can be channeled to a receiver, such as a CCD array, and the spectrum of the signal is recorded therein. [0008] While such probes work sufficiently for their intended purposes, new observations in terms of the type of measurements that are required for diagnostic purposes have required further enhancements and improvements. SUMMARY [0009] The present inventions relates generally to light scattering and absorption, and in particular to probe apparatuses and component combinations thereof that are used to recognize possibly abnormal living tissue. [0010] In one aspect, the embodiments described herein are directed toward an apparatus that emits broadband light obtained from a light source onto microvasculature of tissue, particularly in a mucosal tissue layer disposed within a human body, and receives interacted light that is obtained from interaction of the broadband light with the microvasculature for transmission to a receiver. [0011] In another aspect, the embodiments described herein are directed toward a apparatus that emits broadband light obtained from a light source onto tissue disposed within a human body, particularly in a mucosal tissue layer disposed within a human body, and receives interacted light that is obtained from interaction of the broadband light with the microarchitecture tissue for transmission to a receiver. [0012] In a particular aspect, a disposable, finger mounted optical probe is described. [0013] In a further embodiment, an optical probe that contains a disposable tip with a retractable integral probe is disclosed. [0014] Different further embodiments of both the disposable, finger mounted optical probe and the optical probe that contains the disposable tip with the retractable integral probe are described which include various combinations of optical fibers, polarizers and lenses that assist in the selection of a predetermined depth profile of interacted light for a variety of different wavelength ranges of light, and for different applications. BRIEF DESCRIPTION OF THE DRAWINGS [0015] These and other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures, wherein: [0016] FIGS. 1 and 2 illustrate a housing of a disposable, finger mounted optical probe according to one embodiment. [0017] FIG. 3 illustrates a disposable tip and re-usable trunk usable in one embodiment of the disposable, finger mounted optical probe. [0018] FIGS. 4( a )-( b ) illustrate another embodiment of the disposable, finger mounted optical probe containing a pre-loaded optical assembly. [0019] FIGS. 5 a - 5 c are illustrations of the method of use of the disposable, finger mounted optical probe. [0020] FIGS. 6A , B( 1 )-( 2 ) and C show usage of an embodiment of an optical probe that contains a permanent housing and disposable tip with retractable integral optical fibers. [0021] FIG. 7 illustrates a partial illustration of a particular embodiment of an optical probe that contains a permanent housing and a disposable tip assembly with a retractable integral optical fiber assembly. [0022] FIG. 8 illustrates a partial illustration of another particular embodiment of an optical probe that contains a permanent housing and disposable tip assembly with a retractable integral optical fiber assembly. [0023] FIG. 9 illustrates a particular embodiment of a disposable tip that includes a protective sheath that is used with the optical probe that contains a permanent housing and disposable tip assembly with a retractable integral optical fiber assembly. [0024] FIG. 10 illustrates a partial illustration of a further particular embodiment of an optical probe that contains a permanent housing and disposable tip assembly with a retractable integral optical fiber assembly and an integral CCD module. [0025] FIG. 11 illustrates a particular optical probe assembly configuration used for EIBS. [0026] FIG. 12 illustrates another particular optical probe assembly configuration used for EIBS. [0027] FIG. 13 illustrates a further particular optical probe assembly configuration used for EIBS. [0028] FIG. 14 illustrates in cross section an embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 . [0029] FIG. 15 illustrates in cross section a further embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 . [0030] FIG. 16 illustrates a particular optical probe assembly configuration used for LEBS. [0031] FIG. 17 illustrates another particular optical probe assembly configuration used for LEBS. [0032] FIG. 18 illustrates a further particular optical probe assembly configuration used for LEBS. [0033] FIG. 19 illustrates a further particular optical probe assembly configuration used for LEBS. [0034] FIG. 20 illustrates a further particular optical probe assembly configuration used for LEBS. [0035] FIGS. 21( a ) and ( b ) illustrate in cross section an embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 . [0036] FIG. 22 illustrates in cross section a further embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0037] The present inventions are more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Various embodiments are now described in detail. Referring to the drawings, like numbers indicate like components throughout the views. As used in the description herein, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. Moreover, titles or subtitles may be used in the specification for the convenience of a reader, which shall have no influence on the scope of the present invention. Additionally, some terms used in this specification are more specifically defined below. [0038] The terms used in this specification generally have their ordinary meanings in the art, within the context of the invention, and in the specific context where each term is used. Certain terms that are used to describe the invention are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the invention, For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, not is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification. [0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In the case of conflict, the present document, including definitions will control. [0040] As used herein, “around”, “about” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around”, “about” or “approximately” can be inferred if not expressly stated. [0041] The present invention, in one aspect, relates to a probe apparatus that is used for optically screening a target for tumors or lesions. Various targets and corresponding optical probe types are disclosed, as well as various different probe housing designs are disclosed, and combination of them can be used interchangeably. Certain of the optical probe designs are for use in detecting what is referred to as “Early Increase in microvascular Blood Supply” (EIBS) that exists in tissues that are close to, but are not themselves, the lesion or tumor. Other of the LEBS (Low-coherence Enhanced Backscattering) optical probe designs are for use in detecting backscattered light that results from the interaction of low-coherent light with abnormal scattering structures in the microarchitecture of the tissue that exist in tissues that are close to, but are not themselves, the lesion or tumor. Both of these optical probe types, which have been described in applications previously filed and which are, as a result, known. As will be described herein, whether detection is made using the techniques associated with EIBS or LEBS probes and microarchitecture of the tissue, the probes as described herein, while normally made for usage with one of these techniques, will have aspects that are common between them. [0042] One difference between a probe that detects EIBS and an LEBS probe that detects tissue microarchitecture is that with an probe that detects EIBS, data from a plurality of depths can be obtained in one measurement by looking at co-pol and cross-pol and co-pol minus cross-pol received signals, whereas for an LEBS probe, only one depth is obtained for a specific configuration. [0043] A particular application described herein is for detection of such lesions in colonic mucosa in early colorectal cancer (“CRC”), but other applications such as pancreatic cancer screening are described as well. [0044] The target is a sample related to a living subject, particularly a human being. The sample is a part of the living subject, such that the sample is a biological sample, wherein the biological sample may have tissue developing a cancerous disease. [0045] The neoplastic disease is a process that leads to a tumor or lesion, wherein the tumor or lesion is an abnormal living tissue (either premalignant or cancerous), which for the probes described herein is typically a colon cancer, an adenomatous polyp of the colon, or other cancers. [0046] The measuring step is performed in vivo using the probes described herein and may further comprise the step of acquiring an image of the target. The image, obtained at the time of detection, can be used to later analyze the extent of the tumor, as well as its location. [0047] In the various embodiments, the probe projects a beam of light to a target that has tissues and/or blood circulation associated therewith, depending upon the target type. Light scattered from the target is then measured, and target information is obtained from the measured scattered light. The obtained target information can be information for the targets as described in the patent applications incorporated by reference above, as well as the data related to blood vessel size and oxygenated hemoglobin as described in U.S. patent application Ser. No. 12/350,955 filed Jan. 8, 2009 entitled “Method Of Screening For Cancer Using Parameters Obtained By The Detection Of Early Increase In Microvascular Blood Content” filed on this same day, bearing Attorney Docket Number 042652-0376943. [0048] The beam of light projected is obtained from a light source that may comprise an incoherent light source (such as a xenon lamp, light emitting diode, etc). [0049] In all of the embodiments described herein, there is at least one first type fiber comprises an illumination fiber, wherein the illumination fiber is optically coupled to the light source. [0050] There is also at least one second type fiber formed with one or more collection fibers, wherein the one or more collection fibers are optically coupled to a detector, such as an imaging spectrograph and a CCD at the distal end portion, which imaging spectrograph is used to obtain an image of the target and obtain detected data therefrom. [0051] The following further details of the preferred embodiments that will further describe the invention. Without intent to limit the scope of the invention, exemplary instruments, apparatus, methods and their related results according to the embodiments of the present invention are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the invention. Moreover, certain theories are proposed and disclosed herein; however, in no way they, whether they are right or wrong, should limit the scope of the invention so long as the invention is practiced according to the invention without regard for any particular theory or scheme of action. [0052] The optical probes described herein can be used in-vivo to take optical measurements of tissue, such as just inside the rectum to assess a patient's risk of colon cancer. If rectal, the rectally inserted probe for analysis of rectal mucosa provides a means of assessing a patient's risk of developing colon cancer without the need for colonoscopy or colon purging. [0053] In order to facilitate the acquisition of such a measurement, the probes described herein are necessarily introduced into a patient's colorectal vault via an insertion device such as a colonoscope, an upper GI therapeutic scope (a device which is generally known), a disposable, finger mounted device, or an optical probe that contains a permanent housing and disposable tip with retractable integral optical fibers, the latter of which are further described herein. [0054] For clinical evaluation of a colon, the probe is inserted into the rectum to establish contact with the colorectal mucosal wall, perform optical measurements as needed, and is then removed. The probes described further herein provide an insertion device for guiding the probe on a pathway through the rectum to reach the colo-rectal mucosal wall, while shielding the probe tip from possible blockage caused by loose stool that the probe may encounter. While contacting the colorectal mucosal wall, the insertion device then allows the optical portion of probe to extend some distance out of the tip of the insertion device and perform optical measurements as needed. [0055] The optical probes with insertion devices as described further herein contain components that are partially or entirely disposable, since for health reasons certain components are not readily used in multiple different patients. [0056] FIGS. 1-3 illustrate a housing 110 of a disposable, finger mounted optical probe 100 according to one embodiment, which is a semi-flexible component that includes a finger loop 116 worn over the physicians finger. As shown in FIG. 3 , incorporated within the housing 110 is a complete optical probe 120 , including a re-usable trunk 140 and disposable tip 130 , described further herein, which are connected together by some type of engagement mechanism, such as threads on both the tip assembly 130 and the trunk assembly 140 . This finger mounted optical probe 100 is inserted into the patient's rectum mounted on the finger of the physician, allowing for passage of the optical probe 120 to the mucosal wall for measurement acquisition while shielding from potential loose stool both the optical probe, and particularly the optical components of the optical probe 120 that are disposed within the disposable tip 130 . [0057] The housing 110 of the disposable, finger mounted optical probe 100 is sufficiently lubricious to provide for easy passage of optical fibers through internal lumen 112 , and on its outer surface for non-lubricated device insertion into a patient's rectum. The housing may be made of liquid injection molded silicone rubber or similar material. Further, a parylene-N coating may be added to some or all surfaces of the housing 110 to increase overall lubricity for ease of feeding of probe through inner lumen, and insertion into the patient. [0058] The outer front surface of the housing 110 preferably includes a perforated membrane 114 that shields the probe tips from loose stool that may be encountered within the patient, through which the probe tip can pass through just prior to acquisition of optical measurement on the mucosal wall, as described herein, though such a perforated membrane 114 is not necessarily needed. [0059] Further, the disposable, finger mounted optical probe 100 will preferably either have: 1) a pre-formed geometry/curvature such that it can be guided to the proper location in the colo-rectal mucosal anatomy, 2) sufficient flexibility such that the physician can bend and/or manipulate it to the same area for optical measurement, or 3) some combination of both aforementioned attributes. If preformed, the probe 100 preferably has flexibility such that it could be inserted in a straight fashion, and shape memory such that it would retake its original shape once fully inserted into patient's colorectal vault. [0060] The probe 100 as illustrated in FIG. 1-3 allows for pass through of a fully assembled optical probe. This embodiment require the disposable tip 130 to be attached to the reusable trunk 140 prior to insertion. The disposable tip 130 is clean or sterile when initially used prior to insertion, and also includes attached thereto a hygienic sheath 150 that acts as a hygienic shield to cover the reusable trunk 140 , which need not be sterile or sterilized when used. The hygienic sheath 150 may be made of a sterile thin polyethylene film or similar material. [0061] FIGS. 4( a )-( b ) illustrate another embodiment of the disposable, finger mounted optical probe 100 A containing a pre-loaded optical assembly. In this embodiment, the housing 110 and the lumen 112 therein provides for pre-loading of an optical assembly 160 , such that the re-usable trunk (as described with reference to FIG. 3) will connect to the optical assembly 160 (essentially the same as the disposable tip 130 ) within the lumen 112 , and the entire assembly, once connected, can then continue to be positioned by moving through the lumen 112 , and eventually out through any perforated membrane 114 . As shown in FIG. 4( b ), the optical assembly, in one embodiment, may include a lens mount 162 , a rolling diaphragm 164 that provides fixturing of the optical assembly and a hygienic seal This hygienic seal can be simply a narrowing of the lumen such that the lens mount 162 fits tightly around the optical assembly to prevent fluid from flowing backward but is not so tight as to prevent the optical assembly from sliding forward and back, and a lens 166 , though other components, such as polarizers and spacers, can also be used within optical assembly 160 . [0062] In the embodiment of FIG. 4 , the hygienic sheath is preferably attached to the disposable housing 110 at the entry end 118 of the housing, though the sheath is not shown in the Figure, though it could also be attached within the lumen 112 and be part of the optical assembly 160 to address the possibility of cross-contamination. This sheath would extend back to cover all non-disposable surfaces of the probe assembly which may be manipulated by the physician. The finger-mounted insertion device 100 A is preferably entirely disposable, and intended for single-use. An advancement assist ring 116 may be permanently attached to the optical probe to facilitate single handed probe insertion. [0063] Measurement acquisition may be initiated by a foot pedal connected to an instrumentation unit, a button built into the reusable portion of the probe assembly, or some other mechanism. If blind measurement acquisition and/or insertion is not deemed acceptable, a forward viewing CCD or CMOS camera module may be designed into the device, with camera residing in the reusable probe trunk, and window built into the disposable insertion device, as shown in FIG. 10 . [0064] FIGS. 5 a - 5 c are illustrations of the method of use of the disposable, finger mounted optical probe 100 . In use, the probe assembly 120 , formed of the re-usable trunk 140 and the disposable tip 130 , is inserted into the housing 110 as shown, and an advancement assist ring 180 , permanently attached to the re-usable trunk 140 , will attach to the end 118 of the housing 110 . As shown in FIGS. 5A and 5B , the sheath 150 is pulled back so that it extends sufficiently below the sterile gloved hand of the physician to provide a sterile environment for the patient. As shown in FIG. 5C , the disposable tip 130 of the probe assembly 120 is pushed through the perforated membrane 114 at the time the measurement is taken. [0065] FIGS. 6 A( 1 )-( 2 ), B and C show usage of an embodiment of an optical probe 200 that contains a permanent housing 210 and a disposable tip assembly 220 with retractable integral optical fiber assembly 220 (essentially the same as the optical assembly 120 that is formed of the disposable tip 130 and the re-usable trunk 140 as described in the FIG. 3 embodiment above), as well as an overall view of this embodiment. In all of the embodiments there exist the permanent housing 210 , which preferably includes thereon a trigger activation button 212 , a grip 214 for holding in the physician hand, and a roller wheel 216 or similar element integrated into the housing 210 to facilitate single-handed probe advancement, as shown in FIG. 6A . FIGS. 6 B 1 and 6 B 2 show at a high level both the connection of the disposable tip assembly 230 to the re-usable trunk assembly 240 , as well as the unwrapping of the protective sheath 250 over the exterior of the housing 210 . It is noted that in FIG. 6A the sheath 250 is only shown unrolled on the insertion portion 260 , but preferably the sheath 250 will extend below the entire housing 210 . FIG. 6C provides close up views of the disposable tip assembly 230 , and shows both a CCD forward viewing window 270 for a CCD array disposed therebehind (not shown here, though components illustrated in FIG. 10 can work herein), as well as the perforated membrane 280 through which the disposable tip 220 assembly will be moved when the measurement is taken. In use, the insertion portion 260 is inserted into the patient's rectum, with the grip 214 of the housing 210 held by the physician, allowing for internal optical assembly to be positioned on the mucosal wall while shielded from potential loose stool. This allows for advancement of the internal optical probe assembly, including the lens as described hereinafter, out of the protective cap associated with the disposable tip assembly 220 , and onto the patient's colo-mucosal wall for measurement acquisition. [0066] In a preferred implementation, the housing 210 a two-piece, rigid injection molded handle comprised of ABS (Acrylonitrile butadiene styrene) or similar material. Further, an overmolded soft-touch material such as Pebax or Hytrel may comprise the insertion portion 260 . The disposable tip assembly 230 in this configuration may be comprised of a similar soft-touch material overmolded soft-touch material such as Pebax or Hytrel. The hygienic sheath 250 attached to the lens mount 238 within disposable tip assembly 230 may be made of a thin polyethylene film or similar material. [0067] It is noted that it may be that a sheath 250 isn't used, and the insertion portion 260 is sterilized after each use. In such a use, the insertion portion 260 is preferably lubricious enough on its outer surfaces for non-lubricated device insertion into a patient's rectum. [0068] Further, this probe 200 also preferably has 1) a pre-formed geometry/curvature such that it locates the internal optical assembly, and particularly the optical tip, onto proper location in the colo-rectal mucosal anatomy, and 2) sufficient flexibility such that the physician could bend and/or manipulate the device to the same area for optical measurement. The probe 200 is sufficiently flexible such that it can be inserted in a straight fashion, and has shape memory such that it retakes its original shape once fully inserted into patient's colorectal vault. [0069] FIG. 7 illustrates a partial illustration of a particular embodiment of an optical probe 200 A, with only the optical components shown, not the sheath 250 and lower part of the housing 210 . The shown semi-flexible insertion portion 260 contains therein the retractable integral optical fiber assembly 220 , formed of the disposable tip assembly 230 and the trunk assembly 240 . As shown the trunk assembly 240 will contain an outer sheath 248 , which preferably includes at the distal end a protrusion ring 242 , which abuts a similar protrusion ring 262 associated with the insertion portion of the housing 210 . Also associated with the re-usable trunk assembly 240 is a springing engaging mechanism 244 for the optical components of the disposable tip assembly 230 to connect in an aligned manner, as well as, in certain configurations, other optical components 246 , such as a polarizer or protective cover. Other engagement mechanism, such as threads on both the tip assembly 230 and the trunk assembly 240 can be used. [0070] The disposable tip assembly 230 contains a protective cap 231 that has an alignment element 233 and perforated membrane 236 , described further herein, that maintains the lens mount 238 in place prior to connection to the optical fiber trunk assembly 240 . As shown in FIG. 9 , the disposable tip assembly also preferably has attached thereto the sheath 250 [0071] The lens mount 238 will contain a lens 232 , such as a GRIN lens, a ball lens, an achromatic doublet lens, etc can be used, disposed therein or as part of a one-piece assembly, as well as an alignment member 234 that engages with the alignment element 233 . The alignment member 234 in one embodiment is a channel into which a protrusion that is the alignment element 233 fits. Once the disposable tip assembly 230 , and specifically the lens mount 238 , is connected to the trunk assembly 240 , and the engaging mechanism 244 , the entire optical assembly 220 is moved through the rectum to the measurement point. At that time, the optical fiber assembly 220 can be slightly rotated and moved forward, so that the lens mount 238 , via the alignment member 234 , is guided by the alignment element 233 , so that the lens 232 can protrude through the perforated membrane 236 . [0072] FIG. 8 illustrates a partial illustration of a particular embodiment of an optical probe 200 B, with only the optical components shown, not the sheath 250 and lower part of the housing 210 . In this embodiment, as shown the disposable tip assembly 230 does not contain a front face to the protective cover 231 or a perforated member, and as such the lens 232 , mounted in the lens mount 238 , is exposed. Otherwise, the elements shown in FIG. 8 are the same as those described previously with respect to FIG. 7 . Since the lens 232 is pre-exposed, the probe 200 B does not required advancement of retractable integral optical fiber assembly 220 to break through any protective cap membrane. Thus, once inserted and put into contact with the patient's colo-mucosal wall, the probe 200 B is immediately ready for measurement acquisition. [0073] If blind insertion is not deemed acceptable, a forward viewing CCD camera may be designed into the device, with camera residing in the tip of reusable portion of the wand, and window built into the disposable wand tip, as shown in FIG. 10 . As shown, the disposable tip assembly 230 is modified by including the glass viewing cover 237 as part of the protective cap 231 , and the probe 200 further includes a CCD or CMOS module, as will as an image return wiring 292 as needed. Depending on the configuration, the CCD or CMOS module may include battery power, may be powered via wires for the power, and/or the power and/or image signals may be transmitted wirelessly using various conventional data and short range power transmission schemes. [0074] Different penetration depths are implemented with these probes in a variety of ways. Different fibers and/or disposable tips can be used (in some instances with different probes, in other instances all within the same probe) in order to achieve the desired results. For probes that detect EIBS in particular, the choice of the spacing between the fiber termination and lens (e.g. nominally 1 focal length but could be more or less) and selection of the lens type and focal length adjustment depth can be used to achieve different penetration depth. For LEBS probes that detect tissue microarchitecture, the selection of the lens and the distance from the termination of the fibers to the lens or the length of the glass spacer determine the special coherence length of light, which will vary the penetration depth. [0075] In use, depending upon the target and the application, each probe may take multiple measurements, and the detected data from each measurement stored for subsequent usage. Typically a number of different measurement locations, such as 3-6, but not typically greater than 10 will be made. Depending on the probe or the manner in which the probe is used, various different penetration depths may then be sensed at each measurement location. [0076] FIG. 11 illustrates a particular optical probe assembly configuration used for EIBS. FIG. 12 illustrates another particular optical probe assembly configuration used for EIBS. It is noted that the lens mount and polarizer mount may be combined to form a single component. FIG. 13 illustrates a further particular optical probe assembly configuration used for EIBS. It is noted that the lens mount and polarizer mount may be combined to form a single component. In each of FIGS. 11 , 12 and 13 , the components are identified, and they together show that various combinations of components can be used: certain embodiments may or may not have polarizers, spacers and different numbers of optical fibers can also be used. In this regard, reference is made to the previously filed U.S. patent application Ser. No. 11/604,659 filed Nov. 27, 2006 and entitled “Apparatus For Recognizing Abnormal Tissue Using The Detection Of Early Increase In Microvascular Blood Content.” [0077] FIG. 14 illustrates in cross section an embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 . [0078] FIG. 15 illustrates in cross section a further embodiment of optical fibers and polarizer usable in the optical probe assembly configurations illustrated in any of FIGS. 11 , 12 , and 13 , and shows a decentering or making the fibers slightly asymmetric with respect to the probe center to minimize reflections. This could be used on any probe designs that detect EIBS described herein. [0079] FIG. 16 illustrates a particular optical probe assembly configuration used for LEBS. FIG. 17 illustrates another particular optical probe assembly configuration used for LEBS. FIG. 18 illustrates a further particular optical probe assembly configuration used for LEBS. FIG. 19 illustrates a further particular optical probe assembly configuration used for LEBS. FIG. 20 illustrates a further particular optical probe assembly configuration used for LEBS. In both of the FIG. 19 and FIG. 20 probe designs, no lens is used but the solid glass spacer ( FIG. 20 ) or air gap with coverglass ( FIG. 19 ) between the fiber terminations and the tissue selects a specific (and predetermined) spatial coherence length that corresponds to a desired depth. This lensless concept that uses a fix-distance spacer (air or glass) can be used to establish a spatial coherence length. In the other embodiments, the components are identified, and they together show that various combinations of components can be used: certain embodiments may or may not have polarizers, spacers and different numbers of optical fibers can also be used. [0080] FIGS. 21( a ) and ( b ) illustrate in cross section an embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 . [0081] FIG. 22 illustrates in cross section a further embodiment of optical fibers usable in the optical probe assembly configurations illustrated in any of FIGS. 16-20 . FIG. 22 shows a decentering or making the fibers slightly asymmetric with respect to the probe center to minimize reflections. This could be used on any LEBS probe designs described herein. This gives a potential advantage in that internal reflections off surfaces (e.g. the lens/tissue interface, air/lens interface, etc) will be reflected elsewhere away from the fibers. [0082] The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings.
The present invention relates to probe apparatuses and component combinations thereof that are used to recognize possibly abnormal living tissue using a detected early increase in microvascular blood supply and corresponding applications. In one embodiment there is disclosed an apparatus that emits broadband light obtained from a light source onto microvasculature of tissue disposed within a human body and receives interacted light that is obtained from interaction of the broadband light with the microvasculature for transmission to a receiver. Different further embodiments include combinations of optical fibers, polarizers and lenses that assist in the selection of a predetermined depth profile of interacted light. In another embodiment, a kit apparatus is described that has various probe tips and/or light transmission elements that provide for various combinations of predetermined depth profiles of interacted light. In a further embodiment, a method of making a spectral data probe for depth range detection selectivity for detection of blood within microvasculature of tissue is described.
0
BACKGROUND OF THE INVENTION This invention relates to an illuminated display and more particularly to such a display for wearing on the person. Strings of lighted elements electrically energized, are known for dispersal through a wearer's hair or around articles of wearing apparel where such lighted elements have the purpose of enhancing the wearer's appearance. Such arrays of lighted elements require conducting leads to extend between the lighted elements and also require the wearer to carry an electrical power supply such as a dry cell storage battery somewhere on the wearer's person. The conducting leads together with the bulk of the power supply provide serious inconveniences to the wearer. Other devices are known where the power supply is carried remotely on the person and the conducting leads are connected to a lighted ornamental article through a cord which may serve as a band for hanging the article around the wearer's neck as well as a path for delivering the electrical energy to the lighted elements in the ornamental article. The inconvenience of the bulk of the power supply which must yet be carried and the conductive leads thereto is not overcome. A relatively small lighted ornamental article is desirable which contains lens, lamp and electrical energy source, so that the above referenced remotely located power supply bulk and conducting lead inconvenience between lighted elements and power supply are avoided. SUMMARY AND OBJECTS OF THE INVENTION An ornamental article case has a front section and a rear section which join together to define a battery chamber and a lens chamber therein. The battery chamber is configured to receive a miniature electrical battery. A lens opening is formed in the front case section in communication with the lens chamber and a switch opening is formed in the rear case section in communication with the battery chamber. A lens is mounted in the lens opening and a light source is mounted in the lens chamber cooperating with the lens to transmit light therethrough when energized. A switch member is mounted in the switch opening and a pair of spring terminals are mounted in the case extending into the battery chamber to contact opposed electrical terminals on the miniature battery when placed therein. The switch member carries structure for urging one of the spring terminals away from contact with one of the battery terminals. Conductive leads are connected between the battery and the light source. Consequently, the light source is deenergized when the switch member is positioned so that the structure thereon urges the spring terminal away from the battery terminal. Conversely when the structure on the switch member is not in contact with the spring terminal an electrical circuit is completed through the light source causing light to be transmitted through the lens, thereby providing an illuminated display. The ornamentaL article is envisioned as being suspended from a chain or string and carried about a portion of the wearer's body, or as being pinned to an article of wearing apparel to thereby provide a pleasing display. In general, it is an object of the present invention to provide an ornamental article for wearing on the person which has contained light and light energizing sources. Another object of the present invention is to provide a lighted ornamental article which is controlled to the on and off conditions by the wearer. Another object of the present invention is to provide a lighted ornamental article wherein assembly of a minimum number of structural parts is accomplished in a minimum amount of time by minimally skilled assemblers. Additional objects and features of the invention will appear from the following description in which the preferred embodiment has been set forth in detail in conjunction with the accompanying drawings. BRIEF DESCRIPTON OF DRAWINGS FIG. 1 is an isometric view of the illuminated ornamental article in pendant form. FIG. 2 is a sectional side view of the Illuminated ornamental article of FIG. 1. FIG. 3 is a plan view of the ornamental article with the rear case section removed. FIG. 4 is a rear plan view of the illuminated ornamental article. FIG. 5 is a plan view of the illuminated ornamental article with the front case section removed. FIG. 6 is an electrical schematic of one embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT The ornamental article disclosed herein is seen in perspective in FIG. 1. An outer case 11 has a front case section 12 and a rear case section 13 which are joined together as shown. The ornamental article may be worn by pinning it to an article of apparel on a person by means of a pin (not shown) attached to rear case section 13, or by suspending it on a chain or string 14 as shown in FIG. 1 which surrounds the neck of the wearer, for example. Front case section 12 is shown having a lens aperture 16 therein which accepts a lens 17. Lens 17 may have a decal, such as the star 18 shown thereon in FIG. 1. A set of decals having different designs for placement overlying lens 17 may be provided. In this fashion a selected decal design may be placed on lens 17 in place of star 18. The decals may be snapped into place or held by a yieldable adhesive. The manner in which outer case 11 is formed by joining front case section 12 and rear case section 13 is shown in FIG. 2. Rear case section 13 has an inner locating diameter 19 near the lip thereof and front case section 12 has an outer locating diameter 21 near the lip thereof. When inner and outer locating diameters 19 and 21 respectively are placed adjacent to one another, outer case 11 forms a battery chamber 22 and a lens chamber 23 therein. A passage 24 is also formed through outer case 11 between front and rear case sections 12 and 13 respectively. Passage 24 serves to surround a chain or the supporting string 14 for suspending the ornamental article in pendant form. Lens aperture 16 is seen to be in communication with lens chamber 23 and lens 17 is shown in FIG. 2 to be mounted in lens chamber 23 on a ledge 26 surrounding lens aperture 16. Lens 17 in this embodiment has a planar front face 27 and a convex rear face 28. It should be understood that front face 27 could be convex or concave in keeping with desired light emission characteristics from the display. Lens 17 has a bore 29 formed through convex rear face 28 which is configured to accept a miniature incandescent lamp 31. A pair of conducting leads 32 extend from miniature lamp 31 which are connected to opposite ends of the incandescent light emitting filament therein. It should be understood that other light sources, such as light emitting diodes, could be substituted for miniature incandescent lamp 31. Convex rear face 28 on lens 17 may have a reflective coating 33 thereon so that light entering lens 17 from miniature incandescent lamp 31 will substantially all be reflected through planar front face 27 on lens 17. Rear case section 13 has a switch aperture 34 therein which communicates with battery chamber 22 and in which is mounted a switch member 36. In this embodiment switch member 36 takes the form of a disc having a bead 37 around the circumference thereof which is formed to fit in a matching groove 38 extending around the periphery of switch aperture 34. Switch member 36 also has a switch post 39 attached thereto extending into battery chamber 22. It may be seen that switch member 36 is disposed in switch aperture 34 for rotary motion therein as bead 37 passes in sliding fashion through matching groove 38. Switch member 36 is removable from switch aperture 34 by inserting a lever (not shown) between a ramp 41 and the periphery of switch member 36 and exerting a prying motion on the lever to snap bead 37 out of matching groove 38. In this fashion battery chamber 22 is made accessible from the exterior of outer case 11. A well known miniature battery 42 such as the nickel cadmium type for example, is shown positioned in battery chamber 22. Turning now to FIG. 3, rear case section 13 is removed showing lens 17 in lens chamber 23 and battery 42 in battery chamber 22. A first spring terminal 43, shaped as shown and mounted between a plurality of posts 44 extends into battery chamber 22. First spring terminal 43 is shown contacting the periphery of battery 42, which is one of the electrical terminals thereon. A second spring terminal 46 is shown extending into battery chamber 22 and fixed in position by having a portion thereof entering a slot 47 in a terminal post 48 formed on the interior of front case section 12. Second spring terminal 46 is shown contacting one end of battery 42 which is the opposing electrical terminal thereon. Electrical leads 32 are shown, one each being in electrical contact with one of the first and second spring terminals 43 and 46. An opening 49 is shown in battery chamber 22 through which first spring terminal extends to contact the periphery of battery 42. It is envisioned that case 11 may contain a flasher circuit 50 which could be positioned electrically as shown in dashed lines in FIG. 3. The circuit 50 may be any of several known configurations, one of which is ssen in FIG. 6. When contact 43 is in the closed position, transistors Q1 and Q2 operate at the resonant mode for the series combination of R1 and C1 to provide an oscillatory current through lamp 31. A flashing display is thus provided from lens 17. A pair of case locating posts 51 are shown formed on the inner surface of front case section 12 and a pair of lens locating posts 52 are shown also formed thereon. Lens 17 has side tabs 53 extending from the edge thereof. Tabs 53 have holes 54 fromed therethrough on substantially the same spacing as lens locating posts 52. Lens 17 is fixed in position in lens aperture 16 by pressing tabs 53 over lens locating posts 52 allowing them to pass through holes 54 until planar front face 27 seats on ledge 26. Lens 17 may thereafter be retained on lens locating posts 52 by frictional engagement therewith or by placing some epoxy or other suitable cement around lens locating posts 52 and the surface of tabs 53. Miniature incandescent lamp 31 may also be held in position in bore 29 by the stiffness of conductive leads 32 or by placing some epoxy or other suitable cement about the miniature incandescent lamp 31 after it is inserted into bore 29. With reference to FIG. 4, switch member 36 is shown having a raised center portion 56 thereon for grasping by the fingertips to impart rotational movement thereto. An indicator dot 57 is aligned with switch post 39. With switch post 39 in the position shown in FIG. 2 and as indicated in FIG. 4, first spring terminal 43 will be urged away from the periphery of battery 42 and will rest in a notch 58 in switch post 39. Thus, the circuit from battery source 42 through the incandescent element in miniature incandescent lamp 31 is broken. When raised portion 56 is manually engaged and rotated to a point where indicator dot 57 is opposite the "on" position as indicated in FIG. 4, switch post 39 assumes the position shown in FIG. 3 and first spring terminal 43 passes through opening 49 in battery chamber 22 as urged by the spring force therein, to contact one electrical terminal at the periphery of battery 42. It may thus be seen that it is only necessary for switch member 36 to pass through the angle between the on and off positions seen in FIG. 4 to effect manual control of light emission from miniature incandescent lamp 31. FIG. 5 shows the interior of rear case section 13 together with stops 59 located to limit the rotational movement of switch member 36 to that required for switch post 39 to rotate between the on and off positions shown in FIGS. 3 and 2 respectively. Thus, switch post 39 is rotated between the off position, where it urges spring terminal 43 away from contact with the terminal on battery 42, and the on position, where it assumes an out-of-the-way position allowing first spring terminal 43 to come into contact with one terminal of battery 42. The switch 36 is held in the off position by a V portion on first spring terminal 43 which enters notch 58 on switch post 39. Switch 36 is held in the on position by means of the spring force urging first spring terminal 43 into contact with one terminal of battery 42, which force is sufficiently large to prevent switch post 39 from slipping between first spring terminal 43 and the battery terminal. FIG. 5 also shows a pair of case locating lands 61 on the inner surface of rear case section 13 having locating bores 62 therein for receiving case locating posts 51 on front case section 12. In this fashion front and rear case sections 12 and 13 respectively are located in angular orientation. A colored or metallic coating may be applied to the outer surface of outer case 11 to further enhance the pleasing appearance of the lighted ornamental article. Decals or sets of decals of different decorative design, or decals carrying written inscriptions are envisioned as being available for application to front face 27 of lens 17 in place of the star 18 which is shown. A lighted ornamental article has been disclosed which will emit either steady or flashing light and which is appropriate for pinning on a wearer's apparel or for wearing as a pendant around the neck or wrist, etc. The necessity for carrying remotely located power suuplies or external conductive members extending between light producing elements and the remotely located power supplies is removed. Moreover, an illuminated ornamental article is disclosed which may be manually controlled to emit light or to simply serve as a non-lighted piece of jewelry at the wearer's option.
An illuminated display is presented on an ornamental article through a lens carried by the article. The article has a case in which the lens is mounted which contains a miniature incandescent lamp adjacent to the lens providing the light for illuminating the display. The case also defines a battery compartment configured to hold a miniature electric battery which provides the energy for illuminating the lamp. The case also has mounted therein an externally accessible switch for selectively energizing and de-energizing the lamp.
0
This application is a continuation, of application Ser. No. 08/828.544, filed Mar. 31, 1997 now abandoned. BACKGROUND OF THE INVENTION The present invention relates to a process for making a wet-layed metal fiber nonwoven sheet which also contains metal powder. In particular, the present invention relates to a process for making a metal fiber/metal powder sheet. Papers comprised primarily of metal fibers have been desired by the industry for many years. Various methods have been developed for the preparation of metal fiber sheets. The manufacture of metal fiber nonwoven fabric-like paper structures on papermaking equipment has also been actively pursued due to its commercial attractiveness. Interest in such techniques is described, for example, in the chapter on metal fibers by Hanns F. Arledter in Synthetic Fibers in Papermaking , Editor O. Balestra, chapter 6, pages 118-184. The problem in making metal fiber sheets using conventional papermaking techniques is that the metal fibers tend to clump together. Before paper can be made, it is necessary to open fiber bundles to achieve individual fibers and to disperse the fibers uniformly in a fluid. With most wood pulps, the opening is not usually a difficult task. The pulp or source of fibers is placed in water and the mixture is sheared until the bundles open. With metal fibers, however, both the opening of the bundles and the dispersion of the fibers in order to keep the fibers separated are difficult. Normal types of mixing or shearing devices can easily damage metal fibers. When metal fibers are bent, they will remain bent and eventually will interact to form balls of tangled fibers. Paper made from fibers in this form is unacceptable. It would be of great advantage to the industry, therefore, if a process for making a metal fiber sheet using conventional papermaking techniques, i.e., a wet-laying technique, can be used. Such a process should offer efficiency and commercial viability in terms of cost. Moreover, the cost of a metal fiber sheet can be prohibitive. A metal sheet which is made of metal fiber but is more cost effective would also be attractive. A sheet containing metal fiber and metal powder would be such a sheet. Accordingly, it is an object of the present invention to provide a metal fiber sheet which also contains a metal powder. Yet another object of the present invention is to provide a process for making such a metal fiber/metal powder sheet using a wet laying technique. These and other objects of the present invention will become apparent upon a review of the following specification, the figure of the drawing, and the claims appended hereto. SUMMARY OF THE INVENTION In accordance with the foregoing objectives, provided by the present invention is a wet-layed, nonwoven sheet which is comprised of metal fiber and metal powder. Generally, the amount of metal fiber comprises from 20 to 95% by weight and the amount of metal powder comprises from 5 to 80% by weight of the sheet. Such a wet-layed nonwoven sheet is economically preferable to a sheet comprised totally of metal fiber, since the metal powder is much less expensive. Among other factors, the present invention is based upon the recognition, using various process techniques, that the combination of metal fiber and metal powder can be wet-layed to obtain a structure of sufficient strength for subsequent handling and sintering. In a preferred embodiment, the wet-layed nonwoven sheet comprised of metal fiber and metal powder is made by a process which involves first dispersing metal fibers and the metal powder into an aqueous dispensing fluid which contains a non-carboxy containing water soluble polymer. The aqueous dispensing fluid is then applied onto a screen, with the aqueous dispensing fluid then being removed to thereby form the metal fiber/metal powder sheet. In another preferred embodiment, the wet-layed, nonwoven metal fiber/metal powder sheet of the present invention is made by a process which comprises first dispersing a mixture of the metal fiber, metal powder, wood pulp and a fibrillated material into an aqueous dispensing fluid. Generally, the amount of metal fiber and metal powder together ranges from 60 to 80 weight percent based upon the solids, the amount of wood pulp ranges from about 15 to about 30 weight percent, and the amount of fibrillated material ranges from about 5 to 15 weight percent based upon the weight of solids. The aqueous dispensing fluid is then applied onto a screen, and the fluid is removed to provide a metal fiber/metal powder sheet. BRIEF DESCRIPTION OF THE FIGURE OF THE DRAWING The Figure of the Drawing schematically depicts the process of the present invention useful in making a metal fiber/metal sheet by a wet-laying technique. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In one preferred embodiment, the process of the present invention employs a non-carboxy containing water soluble polymer to aid in dispersing metal fibers into an aqueous dispensing fluid. The dry metal fibers, together with the metal powder, are added to an aqueous dispensing fluid, to which the non-carboxy containing water soluble polymer is also added. Through mixing, the metal fibers and metal powder are dispersed in the presence of the non-carboxy containing water soluble polymer. Among the water soluble polymers useful for the present invention are polyvinyl alcohol, starch or cellulose ethers. Generally, the water soluble polymer comprises from 1 to 5 weight percent of the aqueous dispensing fluid. In a preferred embodiment, starch is the water soluble polymer used as the dispersing aid, and is generally used in an amount ranging from 3 to 4 weight percent based upon the weight of aqueous dispensing fluid. The water soluble polymer can be added directly to the aqueous dispensing fluid, generally before the metal fiber is added. This will allow the water soluble polymer to immediately begin to interact with the dry fiber. While the water soluble polymer allows the dry fiber to disperse, it also aids in the formation of the metal fiber web by maintaining separation of the metal fibers. The fact that such a small amount of a water soluble polymer such as starch can be used to effectively maintain separation is quite surprising. In another preferred embodiment, the process of the present invention employs a combination of wood fibers and fibrillated material to aid in dispersing metal fibers into an aqueous dispensing fluid. The dry metal fibers are added together with the wood fibers and fibrillated material to the aqueous dispensing fluid. Through mixing, the metal fibers, wood fibers and fibrillated material are dispersed. More specifically, the wood fibers can be any conventional wood fiber, such as softwood or hardwood fibers. Mixtures of wood fiber, including mixtures of softwood and hardwood fibers, can be used. Softwood fibers, however, are preferred. The amount of wood pulp fibers used generally ranges from about 15 to 30 weight percent. Together with the wood pulp, a fibrillated material is used. Fibrillated materials are known in the industry, and are generally referred to as fibrids. The materials are high surface area materials of a surface area in the range of from about 5-20 m 2 /g. This is in contrast to wood pulp, which generally has a surface area in the range of from about ½-2 m 2 /g. The fibrillated material can be made by any conventional method, with the use of organic materials being most preferred. It has been found that a combination of the wood pulp with the fibrillated material provide for an excellent metal fiber dispersion and the making of an excellent metal fiber sheet. Cellulon and Kevlar fibrids, both available commercially, are the most preferred fibrillated materials for use in the present invention. Another suitable material is a cellulose acetate fibrid commercially available under the mark FIBRET, available from Hoechst/Celanese Co. The amount of fibrillated material used generally ranges from 5 to 15 weight percent. The presence of the fibrillated material has been found to be very important with regard to the present invention. It is important to generate an aqueous slurry comprised of the wood pulp and the fibrillated material. The slurry is preferably generated generally by the use of a high shear and a high energy agitator. Such agitators are well known. Colloid mills, such as the ones available from Silverson, have been found suitable. The metal fibers are dispersed in the aqueous slurry of the high surface area material by using a non-stapling mixer, as is well understood in the industry. In general, such a mixture would have a leading surface larger in width, height and/or diameter than the length of the metal fibers. It is important to provide sufficient shear to break up the metal fiber bundles but it is equally critical to avoid bending the fibers and creating fiber aggregates. If the metal fiber aggregates are allowed to form by the application of too much mixing energy it is very difficult to re-disperse them. Although it is possible to disperse the metal fibers in a slurry composed only of water and a high surface area material like bacterial cellulose, there are advantages to incorporating wood pulp in this slurry. We have observed that the presence of wood pulp improves the paper making characteristics like uniformity of the dispersion, the wet web strength, and the dry strength. The metal fibers can be any useful metal fiber, with nickel and stainless steel fibers being most preferred. The stainless steel fibers can, for example, be stainless steel 304 fibers, stainless steel 316 fibers or stainless steel Hastelloy X fibers. Nickel and stainless steel fibers are most preferred because their potential uses are exceptional. The metal powder used can be of the same or different metal than that of the metal fibers, and can be made by any conventional method. It is preferred that nickel powder is used, particularly when nickel fiber is used. Suitable nickel powders are available commercially, for example, from INCO Specialty Powder Products of Wyckoff, N.J. Such suitable powders include, for example, the INCO extra fine Nickel Powder TYPE 210, which is a submicron size filamentary powder. It is produced by the thermal decomposition of nickel carbonyl and is virtually free of other metallic impurities. Other suitable nickel powders, and other metal powders, are also available from INCO. Conventional additives can also be added to the aqueous dispensing fluid. Such additives would include, for example, a biocide to inhibit microorganism growth in dispensing fluid. Other conventional additives can also be added. Once the metal fibers have been dispersed in the aqueous dispensing fluid, the dispensing fluid is then applied to a screen as is conventional in papermaking process. The aqueous dispensing fluid is then removed in order to form the metal fiber sheet. Generally this is done through vacuum suction of the fluid through the screen. In a preferred embodiment, the process of the present invention is conducted in a closed system where the dispensing fluid removed from the metal fibers is recycled and reused. Turning now to the Figure of the Drawing, a mixing vessel 1 contains the aqueous dispensing fluid together with the non-carboxy containing water soluble polymer such as starch. The dry metal fiber is added via 2 into the dispensing fluid. Mixing is achieved by a stirrer 3 . Generally, the mixer 3 is an agitator that does not induce fiber stapling, as is known in the art. The mixing continues until the desired fiber separation is achieved. In a preferred embodiment, the aqueous dispensing fluid containing the dispersed metal fibers is passed to a second mixing tank 4 . The additional mixing is optional, but does insure good formation in the subsequent sheet. It is therefore preferred that a plurality of such mixing tanks be employed to insure good dispersion and formation of the metal sheet. The aqueous dispensing fluid is then passed to a headbox 5 , through which the aqueous dispensing fluid containing the metal fibers is applied to a continuous screen 6 . A vacuum system 7 is generally used to remove the aqueous dispensing fluid in order to form the metal fiber sheet on the screen. In a preferred embodiment, the removed aqueous dispensing fluid is then recycled to the mixing tank 1 via line 8 . Generally, about 60 weight percent of the metal powder is retained in the metal fiber sheet using the non-carboxy water soluble polymer. The formed metal fiber sheet is then passed through press rolls, can then be calendared and dried as is conventional in the papermaking industry. Despite the use of such a small amount of water soluble polymer, the residue is sufficient to provide sufficient strength to the metal fiber sheet so that such subsequent handling can occur without incident. The final step is a sintering step which can be conducted at optimum temperatures in an inert or reducing atmosphere. The sintering step introduces a strength to the metal fiber paper, as well as burns off the various organics contained in the metal fiber paper. The sintering step generally involves heating the paper at a temperature of from 1500-1200° F. for a time necessary to burn off the organics. The sintering step is preferably conducted in a hydrogen atmosphere. If desired, a prior pyrolysis step can be conducted at a lower temperature to initially burn off organics. However, the pyrolysis step does not impart the necessary strength to the paper, and should be followed by the sintering step at the higher temperature of from 1500-2000° F. to burn off any remaining organics and to provide the desired strength to the paper. The resulting fiber paper contains at least about 99 weight percent metal. Turning now to the Figure of the Drawing, a mixing vessel 1 contains the aqueous dispensing fluid together with any desired additives. The dry metal fiber is added via 2 into the dispensing fluid, together with the wood pulp and fibrillated material in the desired amounts. Mixing is achieved by a stirrer 3 . Generally, the mixer 3 is an agitator that does not induce fiber stapling, as is known in the art. The mixing continues until the desired fiber separation is achieved. In a preferred embodiment, the aqueous dispensing fluid containing the dispersed metal fibers is passed to a second mixing tank 4 . The additional mixing is optional, but does insure good formation in the subsequent sheet. It is therefore preferred that a plurality of such mixing tanks be employed to insure good dispersion and formation of the metal sheet. The aqueous dispensing fluid is then passed to a headbox 5 , through which the aqueous dispensing fluid containing the metal fibers is applied to a continuous screen 6 . A vacuum system 7 is generally used to remove the aqueous dispensing fluid in order to form the metal fiber sheet on the screen. In a preferred embodiment, the removed aqueous dispensing fluid is then recycled to the mixing tank 1 via line 8 . The formed metal fiber sheet is then passed through press rolls, and can then be calendared and dried as is conventional in the papermaking industry. The metal fiber sheet has sufficient strength to permit subsequent handling to occur without incident. The final step is a sintering step which can be conducted at optimum temperatures in an inert or reducing atmosphere. The sintering step introduces a strength to the metal fiber paper, as well as burns off the various organics, i.e., the wood pulp and the fibrillated material, contained in the metal fiber paper. The resulting fiber paper contains at least about 95 weight percent metal, and most preferably about 99 weight percent. The resulting metal fiber sheet is useful in many different applications. For example, the metal fiber sheet can be used as a battery electrode. Nickel fiber is preferred for such an application. The metal fiber sheets can also be used as fluid filters. The filters can be useful for hydraulic fluids, water or oil. The metal fiber sheets can also be used as gas filters, for example in the filtering of air or exhaust gases. The applications are many, and with the use of the present invention in the preparation of metal fiber sheets, the availability of such sheets in an economic fashion will be increased. The invention will be illustrated in greater detail by the following specific examples. It is understood that these examples are given by way of illustration and are not meant to limit the disclosure or the claims to follow. All percentages in the examples, and elsewhere in the specification, are by weight unless otherwise specified. EXAMPLE 1 8 oz/sq yd metal handsheets were made. The handsheets contained 10% Ni fiber and 50% Ni powder. The basis weight of the 8 oz/sq yd handsheets was equal to 166.6 lb/3000 sq. ft. Total basis weight was (166.6/0.60) or 278 lb/3000 sq ft. This is equal to 57 grams per 14×14 handsheet. The following materials were used in making the handsheets: 10% Ni fiber 0.25 inch × 8 micron 5.72 g Oven Dry 50% Ni powder (Int Nickel Grade 225) 28.6 g Oven Dry 20% Kevlar pulp 11.4 g OD or 62.2 at 18.4% solids 20% Northern Hardwood pulp 11.4 g OD or 12 g at 95% solids The General Procedure Followed Was: Blend Kevlar pulp in 1 liter water in a Waring blender for 3 min at high. Blend the N. Hardwood pulp in 1 liter of water in a Waring blender for 3 min at high. All ingredients were mixed in a 5 gal baffled pot with 8 inch foil blade at 590 RPM for 5 min. No surfactants or binders were added. The handsheet was formed with no pressing. About 80% retention of Ni powder was observed. The sheet contained about 7.75 oz of Ni (powder and fiber) per sq yd. A paper where all of the nickel was in powder form was also attempted. The paper would not hold up during sintering if the metal fiber was missing from the recipe. In this experiment, the nickel fiber improved the strength of the paper during the sintering process. EXAMPLE 2 A 6 oz/sq yd or 125 lb/ream or 25.73 g/14×14 handsheet was made. It was decided to actually use 28.6 g per handsheet to allow for powder loss. The following materials were used: Material Percent, OD Mass, g (OD) Mass, g (AB Is) Ni Powder 50 14.3 14.3 Ni Fiber (8 11 3.15 3.15 micron,) .25 inch No. Softwood pulp 16 4.58 4.90 No. Hardwood pulp 16 4.58 4.90 Cellulon 7 2 10.5 All ingredients were added to a 5 gal baffled pot with 4 liters of water. Mixing occurred for 3 min at 540 RPM with a ¾ inch×9 inch foil agitator. 4 ml of a 1% cationic coagulation aid (Nalco 7520) was added to assist in the retention of the powder. Handsheet was formed with no further dilution, which was pressed with roll weight only. Three handsheets were made, which had an oven dry mass of 28.7, 28.8, and 28.9 grams, respectively. EXAMPLE 3 National Starch's branched starch (amylopectin) known by the trade name Amioca, was used to make a solution about 3% in strength which had a viscosity of 30 centipoise. Four liters of this solution was added to a baffled 5 gallon pot. To this was added the ingredients listed below. Metal fiber, 4 micron by Nickel powder, INCO 255 4 mm long (2.2-3.3 micron) Handsheet 1 4.13 grams  4.13 grams Handsheet 2 4.13 grams 41.30 grams The mixture was stirred with a nine inch foil blade at 1280 RPM for 45 seconds. A single drop of DOW A defoamer was added. The resulting fiber-powder mixture was poured into an eight inch by eight inch handsheet mold with no further dilution. Handsheet 1 was dried and weighed. The sheet retained about 5% starch, so the dry sheet contained about 9% powder, 5% starch, and about 86% metal fibers. Of the metal powder added, about 11% was retained. Sheet 2 was also dried and weighed. It contained about 5% starch, thus the powder content was 70% and the metal fiber content was 25%. Of the powder added, about 25% was retained. No retention aids like cationic polymers or alum solution were added to either handsheet. While the invention has been described with preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and the scope of the claims appended hereto.
Provided by the present invention is a wet-layed, nonwoven sheet which is comprised of metal fiber and metal powder. Generally, the amount of metal fiber comprises from 20 to 95% by weight and the amount of metal comprises from 5 to 80% by weight of the sheet. Such a wet-layed nonwoven sheet is economically preferable to a sheet comprised totally of metal fiber, since the metal powder is much less expensive. Among other factors, the present invention is based upon the recognition that by using various process techniques, the combination of metal fiber and metal powder can be wet-layed to obtain a structure of sufficient strength for subsequent handling and sintering.
3
CROSS-REFERENCE TO RELATED APPLICATION This application is a Continuation-In-Part of my co-pending U.S. patent application Ser. No. 07/471,884 filed Jan. 29, 1990, now U.S. Pat. No. 5,011,524, which is a divisional application of my prior U.S. patent application Ser. No. 07/278,447, filed Dec. 1, 1988, now U.S. Pat. No. 4,897,099. The entire disclosure in that patent is expressly incorporated herein by this reference. BACKGROUND OF THE INVENTION The present invention relates to a method and apparatus for providing purified ice pieces and purified liquid water from a source of unpurified liquid water. More particularly, the present invention provides an alternative approach to melting ice pieces in a method and apparatus of the type generally disclosed in my aforementioned U.S. Pat. No. 4,897,099. In my U.S. Pat. No. 4,897,099 I disclose a method and apparatus for forming purified ice pieces from unpurified water, such as tap water. The ice pieces are periodically harvested and collected in a bin, the bottom of which is heated as necessary to melt desired quantities of the ice to provide a supply of purified water. In the embodiment disclosed in FIG. 2 of my aforesaid patent, heat for melting the ice is derived from a flow of room air, propelled by a fan and conducted along the bottom of the ice bin. The present invention provides the alternative method of transferring heat from the room environment to the bottom of the bin by convective fluid flow, and controlling this heat transfer by a flow control device such as an air damper or a water valve. OBJECTS AND SUMMARY OF THE INVENTION It is an object of the present invention to provide an alternative method and apparatus to that disclosed in my U.S. Pat. No. 4,897,099 for applying thermal energy to a collection bin for purified ice, thereby melting some of the ice to provide and collect purified water. In accordance with the present invention, a fluid medium such as air, or water, is brought in contact with the bottom of the ice bin. As ice is melted in the bin the fluid is cooled, thus becoming denser and heavier. It then falls in a convective downward flow through an air duct or a water pipe to a lower height level where it encounters a like fluid which has been warmed by the room environment and is thus less dense and lighter. As this fluid moves downwardly away from the bin bottom in the duct or pipe, it is replaced by warmer fluid which has been warmed by the room environment. This influx of warm fluid provides more heat to melt ice, and is in turn cooled and flows downward through the duct or pipe. In this way a continuous ice melting and fluid flow is established. BRIEF DESCRIPTION OF THE DRAWINGS These and other objects, features and many of the attendant advantages of the present invention will be appreciated more readily as they become better understood from a reading of the following description considered in connection with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference numerals, and wherein: FIG. 1 is a schematic flow diagram of a system constituting one embodiment of the present invention; FIG. 2 is a schematic flow diagram of a second embodiment of the system of the present invention; and FIG. 3 is a schematic flow diagram of still another embodiment of the system of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS In order to facilitate reference to the disclosure material incorporated herein from my U.S. Pat. No. 4,897,099, two-digit reference numerals appearing in the accompanying drawing are chosen to correspond to those reference numerals employed in the aforesaid patent for like elements. Three-digit reference numerals appearing in the accompanying drawings designate elements not present in the aforesaid patent. In the interest of brevity, and to facilitate understanding of the subject matter of the present invention, the following description omits discussion of the portions of the system not directly related to the invention subject matter. Referring now to FIG. 1 of the accompanying drawings, the overall ice-forming and melting system is illustrated schematically. Compressor 9 draws refrigerant vapor from evaporator 2 and discharges it to condenser 10. Liquid refrigerant flows via liquid line 11 and metering device 12 back to evaporator 2, in a continuous refrigeration cycle. Water pressurized by pump 14 flows over plate 3, and ice pieces 5, 6, 7 and 8 are formed. When periodic harvesting is initiated, the ice pieces fall into bin 18. Bin switch 21 remains closed and thus keeps compressor 9 energized until the level of ice in bin 18 reaches the sensor element of bin switch 21, at which time the switch opens and de-energizes compressor 9. Should the ice level at bin switch 21 drop at a later time, it would close again and re-energize compressor 9. At selected times the ice collected in bin 18 is heated by a flow of ambient air warmed by the room environment and entering inlet duct 200 so as to flow in contact with heat exchange fins 38. Inlet duct 200 slopes downward from its intake to help establish a convective flow by preventing backflow. After contact with fins 38, this cooled air flows downward through down-duct 201, through damper 202, and through discharge duct 203, to mix with ambient air warmed by the room environment. A continuous convective flow is thus established. Any ice which melts in bin 18 drains through a pipe 22, having its inlet at the bottom of the bin, into a bottle 23 or other container resting on a platform 24 hinged at a positionally fixed point 25. By "positionally fixed" it is meant that the hinge or pivot point 25 is stationary relative to the common cabinet or housing for all of the components described herein. If bottle 23 is less than full, its weight is overcome by the resilient bias force of a balance spring 26 pulling platform 24 counter clockwise (as viewed in the drawing) to swing the platform upwardly. This upward movement causes an upward movement of control link 27 connected to platform 24 at connecting pivot 28, the latter being movable relative to the common system housing. Upward movement of control link 27 causes counter-clockwise rotation of a rocker arm 29 about a fixed pivot point 30 to which it is connected at a movable pivot point 31. The rotation of rocker arm 29 causes an override switch 32 to close, thereby bypassing bin switch 21 and permitting compressor 9 to run regardless of the state of the bin switch. Extension arm 204 is attached to platform 24, and control link 205 is connected to it at movable pivot point 206. Control link 205 connects at movable pivot point 207 to control arm 208 to actuate damper 202 about fixed pivot point 209, so that when platform 24 is in the upward position, damper 202 is open. In this way, when bottle 23 is less than full, damper 202 is open and melting of ice by convective air flow continues. Ice resting on the bottom of bin 18 is thus melted at a relatively fast rate and the resulting water is drained via pipe 22 into bottle container 23. As ice melts at the bottom of the bin, the weight of the ice pieces in the bin causes more ice pieces to continually move downwardly to the bin bottom. Meanwhile, the ice-making function continues, providing a supply of fresh ice pieces that are collected in the bin. When container 23 is full, its weight overcomes the bias force of balance spring 26 and causes platform 24 to drop (i.e., pivot clockwise about fixed pivot 25). This movement, transmitted via extension arm 204, control link 205 and control arm 208, causes damper 202 to move to a closed position, thus interrupting the convective air flow and the melting of ice in bin 18. Also, the downward movement of platform 24 is transmitted via control link 27 and rocker arm 29 to the override switch 32 which opens and leaves control of ice making to bin switch 21. The use of control link 205 to couple movements of platform 24 and damper 202 could be replaced by other practical, alternative means of achieving such a coupling. As an additional alternative precaution, for higher overall efficiency, a similar damper might be added to the inlet duct 200 and coupled in the same manner. FIG. 2 illustrates an embodiment in which the ice melting, convective flowing medium is water. Heat exchange tube 220 is in contact with the bottom of bin 18. Warming coil 221 is in the room environment, outside of the insulated cabinet enclosure. Supply pipe 222 and return pipe 223 connect heat exchange tube 220 and warming coil 221, and all of these connected components are filled with water, or some other suitable liquid. Valve 224 is capable of shutting off flow in return pipe 223, and is actuated by a control arm 225 connected to control link 27 at movable pivot point 226. All other features of the system in this embodiment are the same as described in the embodiment of FIG. 1. In operation, when bottle 23 is less than full, platform 24 and control link 27 are in their upward positions, as described earlier. This upward position of control link 27 causes control arm 225 to hold valve 224 in the open position. Water in heat exchange tube 220 is cooled by the presence of ice in bin 18 and flows downward in convective flow, through the open valve 224 and return pipe 223, to warming coil 221. Since warming coil 221 is located in the warmer room environment, the returning water is warmed, and then rises, flowing through supply pipe 222 to heat exchange tube 220 to supply more heat for ice melting, thus establishing a continuous convective flow and melting function. A raised section 227 of supply pipe 222 helps to establish a convective flow by preventing backflow. Standpipe 228 helps maintain water level in the convection loop by allowing for expansion. The melting function continues until bottle 23 is full, at which time platform 24 and control link 27 move downwards causing valve 224 to move to the closed position. This interrupts the convective flow, causing the melting function to cease. The use of control arm 225, to couple movements of platform 24 and valve 224, could be replaced by other practical, alternative means of achieving such a coupling. As an additional alternative precaution, for higher overall efficiency, a similar valve might be added in supply pipe 222 and coupled in the same manner. FIG. 3 illustrates an embodiment similar to the embodiment of FIG. 2 except that the system condenser 230 is specifically air cooled. Condenser fan 231 draws ambient air, warmed by the room environment, over the tubes of condenser 230 where it is warmed further and passes over warming coil 221. This arrangement provides more effective heating by warming coil 221. In this arrangement it is necessary that the system condenser be mounted in a location below the ice bin 18; accordingly, a longer discharge line 232 and longer liquid line 233 are employed. From the foregoing description it will be appreciated that the invention makes available a novel method and apparatus for efficiently melting ice collected in a bin as part of an ice-forming process in which the ice is formed as purified ice pieces from an unpurified source of water, and wherein the purified ice is melted to provide a supply of purified water. Having described preferred embodiments of a new and improved ice maker and water purifier with controlled condensing temperature in accordance with the present invention, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as defined by the appended claims.
A refrigeration system employed as an icemaker, in which part of the ice so produced is stored in a bin, and in which, part of the ice is then melted to provide a supply of purified water in a container. In one embodiment convection flow of air conveys heat from the ambient room environment to the bottom of the ice bin to achieve this melting. In a second embodiment a convection flow of water is employed for this purpose. Controls are provided to automatically control melting, to maintain a predetermined level in the purified water container.
5
This is a continuation-in-part of co-pending International Application PCT/RU97/00234 filed on Jul. 21, 1997 designating the United States. FIELD OF THE INVENTION The present invention relates to mechanical engineering, particularly, to engine designs, and, more particularly, to internal combustion engines, preferably of the two-stroke type with slot-type gas distribution. BACKGROUND OF THE INVENTION Described in DE, A1, 3635873 is a two-stroke internal combustion engine with slot-type gas distribution and crankcase scavenging, comprising a crankcase with a single-throw shaft installed therein, and cylinders connected to the crankcase, each of the cylinders enclosing a piston with a pin connected to the shaft through a connecting rod, and each of the cylinders having exhaust ports communicating with an exhaust pipe, and scavenging ports communicating with a crank chamber through scavenging ports. The problems with the prior art engine include its low fuel efficiency due to the fact that a fresh charge is emitted from the cylinder into the exhaust pipe during scavenging, and the overheating of exhaust port edges, the piston and the other working surfaces. These reasons prevent tuning the engine for the average efficient pressure. Another conventional two-stroke engine with a slot-type scavenging comprises a crankcase with a single-throw shaft installed therein, and a cylinder connected to the crankcase and enclosing a piston with a pin connected to the shaft through a connecting rod, the cylinder having a scavenging port in communication with an inlet pipe, and an inlet/outlet port connected to an inlet/outlet passage, and a slide valve mounted within the inlet/outlet passage so that alternatively connect the passage with the inlet pipe and the exhaust pipe (SU, A1, 56419). The above prior art overcomes many of the problems inherent in the operation process of the two-stroke engines, in particular: as compared to the previously mentioned prior art, the fresh charge emission from the cylinder during the scavenging is notably reduced owing to sealing the inlet/outlet passage by the slide valve; the cylinder charging is increased; and the temperature stress on the edges of the inlet/outlet port and a portion of the piston surface is reduced owing to cooling by fresh charge admitted through the slide valve, the inlet/outlet passage and the inlet/outlet port. However, the prior art engine fails to take full advantage of the significant prospects of improving the time-to-section of the inlet and exhaust parts. US, A1, 5081961 (FIGS. 4.1-4.5) describes an internal combustion engine with slot-type gas distribution, comprising a crankcase with a single-throw shaft installed therein, a cylinder connected to the crankcase and enclosing a piston with a pin connected to the shaft through a connecting rod, the cylinder having two opposite inlet/outlet ports, each of the ports being connected with one of inlet/outlet passages, and each of the inlet/outlet passages having a rotary valve adapted to alternately connect the passage with an inlet and outlet pipes. As compared to SU, A1,6419, this prior art engine provides the increased time-to-section ratio owing to the doubled number of slide valves, however, it fails to take full advantage of the possibility of increasing the time-to-section ratio; the variable volume of the crank chamber is not used as a receiver, and the compression chamber is not used for cooling and lubrication of the conversion mechanism in order to enhance the reliability of the engine firing and to cool the piston and the cylinder wall by a fresh charge. Taken together, the factors above prohibit the attainment of the highest specific characteristics in the piston engines. SUMMARY OF THE INVENTION It is an object of the present invention to provide an engine having improved specific parameters and enhanced reliability. The object of the invention is accomplished in an internal combustion engine with slot-type gas distribution, comprising a crankcase with a single-throw shaft installed therein, at least one cylinder connected to the crankcase and enclosing a piston with a pin connected to the shaft through a connecting rod, the cylinder having at least a pair of opposite inlet/outlet ports, each of the ports being connected with one of inlet/outlet passages, a slide valve mounted within each of the inlet/outlet passages so that to alternatively connect the passage with an inlet pipe and an exhaust pipe, wherein in accordance with the invention said slides are disposed at the opposite ends of the shaft, the cylinder has scavenging ports, and the crankcase defines a crank chamber communicating with the scavenging ports through scavenging passages and connected to the inlet pipe through the slide valve, the inlet/outlet passage and the inlet/outlet port uncovered by the lower edge of the piston as it ascends towards the top dead centre. Each of the slide valves may be disposed in a cylindrical cavity and include a disk separator coaxial with the shaft and having a sealing over its radial surface, and a sector member disposed at an end face of the separator and contacting an end face of the crankcase, wherein said slide valve is mounted within the cavity so that to form an inlet receiver and an exhaust manifold that are connected with the inlet pipe and the exhaust pipe, respectively, said slide valve having an exhaust passage in the region of the sector member, and each of the inlet/outlet passages being made in the end face of the crankcase to periodically communicate with the exhaust manifold through the exhaust passage. The sector member may be made in the form of a counter weight. The piston pin may include a central cylindrical portion and cylindrical segments connected to opposite end faces of the central cylindrical portion and mating segment recesses made in the inner surface of the piston, the cylindrical segments being connected to the piston by threaded members. The piston may be provided with guide rollers which are mounted on shafts in the piston symmetrically about the longitudinal axis of the pin, so that to contact the cylinder inner surface which defines races for the rollers. A pair of the rollers may be mounted on each side of the piston. The scavenging ports may be made at two sides of each of the races. The crank chamber may be defined by an inner surface of a cylindrical groove in the crankcase, said groove being coaxial to the shaft and communicating through a bypass passage with an under-piston cavity defined by inner surfaces of the cylinder and the piston. The bypass passage of the under-piston cavity may be provided in the rocking plane of the connecting rod, while a part of the pin central cylindrical portion is arranged within the crank chamber when the piston is in the region of the bottom dead centre. Parts of the rollers may be received in the bypass passage when the piston is in the region of the bottom dead centre. The single-throw shaft may include two disk-shaped webs and a crank pin which is connected to the webs eccentrically about the shaft rotation axis, rolling bearings being mounted on the external surfaces of the webs and located within the cylindrical groove in the crankcase, and a bearing bush of a lower head of the connecting rod being arranged between the webs on the crank pin. The crank chamber may be provided with disk seals disposed within the crankcase cylindrical groove in the plane perpendicular to the shaft rotation axis, said seals being secured on the crank pin. The seal may include a slit spring collar contacting an inner surface of the cylindrical groove, and two disk membranes mounted with an axial gap relative to the spring collar at two sides thereof and fixed on the crank pin, the membranes having an external diameter lesser than the diameter of the cylindrical groove and greater than the internal diameter of the spring collar. A disk spacer may be secured on the crank pin between the membranes, the spacer having a width greater than the width of the spring collar. Joint nuts may be screwed on the both ends of the crank pin. The engine may be a multicylinder engine, wherein the bushes of the bearing of the lower heads of the connecting rods are sequentially mounted on the crank pin. The axes of the cylinders may be disposed radially to the shaft rotation axis. The engine may comprise a charger connected to the inlet pipe, the crank chamber being in permanent communication with the under-piston cavities in each of the cylinders. The seals may be mounted at both sides of the bearing bush of the lower head of each of the connecting rods so as to define a variable volume chamber between each pair of the seals, communicating with the under-piston cavity of one of the cylinders through the bypass passage. The shaft may be provided with an intermediate support having a eccentric opening in which the crank pin is located, an additional rolling bearing being mounted on the support and disposed in the cylindrical groove in the crankcase. The inlet and outlet pipes may be made in the form of pipe branches arranged between the cylinders in parallel with the shaft rotation axis. The pipe branches of the inlet pipe may communicate with the inlet receivers through radial channels made in the crankcase. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a longitudinal cross sectional view of a single-cylinder engine; FIG. 2 is a longitudinal cross sectional view of a multicylinder engine in accordance with claim 18; FIG. 3 is a similar view of the embodiment in accordance with claim 19; FIG. 4 is a sectional view taken through line A--A of FIG. 2; FIG. 5 is a sectional view taken through line B--B of FIG. 2; FIG. 6 is a sectional view taken through line C--C of FIG. 2; FIG. 7 is an illustration of an embodiment of a piston and a piston pin; FIG. 8 is a sectional view taken through line D--D of FIG. 7; FIG. 9 is a sectional view taken through line E--E of FIG. 7; FIG. 10 is an illustration of an arrangement of the crank chamber seals; FIG. 11 is a similar view illustrating an embodiment of the seal; FIG. 12 is a sectional view taken through line F--F of FIG. 4; FIG. 13 illustrates the operation of the engine in accordance with invention at the instant of beginning the exhaust; FIG. 14 is a similar view showing the slide valve position through line B--B of FIG. 2; FIG. 15 illustrates the operation at the instant of scavenging and commencing the admission of a fresh charge into the cylinder; FIG. 16 is a similar view showing the slide valve position through line B--B of FIG. 2; FIG. 17 illustrates the operation at the instant of compressing the charge in the cylinder and commencing the admission of the fresh charge into the crank chamber; FIG. 18 is a similar view showing the slide valve position through line B--B of FIG. 2. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings, an engine in accordance with the present invention comprises a crankcase 1 defining a crank chamber 2, a single-throw shaft 3, a cylinder 4 enclosing a piston 5 with a pin 6 connected to the shaft 3 through a connecting rod 7, and slide valves 8 mounted at the opposite ends of the shaft 3. The cylinder 4 has scavenging ports 9 in communication with the crank chamber 2 via scavenging passages 10, and inlet/outlet ports 11 connected with an inlet/outlet passages 12. Mounted within each of the inlet/outlet passages 12 is the slide valve 8 adapted to alternately connect the passages 12 with an inlet pipe 13 and an exhaust pipe 14, and connect the crank chamber 2 with the inlet pipe 13 through passages 12 and ports 11 uncovered by a lower edge of the piston 5 as it ascends towards the top dead centre. Each of the slide valves 8 is located within a cylindrical cavity 15 and includes a disk separator 16 coaxial to the shaft 3 and having a sealing 17 over its radial surface, and a sector member 18 disposed at an end face of the separator 16 and contacting the end face of the crankcase 1. The slide valve 8 is mounted within the cavity 15 so that to form an inlet receiver 19 and an exhaust manifold 20 connected with the inlet pipe 13 and the exhaust pipe 14, respectively. In the region of the sector member 18, the slide valve 8 has an exhaust passage 21, while each of the inlet/outlet passages 11 is arranged in the end face of the crankcase 1 so that to periodically communicate with the exhaust manifold 20 via the exhaust passage 21. The sector member 18 may be made in the form of a counter weight. The piston pin 6 may include a central cylindrical portion 22 and cylindrical segments 23 that are connected to the opposite end faces of the portion 22 and mate segment recesses 24 which are provided in the inner surface of the piston 5, the segments 23 being connected to the piston 5 through threaded members 25. The piston 5 may be provided with guiding rollers 26 which are mounted on shafts 27 in the piston symmetrically over the longitudinal axis of the pin 6 so that to contact the cylinder 4 inner surface which defines races 28 for the rollers 26. A pair of the rollers 28 may be mounted on each side, and the scavenging ports 9 are arranged at two sides of each of the races 28. The crank chamber 2 may be defined by the inner surface of a cylindrical groove 29 provided in the crankcase 1, the cylindrical groove 29 being coaxial to the shaft 3 and communicating through a bypass passage 30 with an under-piston cavity 31 defined by inner surfaces of the cylinder 4 and the piston 5. The bypass passage 30 is arranged in the rocking plane of the connecting rod 7 and receives parts of the central portion 22 of the pin 6 and parts of rollers 26 when the piston 5 is in the region of the bottom dead centre. A part of the portion 22 may be also arranged within the cavity defined by the cylindrical groove 29 in the crankcase 1. The shaft 3 may include two disk-shaped webs 32 and a crank pin 33 connected to the webs eccentrically about the shaft 3 rotation axis. Rolling bearings 34 are mounted within the cylindrical groove 29 on external surfaces of the webs 32, and a bush 35 of a bearing of a lower head 36 of the connecting rod 7 is arranged between the webs 32 on the crank pin 33. The crank chamber 2 may be provided with disk seals 37 disposed within the cylindrical groove 29 in the crankcase 1 in the plane perpendicular to the shaft 3 rotation axis, and secured to the crank pin 33. The seal 37 may include a slit spring collar 38 contacting the inner surface of the cylindrical groove 29, and two disk membranes 39 disposed with an axial gap relative to the spring collar 38 at two sides thereof and fixed to the crank pin 33. The external diameter of the membranes 39 is lesser than the diameter of the cylindrical groove 29 and greater than the internal diameter of the spring collar 38. A disk spacer 40 having a width greater than that of the spring collar 38 may be secured on the crank pin 33 between the membranes 39. Joint nuts 41 may be screwed on both ends of the crank pin 33. The engine may be a multicylinder engine, wherein bushes 35 of the bearings of the lower heads 36 of the connecting rods 7 are sequentially mounted on the crank pin 33. The engine may comprise a charger (not shown) connected to the inlet pipe 13, the crank chamber 2 being in a permanent communication with the under-piston cavities 21 of each of the cylinders 4, or the seals 37 may be mounted at both sides of the bush 35 of the bearing of each connecting rod 7 so that to define between each pair of the seals 37 a variable volume chamber 42 in communication with the under-piston cavity 31 of one of the cylinders through the bypass passage 30. The axes of the cylinders 4 may be disposed radially to the shaft 3 rotation axis, i.e. in the star-shape arrangement if their number is more than two. The shaft 3 may be provided with an intermediate support 43 having an eccentric opening 44 within which the crank pin 33 is located. A supplementary rolling bearing 45 is disposed on the support 43 within the cylindrical groove 29 in the crankcase 1. The inlet 13 and outlet 14 pipes may be made in the form of branch pipes disposed between the cylinders 4 in parallel with the shaft 3 rotation axis, the branch pipes of the inlet pipe 13 being in communication with the inlet receivers 19 through radial channels 46 provided in the crankcase 1. An engine in accordance with the present invention operates in the following manner. At the end of the expansion of combustion products in the cylinder 4, the upper edge of the piston 5 as the latter descends towards to the bottom dead centre uncovers the inlet/outlet ports 11 to commence the exhaust of spent gases from the cylinder 4 simultaneously through two inlet/outlet passages 12, the exhaust passages 21 in the slide valve 8 and the exhaust manifolds 20 into the exhaust pipe 14 (see FIGS. 12 and 13). As the piston 5 continues its motion towards the bottom dead centre, its upper edge uncovers the scavenging ports 9 to commence the admission of a compressed fresh charge into the cylinder 4 and to force out residual spent gases to the inlet/outlet ports 11, thereby scavenging the cylinder 4 cavity. At the end of the exhaust, the slide valves 8 rotate and interrupt the communication between the passages 12 and the exhaust manifolds 20 to terminate the exhaust process, and the fresh charge forced out during the scavenging from the cylinder 4 to the passages 12 either enters again the inlet pipe 13, or, depending on the slide valve design, is entrapped within the inlet/outlet passages 12, generating thereby a pressure wave directed towards the inlet/outlet ports 11 and preventing further escape of the fresh charge from the cylinder 4. Wastes of the fresh charge through the exhaust pipe 14 are thus eliminated which significantly improves the engine efficiency. It the engine comprises a charger (not shown), upon the exhaust have been finished, the admission of a compressed fresh charge into the inlet/outlet passages 12 from the inlet pipe 13 via the inlet receiver 19 commences, and the cylinder 4 is charged simultaneously through all ports (9 and 11) in the cylinder 4, enabling the appropriate forced aspiration of the two-stroke engine up to a required degree (see FIGS. 14 and 15). In this embodiment of the operation process, the time-to-section ratio of the ports 9 and 11 is several times greater than the maximum time-to-section ratio possible in four-stroke engines. The charging process continues even when the piston 5 ascends from the bottom dead centre until its upper edge sequentially covers first the scavenging ports 9 and then the inlet/outlet ports 11, whereupon the process of compressing the fresh charge in the cylinder 4 commences. As the piston 5 continues its movement from the bottom dead centre, the lower edge of the piston 5 uncovers the inlet/outlet ports 11, and a fresh charge is admitted into the crank chamber 2 from the inlet pipe 13 via an inlet receivers 19 and the passages 12 either due to negative pressure in the chamber 2 or under the pressure created by the charger (see FIGS. 16 and 17). As this takes place, the combustion products are combusted and expanded in the cylinder 4 above the piston 5, whereupon the cycle repeats. The slide valves 8 operate as follows. The disk separator 16 of each of the slide valves 8 permanently divides the cavity 15 into the inlet receiver 19 and the exhaust manifold 20 using the radial seal 17 mating the inner cylindrical surface of the cavity 15. The sector member 18 of the slide valve 8 is in permanent contact with the end face of the crankcase 1, and the exhaust passage 21 provided in the slide valve 8 is arranged at the same radius about the rotation axis of the shaft 3 as the passage 12 provided in the end face of the crankcase 1. When the passages 21 and 12 align within a predetermined range of the rotation angle of the slide valve 8, the cylinder 4 cavity communicates with the exhaust pipe 14, and the exhaust occurs. In the absence of the communication between the passages 21 and 12, both of the inlet/outlet passages 12 are in permanent communication with the inlet pipe 13 via the inlet receivers 19 and the radial channels 46. Thus, the task of increasing the charging of the engine cylinder 4 is solved by pre-charging the crank chamber 2 with the substantially simultaneous admission of a fresh charge into the cylinder 4 both through the scavenging ports 9 and the inlet/outlet ports 11, which ensures about the twofold increase in the inlet time-to-section ratio as compared to the most pertinent prior art (US, A1, 5981961). The effect is also attained owing to decreased mechanical losses for driving the charger, or due to abandoning the charger at all (the use being made of the suction and compression effects in the crank chamber 2), or owing to the more even admission of the compressed charge (except the short intervals during the periods of sealing the port 11 by the side surface of the piston 5) which lowers the required increase in the charger pressure and flow rate, and, in the case of employing a centrifugal charger, improves its operation conditions in terms of gas dynamics. The fresh charge admission occurs in the substantially uninterrupted manner even in a single-cylinder engine. The improved time-to-section ratio of an internal combustion engine makes it possible to increase the rotation frequency of its shaft without the decrease in the efficient power. This result is provided by the reduced time for charging the cylinder and the decreased hydraulic losses. The possibility of additionally admitting a fresh charge via the crank chamber 2 provided by the operation process in accordance with the invention ensures the threefold increase in the amount of cold charge pumped through the exhaust elements. It enables all excess heat which has not managed to penetrate into the material depth to be removed from the surface of the hottest parts (edges of the ports 11, passage 12 wall and the piston 5), and, hence, improves operational parameters of the process, also owing to the increased charging of the engine cylinder, without adverse effects to its operation reliability. Additionally, the employment of the crank chamber 2 in the operation process ensures a drastic decrease in the thermal stress of the entire piston 5 not only due to fanning its walls with the cold charge through the ports 9 and 1, but also due to the intense cooling of the piston inner surface by the fresh charge admitted into the crank chamber 2 and compressed therein, and by scavenging. The alignment between the rotation axes of the slide valve 8 and the shaft 3 permits the dimensions of the exhaust passage 21 to be best fitted to the engine gas distribution phases without substantial degradation in the weight and dimension characteristics. As to the conventional engines (References 2 and 3), the slide valve shapes and arrangement prohibit the improvement in the time-to-section ratio of the passages switched by them. In addition, the alignment between the slide valve and shaft axes makes it possible to install a counter weight on the slide valve. The possibility of installing the counter weight at a relatively large rotation radius essentially lowers the weight being balanced, and the selected relative arrangement of the piston 5 and the sector member 18 permits the employment of the latter as the counter weight. In so doing, the removal of the counter weights from the crank chamber 2 provides the possibility of making the chamber more compact and minimizing the idle space therein. Thus, the technical approach above results in the essential improvement of the specific weight and dimension characteristics of the engine. The provision of the piston 5 with the guiding rollers 26 contacting the races 28 in the cylinder 4 ensures, at the traditional minimum number of piston collars in two-stroke engines, the essential reduction in the mechanical losses in the cylinder and piston assembly. In addition to the solution of the direct technical task, the presence of the rollers allows the essential reduction in the height of the piston guiding part owing to the reduced stalling torque acting on the piston. As in the operation of the described engine there is no need to seal the exhaust ports by the piston lower part, the height-to-diameter ratio of the piston may be brought to 1/3. The stepped shape of the piston pin 25 with cylindrical segments 28 makes it possible, through the provision of the central portion 22 having the largest diameter and the minimum width possible, to raise the pin load capacity without increasing the weight thereof. The piston 5 can be brought as close to the shaft 3 as possible owing to the fact that the central portion 22 is received, through the bypass channel, in the cylindrical groove 29 in the crankcase 1 and the rollers 26 are partially received in the passage 30. As the scavenging ports 9 are arranged at both sides of the races 28 for the rollers 26, the intense fanning of the latter by fresh charge at scavenging, and the admission of the fresh charge through the ports 11 obviates the problems of cooling both the rollers 26 and the cylinder-and-piston assembly as a whole. The arrangement of the bearings 34 of the shaft 3 on the external surfaces of the webs 32 allows the supports of the shaft 3 to be ultimately brought together, providing maximum rigidity of the crank pin 33, which increases the life of the bearings of the lower head 36 of the connecting rod 7. This is the optimum design of the shaft 3 in the case of a short-stroke engine. The provision of the disk seals 37 at two sides of the bush 35 of the bearing on the lower head 36 of the connecting rod 7 eliminates the problems of sealing the crank chamber 2 and reducing its idle space, by defining an annular cavity in the chamber 42 having a width which is slightly greater than that of the connecting rod 7 (see FIG. 3). The composite form of the seals 37 makes their assembly easier and improves the air-tightness of the chamber 2. The seals operate in the following manner. Owing to its radial flexibility, the spring collar 30 is reliably fixed against cranking relative to the surface of the groove 29 in the crankcase 1. The membranes 39 and the spacer 40 in combination with the bush 35 are fixed against cranking relative to the crank pin 33, e.g. by a spline (not shown), and revolve together with the pin about the shaft 3 axis. As the membranes 39 are mounted with a gap relative to the spring collar 38, a labyrinth between them provides the sealing at minimum mechanical losses, and at the instant of the pressure increase in the chamber 42 between the seals 37 the membranes intermittently urge against the spring collar 38 and improve the air-tightness of the cavity. In a multicylinder engine, for example, with the star-shape arrangement, a fresh charge may be admitted into the crank chamber 2 under a constant pressure to cool and lubricate the crank and connecting rod mechanism. In this embodiment (see FIG. 2), the chamber 2 is employed as an additional fresh charge receiver from which, in order of the cylinder operation, the fresh charge is fed under pressure through the under-piston cavity 31, scavenging passages 10 and ports 11 to accomplish scavenging. In another embodiment (see FIG. 3), the seals 37 are additionally installed between the bushes 35 to seal the chambers 42 each of which is in communication with one of the cylinders 4 through the bypass passage 30. It enables the fresh charge suction and compression strokes to be accomplished in each chamber 42 before scavenging the cylinder, and provides a chance of essentially enhancing the reliability of the engine starting as compared to the previous embodiment. The provision of a supplementary support 43 contributes to rigidity of the shaft 3 in multicylinder engines and in engines tuned for an average efficient pressure, e.g. in diesels. The arrangement of the inlet 13 and outlet 14 pipes along the shaft 3 axis between the cylinders 4 ensures the integration of each cylinder passages into a common system without the increase in the dimensions, and the attachment of the gas distribution systems of several engines when they are integrated into a multimodule structure. In addition, such arrangement of branch pipes improves the intensity of fanning the cylinder at air cooling. Therefore, the engine in accordance with present invention overcomes the major problems encountered in designing engines, particularly: the efficiency of a two-stroke engine is markedly improved as compared to a four-stroke engine, since charge wastes during scavenging are eliminated through the use of slide valves, the mechanical losses being lesser in the two-stroke engine; the restrictions on charging the cylinders of a two-stroke engine are eliminated which allows the forced aspiration of the engine up to a required degree owing to both the provision of slide valves sealing the cylinder cavity, and the intense cooling of the engine interior, which permits the engine to be tuned for an average efficient cycle pressure without the reduction in life; the shaft speed range is extended as compared to the engines having a compatible working volume of one cylinder, which allows the engine to be uprated owing to both the extended gas distribution phases owing to the use of slide valves, and the short-stroke design of the engine; the engine life and its mechanical efficiency are increased owing to changing over the majority of sliding couples to rolling couples (except for the cylinder-and-piston collar couple); the engine reliability is improved owing to the extremely simple overall kinematics (especially evident in a multicylinder arrangement), the maximum rigidity of the conversion mechanism, and the considerably reduced loads in the engine with the star-shape arrangement, achieved only in the two-stroke process, which permits the mechanism in accordance with invention to be used in a two-stroke engine tuned for performance; the engine weight and dimension characteristics are considerably improved owing to the possibility of uprating and tuning the engine for an average efficient pressure, and to the reduced dimensions and, consequently, the weight. Industrial Applicability The present invention can be employed in designing and manufacturing internal combustion engines with slot-type gas distribution. An engine in accordance with the invention resolves the basic problems inherent to the engines, such as the inferior efficiency of two-stroke engines caused by great wastes of fresh charge during scavenging, and mechanical losses for driving a charger, the high thermal stress of the piston and the exhaust system components. The engine specific weight and dimension characteristics are comparable to those of gas-turbine engines, while the engine in accordance with the invention is more efficient and reliable, less expensive and has a simpler structure.
The present invention pertains to the field of engine construction and relates to internal combustion engines with scavenging and more precisely to two-stroke engines. At the beginning of the exhaust stroke, the exhaust gases are expelled from the engine cylinder through inlet and outlet ports, inlet and outlet passages and slide valves into an exhaust pipe. Scavenging ports are then uncovered by an upper edge of the piston and used to feed a fresh charge into the cylinder from the crank chamber while the cylinder cavity is scavenged. After expelling the exhaust gases from the cylinder cavity, the slide valves rotate to interrupt the communication between the cylinder cavity and exhaust manifold. Upon further rotation of the slide valves, the cylinder cavity is connected with the inlet pipe through the same gas-distribution organs used for the exhaust gas outlet, i.e. the inlet and outlet ports, the inlet and outlet passages and the slide valves. A fresh charge can thus be fed into the cylinder through all the ports it comprises, whereby the cylinder of a two-strike engine may be charged without any losses in the charges and with the appropriate preliminary compression ratio.
8
TECHNICAL FIELD The invention relates generally to a space-based observatory platform and in particular to an observatory platform in which a positioning boom disposed between the platform and its instrument payload provides thermal and dynamic isolation as well as fine pointing and momentum control. BACKGROUND In deploying an instrument platform for space-based observation, it is often required that the platform provide shielding from solar influence. This generally requires that a sun shield be included as part of the platform structure. The sensitive instrumentation in the instrument payload is susceptible to thermal effects and mechanical noise originating in the platform itself. In addition, it is frequently a requirement that the instrument payload be capable of a wide range of motion in order to aim the instrument as desired. Repositioning of the instrument payload can result in momentum buildup that must often be corrected at the cost of fuel or stored electric power. Thus, a need exists for a space-based observatory platform with enhanced immunity to mechanical vibration and thermal effects, as well as fine pointing capability that does not increase the platform's susceptibility to momentum buildup. SUMMARY These needs and others are satisfied by the present invention, in which a positioning boom disposed between the platform and its instrument payload provides thermal and dynamic isolation as well as fine pointing and momentum control. The basic problem addressed by this invention is design of a system that isolates a sensitive payload from a warm, dynamically noisy spacecraft, which includes a sunshield. Isolation is required in terms of dynamics and heat flow, both in terms of the absolute level and its variance (thermal isolation). Secondly, it was desired that the design provide intrinsic control over momentum buildup (which is due to the separation of the center of pressure from the center of mass). The design also needs to provide a view (field of regard) to at least half the sky (in the anti-sun direction). In one embodiment in accordance with the present invention, an improved space-based observatory platform, having an instrument payload and a sunshield, is provided. The improvement comprises a gimbaled positioning boom having a high length-to-width aspect ratio coupling the instrument payload to the observatory platform, wherein the boom has a relatively low natural frequency to minimize transmission of dynamic noise between the instrument payload and the observatory platform. In accordance with one form of the invention, the positioning boom is articulated to position the instrument payload center of gravity with respect to the sunshield center of solar pressure. The positioning boom may include a piezoelectric actuator at the point of articulation. In one embodiment, the positioning boom further includes biaxial gimbal drives positioned proximate the instrument payload to provide rotation capability about both an elevation axis and an instrument boresight axis. The gimbal drives include piezoelectric stack-type actuators. In accordance with one aspect of the invention, the positioning boom length-to-width aspect ratio is in the range between 30 and 60. In one form of the invention, the relatively long positioning boom positions the instrument payload at a distance from the sunshield for thermal decoupling. Furthermore, an attitude control system associated with the platform provides rotational motion control about the solar axis that extends from the sun, through the sunshield, to the instrument payload. The attitude control system may be based upon a reaction wheel arrangement. In one embodiment, the positioning boom is coupled to the observatory platform at two points of the observatory platform structure using relatively thin, highly damped bipod flexures to provide z-axis stability. The positioning boom may be layered with visco-elastic material to provide passive damping, or the positioning boom may include a plurality of piezoelectric patches disposed thereupon to provide active damping. DESCRIPTION OF THE DRAWINGS Features of exemplary implementations of the invention will become apparent from the description, the claims, and the accompanying drawings in which: FIG. 1 is a perspective view of a space-based observatory platform with its instrument payload in a deployed configuration; FIG. 2 is an elevational view of the instrument payload in a first configuration; FIG. 3 is an elevational view of the instrument payload in a second configuration; FIG. 4 illustrates mounting of the positioning boom to the platform; FIG. 5 is a close-up view of the mounting detail of FIG. 4 ; and FIG. 6 depicts pointing actuators for the instrument payload. DETAILED DESCRIPTION The present invention contemplates the use of a long, gimbaled, highly damped positioning boom to attach the payload to the spacecraft. The boom has a low natural frequency, which minimizes transmission of dynamic noise from the spacecraft, satisfying the first requirement. The boom can rapidly damp our vibrations induced by these disturbance sources. The boom is also a poor thermal conductor, since it is long with a small cross-section, and it moves the telescope away from the heat shield, lowering the radiative coupling between the payload and spacecraft. The reduced coupling between the sunshield and spacecraft significantly lowers the magnitude of thermal variations as the telescope's orientation is changed. In one embodiment, an active damping system is employed for the boom, with feedback control that operates at very low levels. The boom may have piezoelectric patches for active vibration damping and small pointing adjustments. Furthermore, a gimbal at the end of the boom provides the ability to move the payload relative to the line connecting the sun and the center of solar radiation pressure, thus moving the center of mass of the entire satellite, relative to the center of pressure, in such a way as to minimize solar torques, momentum buildup, use of the reaction wheels, dynamic input, and consumption of fuel for momentum dumping. The positioning boom can also be made to offset the CG from the CP in a selected direction in order to reduce the momentum stored in the reaction wheels, eliminating the need to use propellant to dump momentum in most cases. The positioning boom is not in the launch load path and is not required to carry launch-induced stresses. Therefore, it can be made to meet all of these requirements. In operation, one of the advantages of the present invention is that the boom can be designed to have very low frequency modes, effectively isolating the dynamic disturbances (from the spacecraft) from the instrument payload (such as a telescope). The positioning boom can also be made a “smart strut” that can be tuned in terms of its stiffness once on orbit (and bent slightly to make pointing adjustments). The decrease in the thermal input from the spacecraft and sunshield relaxes the requirements on the sunshield, and improves telescope performance. Finally, the ability to move the center of mass of the entire satellite, relative to the center of pressure, allows for reduced reliance on the reaction wheels to counter solar torques, thus minimizing momentum buildup and reducing their dynamic input. This kind of momentum management allows for more efficient use of fuel needed to unload saturated momentum wheels. This allows for longer and more efficient missions, since thruster firings for momentum unloading are fewer and further between. Locating the telescope further away from the sunshield allows the telescope to look at more than half the sky, relaxing operational constraints and making for a higher performance mission. Turning to FIG. 1 , a perspective view of a space-based platform is presented. One should consider that the illustrated configuration is consistent with the design strategies of the James Webb Space Telescope, or JWST, intended for deployment in 2011. The JWST will observe primarily the infrared light from faint and very distant objects. But all objects, including telescopes, also emit infrared light. To avoid swamping the very faint astronomical signals with radiation from the telescope, the telescope and its instruments must be very cold. Therefore, JWST has a large shield that blocks the light from the Sun, Earth, and Moon, which otherwise would heat up the telescope, and interfere with the observations. In order for this concept to operate properly, JWST must be in an orbit where all three of these objects are in about the same direction. The most convenient point is the second Lagrange point (L2) of the Sun-Earth system, a semi-stable point in the gravitational potential around the Sun and Earth. Of course, these constraints also apply to instrument payloads that are not designed to collect optically-derived data. An optical payload is shown in the drawings merely for illustrative purposes. FIG. 1 illustrates an optical payload with a bore-sight as indicated, having a primary focal point 102 within the tube structure, or tower housing, of the telescope. A secondary mirror 101 is disposed within the tower housing. The telescope has a gregorian-style off-axis paraboloid mirror 107 and a primary mirror reaction structure 108 that provides an adjustment base for fine tuning the primary mirror surface. Structurally, the instrument includes a support truss 103 and a tertiary optical component housing 104 . In one embodiment, the positioning boom 106 includes a telescoping mechanical damper with 50% to 100% Cr damping. This may be termed a jitter isolation damper. The damping of the boom may be active or passive. A piezoelectric actuator 109 at the point of articulation of the positioning boom 106 keeps the instrument payload center of gravity (CG) lined up with the solar pressure force center, as will be described more fully below in conjunction with FIGS. 2 and 3 . As noted previously, the platform is a JWST-style system, having a JWST-type Bus/solar array/com system 112 . The entire platform may be rotated 360 degrees about the sun vector 111 , using an attitude control system that may be based upon one or more reaction wheels, for example. FIG. 2 shows the instrument payload 201 in a first orientation with the bore-sight aimed in a first desired direction. It should be noted that the positioning boom 106 is articulated in a first direction on order to maintain the instrument payload CG in alignment with the solar pressure force center. In FIG. 3 , which shows the instrument payload in a second configuration, aiming of the bore-sight has been altered dramatically, and the positioning boom 106 is articulated in the opposite direction from the configuration shown in FIG. 2 to maintain the payload CG in its proper alignment. The positioning boom 106 , which may be highly damped in one embodiment, serves multiple purposes. It positions the instrument payload CG with respect to the sunshield solar pressure CG, it serves as a very low frequency isolator (around 0.1 Hertz) in order to structurally decouple the instrument payload from the platform, and it positions the instrument payload at a distance away from the sunshield that is sufficient for thermal decoupling. FIGS. 4 and 5 depict the mounting arrangement utilized for the positioning boom 106 at the space platform end. The positioning boom 106 , which is long, skinny, and highly-damped in one embodiment, provides flexibility in five degrees of freedom (with the exception of z-axis translation). The boom 106 is secured in position at the platform end by thin, highly damped bipod flexures 402 that are mounted at two points of the spacecraft structure in order to maximize z-direction flexibility. For proper performance, the boom 106 must have a relatively large length-to-width aspect ratio, although the specific value is dependent upon a number of factors. Aspect ratios in the range from about 30 to 60 have been shown to work adequately. As a general matter, the boom 106 should be from 10 to 20 meters in length, with a width from about 150 mm to about 300 mm. The boom 106 is constructed of graphite in one embodiment, such as a GFRP graphite material. Of course, other materials, such as titanium, for example, will also perform well, although metallic implementations may be undesirable where weight is a concern. For passive damping, a graphite boom would be layered with a visco-elastic material. Of course, a passively damped system must be kept warm for proper operation. This can be accomplished by surrounding the boom with a heated sock, for example, as known in the art. Active damping is generally accomplished by disposing a plurality of piezoelectric actuators 403 along the length of the boom 106 . Stresses along the boom 106 caused by flexing are transmitted to the proximate piezoelectric sensor, and a corresponding actuator is then used to provide a force acting on the boom in the opposite direction. FIG. 6 is illustrative of the pointing actuators for the instrument payload. Instrument payload fine-pointing actuators 601 , with nano-radian resolution, are implemented using a tip/tilt plate (for azimuth and elevation of the instrument) using piezoelectric stacks. A bore sight axis rotation gimbal 602 yields a plus-or-minus 90 degree range of adjustment with 50 micro-radian resolution. A cable-wrap safely routes the harness across the joint, with cable wrap diameter sized according to wire count. The elevation axis gimbal 603 provides the same range of motion and resolution as the rotation gimbal 602 , with low load level hysteresis less than one nano-radian. As noted previously, the positioning boom 106 is highly damped (50% to 100% Cr) in one embodiment, and overall platform rotation about the azimuth axis 604 is provided by the platform's attitude control system (ACS). Rotation has a range of plus-or-minus 180 degrees with a 50 micro-radian resolution, and low load level hysteresis less than one nano-radian. Although exemplary implementations of the invention have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions, and the like can be made without departing from the spirit of the invention and these are therefore considered to be within the scope of the invention as defined in the following claims.
A positioning boom disposed between a space-based observatory platform and its instrument payload provides thermal and dynamic isolation as well as fine pointing and momentum control. The inventive system isolates a sensitive payload from a warm, dynamically noisy spacecraft, which includes a sunshield. Isolation is required in terms of dynamics and heat flow, both in terms of the absolute level and its variance (thermal isolation). The present invention provides intrinsic control over momentum buildup (which is due to the separation of the center of pressure from the center of mass). The space-based platform also provides a view (field of regard) to at least half the sky (in the anti-sun direction).
7
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention pertains to skates such as in-line skates and the like. More particularly, this invention pertains to such a skate which may accommodate a variety of shoe sizes. [0003] 2. Description of the Prior Art [0004] In recent years, the sport of in-line skating has enjoyed a tremendous growth in popularity. In addition to being enjoyable exercise for adults, children have participated in in-line skating. [0005] High quality in-line skates can be expensive. The expense is particularly frustrating for parents of young children. As the children grow, their foot sizes expand necessitating frequent replacement of footwear of any type including recreational footwear such as in-line skates. [0006] In the past, in-line skate manufacturers have accommodated growth in foot size by having an oversized molded boot containing a replaceable liner. Liners of various wall thicknesses could be provided such that the liners could be replaced to accommodate different foot sizes. Alternatively, various techniques have been provided for permitting the boot of the skate to adjust to accommodate growth in foot size. However, such techniques have commonly been lacking in providing for a construction which is secure after adjustment and without impairing performance of the skate. SUMMARY OF THE INVENTION [0007] According to a preferred embodiment of the present invention, an adjustable fit in-line skate is provided having a rigid frame with a plurality of in-line skate wheels secured to the frame. A boot is secured to the frame with the boot having a toe portion and a heel portion. The heel portion includes a sole and the heel portion is fixed to the frame. The toe portion has a base and is fastened to the heel portion by means which releasably secure each of the base and the sole to at least a portion of the frame. The toe portion is slidable relative to the heel portion along a line of travel which is generally parallel to the longitudinal dimension of the skate. The toe portion may be fixed at any one of a plurality of fixed positions along the line of travel. BRIEF DESCRIPTION OF THE DRAWINGS [0008] [0008]FIG. 1 is a front, right and top perspective view of the skate of the present invention; [0009] [0009]FIG. 2 is an exploded perspective view of a liner for use with the skate of FIG. 1; [0010] [0010]FIG. 3 is a right side elevation view of the skate of FIG. 1 shown adjusted to a minimum foot size adjustment; [0011] [0011]FIG. 4 is a left side elevation view of the skate of FIG. 1; [0012] [0012]FIG. 5 is a front elevation view of the skate of FIG. 1; [0013] [0013]FIG. 6 is a rear elevation view of the skate of FIG. 1; [0014] [0014]FIG. 7 is a top plan view of the skate of FIG. 1; [0015] [0015]FIG. 8 is a bottom plan view of the skate of FIG. 1; [0016] [0016]FIG. 9 is the view of FIG. 3 separately shown to compare with FIG. 10; [0017] [0017]FIG. 10 is the view of FIG. 9 with the skate adjusted to a maximum foot size adjustment; [0018] [0018]FIG. 11 is an exploded perspective view of the skate of FIG. 1 (without showing a liner); [0019] [0019]FIG. 12 is a side sectional view of a toe portion of the skate of FIG. 1; [0020] [0020]FIG. 13 is an enlarged view of a heel portion of the skate of FIG. 1 (with a cuff shown in phantom and without showing a frame); and [0021] [0021]FIG. 14 is a view taken along line 14 - 14 of FIG. 13. DESCRIPTION OF THE PREFERRED EMBODIMENT [0022] With reference now to the various drawing figures in which identical elements are numbered identically throughout, a description of the preferred embodiment of the present invention will now be provided. [0023] In the various figures, an in-line skate 10 is illustrated having a skate boot 12 secured to a frame 14 and containing a liner 110 . The frame 14 carries a plurality of wheels 16 which, in an in-line skate, are arranged in a line. Also, the frame carries a resilient brake pad 18 as is conventional. [0024] Shown best in FIG. 11, the frame 14 includes two halves 14 a , 14 b . The frame halves 14 a , 14 b are slidably joined at offset and overlapping front tongues 20 a , 20 b (having holes 23 ) and rear tongues 22 a , 22 b (having holes 24 ). Holes 23 are in alignment when the halves 14 a , 14 b are joined. Holes 24 are similarly aligned when the halves 14 a , 14 b are joined. When the halves 14 a , 14 b are joined together, flat rear upper surfaces 26 of the halves 14 a , 14 b are in generally planar alignment to define a rear support platform. Upper surface 27 in the toe area of the frame defines a front support platform when the halves 14 a , 14 b are joined. As shown in FIG. 12, surfaces 27 are arcuate to mate with a base 76 to toe portion 34 as will be described. [0025] Referring back to FIG. 11, the boot 12 includes a heel portion 30 , cuff 32 , toe portion 34 and tongue 36 . The heel portion 30 includes a sole 40 and a raised heel wall 42 having sidewalls 44 , 46 each with holes 48 , 50 . The heel wall 42 surrounds the heel and lower ankle of the wearer with wall 46 being raised on the inside of the foot to provide additional support 41 for the arch of the user. [0026] The sole 40 includes a hole 52 formed in a recess 54 at a heel end of sole 40 . Similarly, at a toe end of the sole 40 , a hole 56 is provided between two ramped surfaces 58 . The base or sole 40 is sized to rest on the rear support platform 26 and the front support platform 28 with hole 52 aligned with holes 24 and with hole 56 aligned with holes 23 . A bolt 60 is sized to be passed through hole 52 with the head end of the bolt received within the recess 54 and with the bolt 60 further passing through holes 24 and secured by a nut 62 . Similarly, a bolt 64 having a head 66 sized to be received between ramped surfaces 58 is provided with the bolt 64 passing through hole 56 and aligned holes 23 and received within an elongated nut 68 . As can be seen, since holes 52 , 56 are approximately equal to the diameter of bolts 60 , 64 , once the heel portion 30 is secured to the frame 14 , the heel portion 30 is restricted from movement relative to the frame 14 . [0027] The toe portion 34 includes a toe box having sidewalls 70 , 72 and a top wall 74 . Further, as shown in FIG. 12, toe portion 34 has a bottom wall 76 . The bottom wall 76 is provided with an elongated slot 78 extending in a longitudinal dimension of the skate to pass the bolt 64 . When assembled with the heel portion 30 , the toe portion 34 is provided with the base 76 in underlying relation relative to the sole 40 of the heel portion 30 . Further, the sidewalls 70 , 72 are positioned in overlying relation to the exterior surfaces of the sidewalls 44 , 46 of the heel portion 30 . The sidewalls 70 , 72 are provided with elongated slots 75 , 77 aligned with holes 48 , 50 , respectively. With the construction thus described, upon loosening of elongated nut 68 (by use of an Allen wrench received in hole 69 —see FIG. 12), the toe portion 34 may move along a line of travel which is generally parallel to the longitudinal dimension of the skate. The slots 75 , 77 are aligned such that throughout the path of travel, the slots 75 , 77 remain aligned with holes 48 , 50 . [0028] The cuff 32 is provided to surround an upper ankle area of the wearer and surrounding the heel portion 42 as well as the rearward ends of the sidewall 70 , 72 . The cuff 32 has at its lower end pivot locations 80 , 82 having holes 84 , 86 aligned with holes 48 , 50 . A recessed area 88 surrounds hole 84 . Although not shown, an identical recessed area surrounds hole 86 . [0029] The attachment of the ends 80 , 82 at holes 48 , 50 is identical for both sides of the skate and a description with respect to end 80 will suffice as a description of end 82 . The attachment is best shown in FIGS. 13 and 14 where a plug 90 (shown partially in phantom) is provided sized to be received within the recess 88 and with a sleeve 91 having an internal thread passed through hole 84 , slot 76 and hole 48 . A threaded bolt 92 is threaded into the interior of the sleeve 91 . This method of attachment permits pivoting movement of the cuff 32 relative to the heel 30 and toe 34 . Further, the connection permits relative sliding movement of the toe 34 relative to the heel portion 30 upon the loosening of nut 68 . [0030] A conventional buckle arrangement having a release fastener 96 secured to one side of cuff 32 and a tensioning buckle and strap 98 secured to the opposite side of cuff 32 is provided to permit the cuff 32 to be securely fastened to the leg of a wearer. Similarly, a like buckle arrangement having a tension strap and buckle 97 and a release fastener 102 are provided on opposite sides 70 , 72 of the toe portion 34 to securely fasten the instep of the wearer's foot to the boot 12 . Finally, a tongue 36 is provided as is conventional. [0031] With the construction thus described, a wide variety of foot sizes can be accommodated by simply loosening nut 68 such that the toe portion 34 is moved relative to the heel portion 30 . About four different foot sizes can be achieved by permitting a stroke of movement equal to about one inch. Accordingly, the slots 76 , 78 will have a length of about one inch. Since a sliding adjustment is provided, unique adjustment is possible to accommodate unique foot sizes within a range between a minimum foot size (FIG. 9) and a maximum foot size (FIG. 10). Further, the foregoing design permits the use of a pivoting cuff 32 which has numerous advantages in the performance of in-line skating. Also, throughout the adjustment of the length, the positioning of the user's heel relative to the frame 14 and wheels 16 remains unchanged which presents a significant advantage in the performance of in-line skating since heel positioning is important to the performance of the skate. [0032] The present invention also utilizes a novel construction of a liner 110 (FIG. 2) to accommodate increases in shoe size. The use of resilient liners in in-line skates is well known. The present liner 110 includes a toe portion 112 joined to the main body portion 114 by an expandable resilient section 116 positioned surrounding the instep area of the foot. Accordingly, the toe portion 112 may move relative to the main body portion 114 . A lug 117 is provided on the toe portion 112 . The lug 117 is secured to the upper wall 74 of the boot toe 34 by passing the lug 117 through a hole 118 formed in the upper surface 74 and securing the lug 117 in said position by a bolt or screw 120 (FIG. 12). The area surrounding the hole 118 is provided with a recess 121 to receive a decorative cap 122 . Accordingly, as a user adjusts the size of the boot by expanding the toe portion 34 of the boot, the toe 112 of the skate liner 110 follows the toe 34 of the boot 12 . [0033] From the foregoing detailed description of the present invention, it has been shown how the objects of the invention have been attained in the preferred manner. However, modifications and equivalents of the disclosed concepts such as those which readily occur to one skilled in the art are intended to be included within the scope of the claims which are appended hereto.
An adjustable fit in-line skate is disclosed having a rigid frame carrying a plurality of skate wheels. A boot is secured to the frame with the boot having a toe portion and a heel portion. The heel portion has a sole plate which is carried over the length of the frame. The toe portion receives the sole plate and is slidably attached to the heel portion.
0
TECHNICAL FIELD This application claims the benefit under 35 U.S.C. §119 of U.S. patent application No. 60/570,817 filed on 14 May 2004 and entitled DIELECTRIC WELDING METHODS AND APPARATUS. TECHNICAL FIELD The invention relates to methods and apparatus for welding dielectric materials such as plastics. Some embodiments of the invention relate to welding using electromagnetic signals (e.g. radiofrequency signals). The invention may be applied to welding plastic membranes together in the presence of metals or other exposed electrically conductive materials (hereinafter referred to as ECM). The invention has broad application for manufacturing products which include welded plastic membranes that have ECM near to the weld locations. BACKGROUND Dielectric welding, also known as capacitance, radio-frequency, or high frequency welding, provides a way to fuse materials together. The resulting weld can be as strong as the original workpiece materials. Dielectric welding is commonly used for joining various plastic materials together. In dielectric welding, an alternating electrical field (typically alternating at a high frequency) is applied across an area to be welded. This is typically done by applying a signal between electrodes. The signal creates a varying, high-frequency electromagnetic field. When a material which is a poor electrical conductor is exposed to such a field, heat is generated in the material. The heat results from electrical losses that occur in the material. The heat deposited in the material causes the temperature of the material to rise. The heated materials become fused together. Dielectric welding relies on certain properties of the material in the parts being welded, for example, the geometry and dipole moments of molecules of the material, to cause the generation of heat in a rapidly alternating electromagnetic field. Not all materials can be dielectric welded. Polyvinyl chloride (PVC) is commonly welded by dielectric welding. Other thermoplastics that can be dielectric welded are EVA and polyurethanes. A typical dielectric welding apparatus places materials to be joined between two electrodes, which are typically metal plates or bars. The electrodes are connected to an oscillator. The oscillator is turned on to heat the materials, which fuse together when they have been heated sufficiently. The electrodes may hold the materials together during heating and cooling. There are situations where it is desirable to make products which have ECM, e.g. metal components, embedded in or attached to one or more membranes or other parts of a dielectric material which are to be welded together. A problem is that ECM in the vicinity of the electrodes of a dielectric welder can cause electrical discharges in the form of arcs or sparks. Such electrical discharges can damage the product being made, the welding apparatus and/or the dielectric welder itself. Electrical arcing can be dangerous to machines and humans. It is not always possible or convenient to add ECM after welding has been completed. There is a need for methods and apparatus which may be used to perform dielectric welding in the vicinity of ECM. SUMMARY OF THE INVENTION The invention relates to methods and apparatus for welding plastic materials membranes together in the vicinity of electrically conductive materials. Various aspects of the invention and features of specific embodiments of the invention are described below. BRIEF DESCRIPTION OF THE DRAWINGS In drawings which illustrate non-limiting embodiments of the invention, FIG. 1 is a schematic view of a dielectric welding apparatus; FIG. 2 is an isometric view showing first and second electrode assemblies; FIG. 3 is a perspective view of one of the electrode assemblies of FIG. 2 ; FIG. 4 is a plan view of one of the electrode assemblies of FIG. 2 ; FIG. 4A is a cross sectional view (in the plane A—A of FIG. 4 ) of the electrode assembly of FIG. 4 ; FIG. 4B is an exploded view of the electrode assembly of FIG. 4 ; FIG. 5 is a plan view of the other one of the electrode assemblies of FIG. 2 ; FIG. 6 is an isometric view of a buffer member; FIG. 6A is a top plan view thereof; FIG. 6B is a section in the plane A—A thereof; and FIG. 6C is a section in the plane B—B thereof; FIG. 7 is an isometric view of a part of an electrode assembly; FIG. 7A is a top plan view thereof; FIG. 7B is a section in the plane C—C thereof; and FIG. 7C is a section in the plane D—D thereof; FIG. 8 is an isometric view the electrode assembly of FIG. 7 holding a product to be welded with a top membrane removed for clarity; FIG. 8A is a top plan view thereof; FIG. 8B is a section in the plane E—E thereof; and FIG. 8C is a section in the plane F—F thereof; FIG. 9 is an isometric view the electrode assembly of FIG. 8 with the top membrane of the product in place to be welded; FIG. 9A is a top plan view thereof; FIG. 9B is a section in the plane G—G thereof; and FIG. 9C is a section in the plane H—H thereof; FIG. 10 is an isometric view the electrode assembly of FIG. 9 showing electrodes, but not a buffer portion, of a top electrode assembly; FIG. 10A is a top plan view thereof; FIG. 10B is a section in the plane I—I thereof; and FIG. 10C is a section in the plane J—J thereof; FIG. 11 is an isometric view the electrode assembly of FIG. 10 showing the buffer portion of the top electrode assembly; FIG. 11A is a top plan view thereof; FIG. 11B is a section in the plane K—K thereof; and FIG. 11C is a section in the plane L—L thereof; FIG. 12 is an isometric view of the top electrode assembly portion shown in FIG. 11 ; FIG. 12A is a top plan view thereof; FIG. 12B is a section in the plane M—M thereof; and FIG. 12C is a section in the plane N—N thereof; and, FIG. 13 is an isometric view of the top electrode assembly portion shown in FIG. 11 supporting a top membrane of a product; FIG. 13A is a top plan view thereof; FIG. 13B is a section in the plane O—O thereof; and FIG. 13C is a section in the plane P—P thereof. DESCRIPTION Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense. Consider the case where one wishes to create a pattern of welds joining a pair of membranes. The membranes are made of a plastic material which is suitable for dielectric welding. However, one or both of the membranes has attached to it, or embedded in it, one or more electrically conductive elements (ECM). The ECM may, for example, be metal parts. The ECM may be exposed. If the one or more ECM is near to a location in which it is desired to weld the membranes together then the presence of the one or more ECM may interfere with dielectric welding of the membranes together using conventional methods. Welding methods and apparatus can interpose an electrically insulating barrier between ECM in a product being fabricated and the electrodes of a dielectric welder. Provision of an electrically insulating barrier supports welding non-conductive membranes in close proximity to ECMs. Electrode structures for dielectric welding may have integrated insulating barriers located so that the insulating barriers will be interposed between electrodes of the electrode structures and the ECMs when the electrodes are in position to make a weld. In some embodiments, the electrode structures include one or more electrodes arranged in a pattern corresponding to a desired weld pattern. The electrodes may be made of any suitable electrically conducting materials. Aluminum, brass, and copper are examples of materials from which electrodes may be fabricated. The electrodes may be fabricated using any suitable process. For example, the electrodes may be machined, assembled from component parts, cast, etc. Buffers are located between the electrodes. The buffers are made of electrically insulating materials. The buffers are hollowed out to receive projecting portions of one or more ECMs. In some embodiments the buffers fill the spaces between the electrodes. The buffers may be made from any of a wide variety of suitable materials. Examples of materials suitable for use as buffers include: electrically non-conductive ceramic materials, polytetrafluoroethylene, polyurethane, polypropylene, polyethylene, silicone, and combinations of these materials. The buffers may be made using any suitable manufacturing processes. For example, the buffers may be machined or otherwise formed from solid materials or cast. A castable polyurethane or silicone may be used to cast all or part of the buffers. The buffers may be partially cast and partially made from solid materials. In preferred embodiments, the buffers have dielectric strengths at least 2 times greater than a dielectric strength of air in a range of frequencies of a high frequency welding current to be used. FIG. 1 shows schematically a dielectric welding apparatus 10 according to one embodiment of the invention. Apparatus 10 includes first and second electrode assemblies 12 A and 12 B. Electrode assemblies 12 A and 12 B are disposed on either side of a product 14 comprising plastic materials, typically membranes 16 , to be welded together and one or more ECMs 18 . First and second electrode assemblies 12 A and 12 B each have a face 13 facing toward the other electrode assembly. Apparatus 10 comprises a frame 11 . First electrode assembly 12 A is supported by frame 11 and is movable toward and away from second electrode assembly 12 B to permit product 14 to be compressed between electrode assemblies 12 A and 12 B. In some embodiments, electrode assemblies 12 A and 12 B can be pressed together with a desired force by a mechanical linkage mechanism, a pneumatic or hydraulic mechanism, an electrically controlled actuator or some other suitable pressing means. Electrode assemblies 12 A and 12 B may be supported by any suitable mechanisms which maintain registration between electrode assemblies 12 A and 12 B. In the illustrated embodiment, frame 11 may be the frame of a conventional dielectric welding machine, for example. First electrode assembly 12 A is mounted to a first platen 19 A. Second electrode assembly 12 B is mounted to a second platen 19 B. Either or both of the platens are movable to achieve placement of products to be welded and removal of welded products. Apparatus 10 supports the compression, welding, and cool down phases of dielectric welding. As the basic operation and constructions of dielectric welding machines are understood by those skilled in the art, features known from conventional dielectric welding apparatus are not described in detail herein. First and second electrode assemblies are each connected to a dielectric welding power supply 20 . In the illustrated embodiment, the first and second electrode assemblies are in electrical contact with power supply 20 by way of electrical contact between their bases (or non-welding sides) and the corresponding platens 19 A, 19 B. Except as indicated herein, apparatus 10 may be constructed and operated in substantially the same manner as an existing dielectric welding machine. In operation: product 14 is compressed between first and second electrode assemblies 12 A and 12 B; power supply 20 is operated to supply high frequency dielectric welding current to first and second electrode assemblies 12 A and 12 B; and, after sheets 16 have had an opportunity to fuse together at the weld locations, the high frequency current is discontinued and, optionally after a cooling interval, first and second electrode assemblies are separated to allow the welded product 14 to be removed. FIG. 2 is an isometric view showing first and second electrode assemblies 12 A and 12 B according to an example embodiment of the invention. Each electrode assembly 12 A and 12 B has one or more electrodes 30 . Electrodes 30 of first electrode assembly 12 A are arranged as a mirror image of electrodes 30 of second electrode assembly 12 B. When first and second electrode assemblies 12 A and 12 B are brought together face-to-face the electrodes 30 of electrode assemblies 12 A and 12 B follow one another. Electrodes 30 of first and second electrode assemblies 12 A and 12 B are directly opposed to one another on either side of product 14 . The pattern of electrodes 30 defines the pattern of locations at which membranes 16 will be welded together. In the illustrated embodiment, electrodes 30 include a peripheral electrode 30 A which welds a peripheral seam on product 14 , internal electrodes 30 B which define a pattern of welds in the interiors of products 14 , and electrodes 30 C which make spot welds on product 14 . In the illustrated embodiment, electrodes 30 A and 30 B are linear electrodes and electrodes 30 C are isolated spots. All of the electrodes are electrically connected to an electrically conducting base 33 . When first and second electrode assemblies 12 A or 12 B are mounted to corresponding platens 19 A and 19 B, bases 33 are in electrical contact with the platens and thereby establish electrical contact between the welding power source 20 , which is connected to the platens, and electrodes 30 . The spaces between electrodes 30 are filled with buffer areas 32 . In the illustrated embodiment, buffer areas 32 are composed of a cast material 32 cast between electrodes 30 . Buffer areas 32 have recesses 34 to receive the projecting parts of ECMs 18 . Recesses 34 may be shaped to substantially conform with the shapes of the projecting parts of ECMs 18 . Different ones of recesses 34 may have different shapes and configurations. As shown best in FIG. 4A , buffers 32 fill the space between electrodes 30 . Buffers 32 are flush with the tops of electrodes 30 . Buffers 32 provide barriers 33 of electrically insulating material between recesses 34 and electrodes 30 . When first and second electrode assemblies are brought together on either side of product 14 , the embedded and projecting ECMs 18 are seated in features 34 . This insulates ECMs 18 from electrodes 30 . Features 34 can also support, locate, and align ECMs 18 in relation to one another and the membranes 16 to be welded. Buffer areas 32 may optionally contain features to pre-form, locate and pre-align membranes 16 to be welded. Such features may include electrical-mechanical devices and or intermittent differential air pressures or vacuums. Buffer areas 32 may contain features to assist the ejection and removal of welded membranes with embedded ECM from the major components of the device. Such features could be implemented, for example, by providing electrical-mechanical devices and or intermittent differential air pressures or vacuums. FIGS. 6 through 13C are more detailed views of portions of example first and second electrode assemblies which cooperate to make a weld. FIG. 6 shows a section of buffer material 32 which extends between a pair of electrodes 30 in an electrode assembly 12 B as shown in FIG. 7 . FIG. 7 shows only a part of electrode assembly 12 B. Electrode assembly 12 B cooperates with another electrode assembly 12 A as shown in FIG. 11 . When electrode assemblies 12 A and 12 B are brought together on either side of a product 14 , electrodes 30 of electrode assembly 12 A overlie and are aligned with electrodes 30 of electrode assembly 12 B. As shown in FIGS. 8 through 11C , an ECM 18 is received in recess 34 of electrode assembly 12 B. ECM 18 is attached to a first membrane 16 B of a weldable plastic material. Recess 34 is shaped to generally correspond to the shape of the end of ECM 18 which projects from membrane 16 B on the side toward electrode assembly 12 B. As shown in FIGS. 9 through 11C , a second membrane 16 A of product 14 is curved away from membrane 16 B to provide a tubular passage 37 in product 14 . The buffer 32 of first electrode assembly 12 A is cut away to form a groove 38 which accommodates and shapes second membrane 16 A. Vacuum ports (not shown) may be provided in buffer 32 of second electrode assembly 12 A to pull second membrane 16 A into and against the contours of groove 38 prior to welding. After welding, the end of ECM 18 which is closest to first electrode assembly 12 A is located within passage 37 . Applying a high frequency alternating welding current between electrodes 30 of first electrode assembly 12 A and second electrode assembly 12 B causes membranes 16 B and 16 A to become fused together at locations 17 ( FIG. 11B ). Where a component (e.g. a member, part, assembly, device, circuit, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention. As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example: Buffers 32 are not necessarily present in areas away from ECMs. Buffers 32 are present in only one of first and second electrode assemblies in some embodiments of the invention. The widths of electrodes 30 may be varied. Electrodes 30 may be arranged to form any suitable pattern. A welding power supply may be connected directly to electrodes 30 or bases 33 instead of indirectly by way of platens 19 A and 19 B, as illustrated. While a number of example aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true scope.
Dielectric welding apparatus has opposed electrodes that can be engaged on either side of a product to be welded and a dielectric welding power supply that supplies welding potentials to the electrodes. The apparatus includes electrically insulating buffer material adjacent to at least one of the electrodes. A recess formed in a surface of the buffer material receives an end of an electrically-conductive member in the product. The buffer material prevents arcing between the electrodes and the electrically-conductive member.
1
FIELD OF THE INVENTION My invention relates to the generation of heat energy. More specifically, my invention relates to a process of producing and capturing heat energy at very high temperatures using a chemical reaction of inexpensive and readily available reagents in the presence of steam. BACKGROUND OF THE INVENTION “Heat” is a well known form of energy that is used every day to provide power throughout the world. Heat energy is obtained in many ways. Two of those include the “heat of solution” and “the heat of reaction,” both of which are well known phenomenon that generate heat energy. The “heat of solution” is defined as the amount of energy (heat) given off (or absorbed) in the formation of a solution when a solute is dissolved in a solvent. Similarly, the “heat of reaction” is the amount of heat given off (or absorbed) during the formation of a given molecule during a chemical reaction. When heat is “given off” we say the heat of reaction and/or heat of solution is exothermic. This exothermic heat release is the basis of my invention. Using the heats of solution and reaction that occur when simple acids and bases are diluted in a solvent (such as steam) and then combined I have created a process that generates large and inexpensive quantities of recoverable energy. This energy can then be used as a substitute for conventional fossil fuel and/or nuclear based power generating facilities. In fact, my process will produce heat at $0.04 per barrel compared to an equivalent heat production based crude oil selling at $35–$50 per barrel. Although the reaction of acids and bases is well known and has been employed for many years in the production of fertilizers, such as ammonium salts (see U.S. Pat. Nos. 1,988,701; 4,370,304; and 6,117,406), I have found no references where controlling the heats of solution and/or reaction is employed as a means of generating recoverable heat energy. SUMMARY OF THE INVENTION My invention is directed to a process for producing recoverable heat energy from mixing at least one acid with steam in a reactor to generate a heat of solution and then adding at least one base to the acid stream mixture to generate a heat of reaction. The total heat produced is a combination of the heats of solution and reaction. In addition, a byproduct is formed in my process by the reaction of the acid and base. This byproduct can be used as a fertilizer. The steam is introduced into the reactor at 100° C. or higher alone, before introducing the acid. My process also works if the base is added to the steam first followed by acid addition. My invention also relates to a combination of the above described process with the generation of steam and power in what is currently referred to as a “steam cycle.” A steam cycle is a process that uses steam in a turbine to generate a work output. This combination of heat capture and a steam cycle can produce electrical power and thus eliminate the need for coal and natural gas fired boilers and nuclear reactors, which are typically the processes currently used to generate steam. The key to my invention lies in controlling the input temperature during the mixing of the acid or base with steam and during the chemical reaction. Because acid and bases can be characterized as proton donors and proton acceptors, the very rapid movement of these protons becomes the source of the heat generated. In other words, as the input temperature increases the point velocities of the protons increase, which increases the frequency of point collisions, thus resulting in point temperatures that far exceed the overall reaction temperature of the mixture. In typical acid-base reactions it is highly desirable to maintain the overall temperature at room temperature or some slight elevated temperature to avoid a runaway reaction, which leads to a runaway temperature that causes equipment melting or worse, an explosion. As the input temperature of reactants is increased to a critical point, additional energy from the reaction is released at an exponential rate. The relationship is shown in FIG. 2 as a graph of heat energy released versus inlet temperature of steam. My invention uses this exponential relationship, in a controlled manner, to provide heat necessary to vaporize water to generate steam, which can then be used to provide useful work such as to drive a turbine to produce electricity. Cooling water is used indirectly, such as in a heat exchanger device, to control the reaction temperature, to remove the energy produced by my process and to provide the water that is converted into steam that eventually drives a turbine or other mechanical device. Controlling the input temperature in my process involves introducing into a reactor a quantity of steam at 100° C. or higher before the acid or base is introduced into the reactor. Any acid that is a proton donor will work in my process, however, preferred acids include sulfuric, nitric, and phosphoric acids. Likewise, any base can be used, however, preferred bases included ammonia, water or other polar bases. The use of steam not only is instrumental in controlling the temperature of the process, but also provides the ignition temperature that starts and modulates the reaction. In a preferred embodiment the steam is added at a temperature of less than or equal to 1200° C. more preferably less than or equal to 350° C. The acid can be added to the process at ambient temperature and when mixed with the steam will produce a solution having a first measurable temperature higher than the steam input temperature due to the exothermic release of energy caused by the heat of solution. The base is then added to the resultant mixture of the acid and steam. The reaction process occurs over a wide pressure range, but is highly desirable at atmospheric pressure to avoid a rupture of the softened reactor shell that occurs as the higher temperatures reduce the tensile strength. Steam fills the reactor tube and acid is injected into the steam. A base is injected into the acid-steam-mixture to reduce the corrosive action. The base is added to the reactor at or below ambient temperature, preferably at −29° C. or higher. The base is added in proximity of the acid-steam mixture. The reactor is fairly compact, but size-dependent on the attached surface area that forms the heat-exchange surface. The acid is injected into the steam vapor cloud allowing a rapid atomization of the acid and consequent reaction, the mechanism of which is undetermined. The heat producing reaction is dependent upon the input temperatures of the steam, acid and base. As the input temperatures are increased independently, heat released increases exponentially to a point where the quantity of the input streams is required to be greatly reduced. The maximum heat released is limited by the size of the heat exchanger surface. Consequently, a constant release of heat is created by reducing the quantity of input streams inversely to the temperature of the input streams. This is an exponential increase in the amount of heat released, by definition. When the base mixes with the steam/acid mixture, a chemical reaction begins and proton transfer occurs causing a dramatic rise in a second measurable temperature due to the exothermic energy release caused by the heat of reaction. Although the temperature rise of this second measurable temperature is exponential, it can be controlled to optimize the total heat production from the reactor. Temperature control can be accomplished by controlling the steam input temperature, the acid input temperature, and the base input temperature, and by decreasing the quantity of the three input streams as the input temperature of the three streams increases. The stoichiometric ratio is maintained for convenience in obtaining a useful byproduct. As mentioned, the total heat production (the sum of the heats of solution and reaction) is recovered using a heat exchange medium, such as cooling water, that exchanges heat with the steam/acid/base reaction mixture. Any type of heat exchange configuration can be used to recover the total heat production. Preferably a fire-tube boiler or finned tube exchanger arrangement is used to remove the heat generated in the reactor. The use of cooling water is preferred because the transferred total heat production will cause the water to vaporize forming steam that can then be used in other mechanical equipment to generate energy, such as in a turbine to produce electricity. A properly designed air cooled heat exchanger may be utilized as a source of heat recovery, allowing direct replacement of gas fired power burners in conventional boilers. The heated air from the heat exchanger at 1200 F. to 1800 F. would be a suitable replacement for natural gas combustion found in many conventional hot water and steam boilers used in industry and real estate as the primary source of heat. Extremely low cost steam production would be beneficially applied in desalinization plants. A side benefit of my process is that a useful byproduct is formed by the reaction of the acid and base. For example, if sulfuric acid and ammonia are used, then ammonium sulfate is produced, which is a commercially acceptable fertilizer. Further processing of the reaction mixture of my invention may be necessary to recover a marketable fertilizer product, however, those skilled in the art are well aware of such further refining processes. Although I have described my process where the acid is added to the steam before the base, the process can also be operated where the base is added to the steam first, followed by the addition of acid, recognizing that water is a weak polar base and ammonia is a strong polar base. This may offer an advantage because starting with the stronger base may minimize the corrosive effect that the acid would have if it was introduced first. No significant changes in the process are needed by reversing the order of addition of the acid and base. The invention may take form in various parts and arrangement of parts. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a schematic representation of one possible process flow scheme my invention. FIG. 2 is a graphical presentation of the increased energy output generated by my invention. DETAILED DESCRIPTION Referring now to the drawings, and specifically to FIG. 1 , one embodiment of my invention is shown schematically. In describing this flow scheme and that shown in FIG. 1 it will be assumed that the acid is added first followed by the base, but as described above the order of addition is not critical to my invention. Using a variable speed pump 2 P and an inline heater 2 H, steam is fed to reactor 1 at a temperature of 100° C. or above via line 2 . Using a variable speed pump 4 P, at least one acid is added to reactor 1 via line 4 where it combines and mixes with the steam in mixing zone 6 . The input temperature of the acid is controlled by the inline heater 4 H. Mixing can be accomplished by any means known to the art, with a static mixer being preferred. Thermocouple 30 is positioned at the outlet of mixing zone 6 to measure the solution temperature as a result of the release of energy due to the heat of solution. Using a variable speed pump 5 H, at least one base is added via line 5 and mixed with the acid/steam mixture exiting mixing zone 6 . The input temperature of the base is controlled by the inline heater 5 H. Mixing of the base with the acid/steam mixture occurs in mixing zone 7 . Again, any mixing technology can be used that is known to those skilled in the art. Upon introduction of the base to the acid/steam mixture, energy is rapidly released as a result of the heat of reaction that results from the chemical reaction of the acid and base. This energy release results in a rapid rise in solution temperature in reaction zone 8 and is measured by thermocouple 31 . Removal of the total heat production, which is a combination of the heats of solution and reaction, is accomplished by a heat exchanger 16 with a cooling medium flowing in line 13 . Preferably the cooling medium is water. The amount of energy generated in reactor 1 is sufficient to vaporize the water in line 13 to produce steam that is removed in line 14 . The steam in line 14 can be used in a variety of other downstream processes and/or equipment to perform useful work or to produce other forms of energy such as electricity. Once the energy is removed by the cooling medium in line 13 the cooled reaction mixture is removed from the reactor via line 9 as liquid and vapor to further reclaim the heat energy in de-superheaters, condensers or waste-heat boilers (not shown), as one who knows the art will understand. Line 9 will contain a commercially useful byproduct and water. Optionally, further processing of the reaction solution can be performed to recover the byproduct. One option is to use a settling device 10 to collect a byproduct concentrate stream which is removed via line 11 . The remaining liquid reaction solution is re-circulated via line 12 and can be used to generate additional preheat feed steam by heat exchanging in exchanger 15 with all or a portion of the steam removed from reactor 1 via line 14 . Without need for a schematic, a conventional closed loop steam system would be used as an embodiment of my invention where the steam in line 14 is used to drive a turbine to produce work output. Spent steam is removed from the turbine and used to heat exchange recycled reaction solution in line 12 and to generate more steam at the steam heater 2 H in line 2 . Referring to FIG. 1 , the heat exchanger 16 may use a cooling medium 13 such as air to produce heated air 14 at similar temperatures to products of combustion from natural gas. The heated air 14 would be a direct replacement for the gas-fired products of combustion that are used to produce hot water and steam in large conventional boilers, as one who knows the art will understand. Using my claims for heating process and work cycle in this application, the reactor 1 and heat exchanger 16 would be sized to fit in many existing gas-fired or coal-fired boilers which provide heating for commercial, institutional buildings and larger central heating plants for building campuses, as one who knows the art will understand. The extremely low cost of operation using acids and bases for heating in place of natural gas or coal, would represent a 95% to 99% reduction in fuel costs. Referring to FIG. 1 , the heat exchanger 16 may use a cooling medium 13 such as liquid sodium to produce a heated heat-transfer fluid 14 at similar temperatures to fluid heat-transfer products used in nuclear power generating plants. Using my claims for heating process and work cycle in this application, the reactor 1 and heat exchanger 16 would be sized to fit in many existing large nuclear boilers which produce large amounts of high pressure steam to produce work in driving large turbines to produce electrical energy, as one who knows the art will understand. The extremely low cost of operation using acids and bases for heating in place of nuclear power, would represent a 99% reduction in fuel costs. EXAMPLE FIG. 2 is a graphical presentation of the increased energy output generated by an experimental procedure with a crude apparatus. The method for generating the increased release of heat energy is the same as described in my claims. The apparatus consisted of a modular fire-tube pipe reactor with a split external jacket surrounding the fire-tube-reactor for preheating the ammonia, acid and water. The acid was introduced at one end and mixed with water to produce the initial heat release to warm the external jacket around the reactor. As the flow of water and acid was controlled for heat release to the jacket, the water, acid and ammonia were heated and measured at the input point to the fire tube. A direct flow of cooling water was introduced to the fire tube at a point downstream of the reactor core. The process is similar to steam-sparging for heating water. It should be understood that the embodiments and examples disclosed herein are presented for illustrative purposes only and that many other combinations and articles that embody the methods, formulations and systems will be suggested to persons skilled in the art and, therefore, the invention is to be given its broadest interpretation within the terms of the following claims:
Energy in the form of heat is recoverable and controllable in a process that reacts an acid and a base in the presence of steam. The recovered heat energy can be used to vaporize water to form steam which when used in conjunction with a turbine will produce electricity.
5
This is a division of application Ser. No. 330,359 filed Feb. 7, 1973 now U.S. Pat. No. 3,888,840. BACKGROUND OF THE INVENTION 1. field of Invention This invention relates to novel α-hydrazinocarboxamide and α-(α '-acylhydrazino)carboxamide derivatives, to processes for their preparation and to their use as intermediates for the preparation of related derivatives. 2. Description of the Prior Art Only within the last ten years has some attention been focused on α-hydrazinocarboxamides. This attention resulted from a chemical investigation by I. Ugi and F. Bodesheim, Justus Liebigs Ann. Chem., 666, 61 (1963). In this particular investigation α-(α ', β'-diacylhydrazino)carboxamides were prepared by the α-addition of acylhydrazones and carboxylic acids to isonitriles. The carboxamides of this latter study are readily distinguished from the compounds of the present invention by their lack of a basic nitrogen. Indeed, the successful preparation of the present α-(hydrazino)- and α-(α'-acylhydrazino)caboxamides from hydrazones, acids and isonitriles is somewhat unexpected and surprising in light of a recent comment by Ugi. More explicitly, in "Newer Methods of Preparative Organic Chemistry", Vol. IV, N. Foerst, Ed., Academic Press, New York and London, 1968, p. 28, Ugi states that the lower basicity of the α-nitrogen in a hydrazone system has an adverse influence on α-additions involving hydrazones and it may be assumed that such reactions can rarely be used for preparative purposes. SUMMARY OF THE INVENTION The α-hydrazinocarboxamide derivatives of the present invention may be represented by Formula I, ##STR4## in which R 1 and R 2 each are lower alkyl or R 1 and R 2 together with the nitrogen atom to which they are joined form a piperidino or morpholino radical; R 3 is hydrogen, lower alkanoyl, benzoyl, p-nitrobenzoyl, p-aminobenzoyl, p-chlorobenzoyl, isocyanoacetyl, or protected amino acyl radicals, for example, N-formylglycyl or ##STR5## (N-carbobenzoxyglycylglycyl); R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is hydrogen or phenyl and R 8 is hydrogen or lower alkyl; R 5 is hydrogen or lower alkyl; or R 4 and R 5 together with the carbon atom to which they are joined form a cyclohexylidene radical; and R 6 is a cyclohexyl or CHR 9 COY wherein R 9 is hydrogen or benzyl and Y is hydroxyl, lower alkoxy or amino, with the provisos that when Y is hydroxyl then R 8 is hydrogen, that when Y is lower alkoxy then R 8 is lower alkyl and that when Y is amino R 4 is lower alkyl. In one aspect of this invention the preparation of the compounds of formula I involve a key reaction wherein a hydrazone of formula II in which R 1 , R 2 and R 5 are as defined hereinbefore and R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is as defined hereinbefore and R 8 is lower alkyl or R 4 or R 5 together with the carbon atom to which they are joined form a cyclohexylidine radical, is treated with an acid of formula R 3 X in which R 3 is as defined hereinbefore and when R 3 is hydrogen, R 3 and X together represent an inorganic acid ionizable to provide a proton, and when R 3 is other than hydrogen as defined hereinbefore X represents a hydroxyl, in the presence of an isonitrile of formula R 6 NC in which R 6 is cyclohexyl or CHR 9 COY wherein R 9 is as defined hereinbefore and Y is lower alkoxy to obtain the corresponding compound of formula I ##STR6## In another aspect of this invention compounds of formula I in which R 1 , R 2 , R 3 and R 5 are as defined in the first instance, R 4 is CHR 7 COOR 8 in which R 7 is as defined hereinbefore and R 8 is lower alkyl and R 6 is CH 2 COY in which Y is lower alkoxy are transformed to 2,5-dioxopyrrolidines of formula III either spontaneously during the formation of said latter compounds of formula I or by subjecting said latter compounds of formula I to alkaline conditions. DETAILED DESCRIPTION OF THE INVENTION The term "lower alkyl" as used herein contemplates straight chain alkyl radicals containing from one to six carbon atoms and branched chain alkyl radicals containing three to four carbon atoms and includes methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl and the like. The term "lower alkanoyl" as used herein contemplates both straight and branched chain alkanoyl radicals containing from one to six carbon atoms and includes formyl, acetyl, propionyl, hexanoyl and the like. The term "lower alkoxy" as used herein contemplates both straight and branched chain alkoxy radicals containing from one to six carbon atoms and includes methoxy, ethoxy, propoxy, hexyloxy and the like. It will be noted that the structure of the compounds of this invention includes asymmetric carbon atoms. It is to be understood accordingly that the isomers arising from this asymmetry are included within the scope of this invention. Such isomers are obtained by classical separation techniques and by sterically-controlled synthesis. The compounds of formula I of this invention exhibit utility as antibacterial agents against a number of microorganisms, for example, Pseudomonas aeruginosa, Proteus mirabilis, Proteus vulgaris, Klebsiella pneumoniae and Serratia marcescens, in standard tests for antibacterial activity, such as those described in "Antiseptics, Disinfectants, Fungicides and Sterilization", G. F. Reddish, Ed., 2nd ed., Lea and Febiger, Philadelphia, 1957 or by D. C. Grove and W. A. Randall in "Assay Methods of Antibiotics", Med. Encyl. Inc., New York 1955. For example, a test like the serial broth dilution, see Grove and Randall, cited above, in which dilutions of the compounds of this invention in nutrient broth are inoculated with the mircroorganisms or fungi, described above, incubated at 37° C. for 2 days, respectively, and examined for the presence of growth, shows that 3-[N-(dimethylamino)formamido]-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester (Example 27) is able to inhibit growth totally in this system of Proteus vulgaris, Klebsiella pneumoniae and Serratia marcescens at a concentration of 100 mcg/ml. or less. When the compounds of formula 1 are employed as antibiotic or antifungal agents in warm-blooded animals, e.g. rats, they may be administered alone or in combination with pharmacologically acceptable carriers. The proportion of the compound is determined by the solubility and chemical nature of the compound, chosen route of administration and standard biological practice. For example, they may be administered orally in solid form containing such excipients as starch, milk sugar, certain types of clay and so forth. They may also be administered orally in the form of solutions or they may be injected parenterally. For parenteral administration they may be used in the form of a sterile solution containing other solutes, for example, enough saline or glucose to make the solution isotonic. The dosage of the present compounds as antibiotic agents will vary with the form of administration and the particular compound chosen. Furthermore, it will vary with the particular compounds chosen. Furthermore, it will vary with the particular host under treatment. Generally, treatment is initiated with small dosages substantially less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. In general, the compounds of this invention are most desirably administered at a concentration level that will generally afford antibacterially or antifungally effective results without causing any harmful or deleterious side effects and preferably at a level that is in a range of from about 1.0 mg to about 1000 mg. per kilo per day, although as aforementioned variations will occur. However, a dosage level that is in the range of from about 10 mg to about 500 mg per kilo per day is most desirably employed in order to achieve effective results. In addition, the said ultimate products may be employed topically. For topical application they may be formulated in the form of solutions, creams, or lotions in pharmaceutically acceptable vehicles containing 0.1-5 per cent, preferably 2 per cent, of the agent and may be administered topically to the infected area of the skin. Also the antibacterial properties of the said ultimate products may be utilized for washing equipment in hospitals, homes and farms, instruments used in medicine and bacteriology, clothing used in bacteriological laboratories, and floors, walls and ceilings in rooms in which a background free of gram-positive and gram-negative microorganisms, such as those listed above, is desired. When employed in this manner the said ultimate products are formulated in a number of compositions comprising the active compound and an inert material. In such compositions, while the said ultimate products may be employed in concentrations as low as 500 p.p.m., from a practical point of view, it is desirable to use from about 0.1% to about 5% by weight or more. The formulations that may be used to prepare antiseptic wash solutions of the compounds of this invention are varied and may readily be accomplished by standard techniques, see for example, "Remington's Practice of Pharmacy", E. W. Martin et al., Eds., 12th ed., Mack Publishing Company, Easton, Penn., 1961, pp. 1121-1150. In general, the said ultimate products are made up in stock solutions. They can also be formulated as suspensions in an aqueous vehicle. These make useful mixtures for decontaminating premises. Also, aqueous vehicles containing emulsifying agents, such as sodium lauryl sulfate, and relatively high concentrations, e.g., up to about 5% by weight, of the compounds may be formulated by conventional techniques. A typical antiseptic preparation useful for disinfecting floors, walls, ceiling, and articles in a contaminated room may be prepared by adding 5 to 25 g. of 3-[N-(dimethylamino)formamido]-3-methyl-2,5-dioxo-1-pyrrolidine-acetic acid ethyl ester to a mixture of 150 to 300 g of polyethylene glycol 1540 and 150 to 300 g of polyethylene glycol 300. The resulting mixture is stirred while a solution of 1 to 10 g of sodium lauryl sulfate in 300 to 400 ml of water is added portionwise. The article to be disinfected is coated or immersed in the preparation for a prolonged time, for example, one hour, and then rinsed with sterile water. In addition, the compounds of formula I exhibit trichomonacidal activity against certain Trichomonas species, for example, Trichomonas vaginalis. A demonstration of this activity is readily achieved in standard tests for trichomonacidal activity; for example, see R. J. Schnitzer in "Experimental Chemotherapy", Vol. 1, R. J. Schnitzer and F. Hawking, Ed., Academic Press, New York, 1963, p. 289. When the compounds of formula I are employed as trichomonacidal agents they may be administered in the same manner described above for their application as antibacterial agents. Likewise, the 2,5-dioxopyrrolidines of formula III exhibit a similar degree of the antibacterial and trichomonacidal activities, described above. Accordingly, they may be used for this purpose in the same manner as described for the compounds of formula I. In practising the process of this invention three classes of starting material are required; namely, hydrazones of formula II, acids of formula R 3 X and isonitriles of formula R 6 NC. The requisite hydrazones of formula 11 are prepared by condensing an appropriately substituted hydrazine of formula R 1 R 2 NNH 2 in which R 1 and R 2 are as defined in the first instance, with a carbonyl compound of formula R 4 R 5 CO in which R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is hydrogen or phenyl and R 8 is lower alkyl and R 5 or R 4 and R 5 together are as defined hereinbefore. Hydrazines of formula R 1 R 2 NNH 2 are either known for example, 1,1-dimethyl hydrazine, N-aminopiperidine, N-aminomorpholine, or they are prepared by known methods; for example, see E. Muller in "Methoden der Organischen Chemie", Houben-Weyl, E. Muller, Ed., Vol. 10/2, Georg Thieme Verlag, Stuttgard, 1967, p. 50. Likewise, the carbonyl compounds of formula R 4 R 5 CO are known and most are commercially available, for example, ethyl acetoacetate, isobutyraldehyde and cyclohexanone, or are prepared by known methods; for example, see P. Karrer, "Organic Chemistry", 2nd ed., Elsevier Publishing Co., Inc., New York, 1946, p. 149. The condensation of the hydrazine of formula R 1 R 2 NNH 2 and the carbonyl compound of formula R 4 R 5 CO is preferably carried out in an inert solvent at an elevated temperature, at or near the reflux temperature of the mixture. Either an anhydrous, water-immiscible hydrocarbon solvent, for example, benzene or toluene, with concomitant physical removal of water as it is being formed, e.g. by means of a Dean-Stark water separator, or a lower alkanol solvent, for example, ethanol, propanol or isopropanol may be employed. Thereafter, evaporation of the solvent and purification of the residue, for example, by distillation or crystallization, yields the corresponding hydrazone of formula II. The acids of formula R 3 X are known and are commercially available and include the inorganic acids, hydrochloric, sulfuric, phosphoric, hydrobromic acid and the like, or the organic acids, formic, acetic, benzoic, p-nitrobenzoic and the like. The requisite isonitriles of formula R 6 NC also are known, for example, cyclohexyl isonitrile [(I. Ugi and R. Meyr, Ber., 93, 239 (1960)] and ethyl isocyanoacetate [R. Appel et al., Angew. Chem., Int. ed., 10, 132 (1971)], or are easily prepared by known methods, for example, see P. Hoffmann, et al., in "Isonitrile Chemistry", Organic Chemistry, Vol. 20, I. Ugi, Ed., Academic Press, New York, 1971, p. 9. Next, in a key reaction of the process of this invention, the aforementioned hydrazone of formula 11 is condensed with the acid of formula R 3 X, and the isonitrile of formula R 6 NC, described above, to yield the corresponding compounds of formula I. Although not critical it is preferable to use approximately equimolar amounts of the three requisite starting materials, for this condensation. The condensation is effected most conveniently in an inert solvent, for example, halogenated hydrocarbons including methylene dichloride, chloroform, and carbon tetrachloride, ethers and cyclic ethers including dioxane, diethyl ether and tetrahydrofuran, or lower aliphatic alcohols including methanol, ethanol and propanol. However, when the three starting materials are mutually soluble or the mixture thereof becomes liquid during the course of the condensation the solvent may be omitted without any deleterious effects. The temperature and duration of the condensation also are not critical. The reaction may be performed at temperatures ranging from -20° to 100° C.; however, a range from 10° to 40° C is most convenient, with room temperature to the boiling point of the solvent employed being preferred. The reaction time varies widely and depends on the reactivity of the various starting materials; however, reaction times from 15 minutes to several days are employed generally, with six hours to two days being preferred. Thereafter the product is isolated and purified according to standard procedures. For instance the product is extracted with a water-immiscible solvent and, if needed, purified by chromatography and crystallization. In this manner there are obtained the compounds of formula I in which R 1 , R 2 , R 3 and R 5 are defined in the first instance, R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CHCOOR 8 wherein R 7 is hydrogen or phenyl and R 8 are lower alkyl or R 4 and R 5 together with the carbon atom to which they are joined form a cyclohexylidene radical, and R 6 is cyclohexyl or CHR 9 COY in which R 9 is as defined hereinbefore and Y is lower alkoxy. As noted hereinbefore the compounds of formula I in which R 1 , R 2 , R 3 and R 5 are as defined in the first instance, R 4 is CHR 7 COOR 8 in which R 7 is as defined hereinbefore and R 8 is lower alkyl and R 6 is CHR 9 COY in which R 9 is hydrogen and Y is lower alkoxy are transformed to the corresponding 2,5-dioxopyrrolidines of formula III. This transformation takes place spontaneously to some extent (10-80%) during the course of the condensation of the hydrazone of formula R 1 R 2 NN = C(R 5 )CH 2 COOR 8 in which R 1 , R 2 and R 5 are as defined herein and R 8 is lower alkyl, with a lower alkyl ester of isocyanoacetic acid and an acid of formula R 3 X as defined herein under the conditions described above for such condensations. The mixture of the corresponding products of formulae I and III obtained under these conditions may be separated by crystallization or chromotagraphy on silica gel. If desired, the mixture is readily converted totally to the corresponding compound of formula III by treating the mixture with a base, for example, the alkali metal carbonates including sodium or potassium carbonate or the alkali metal hydroxides including sodium or potassium hydroxide in an inert solvent, for example, chloroform, benzene, tetrahydrofuran or ethanol. Completion of this conversion under alkaline conditions is achieved usually at temperatures ranging from 20° to 100° C, preferably 50° to 60° C., and reaction times of from 10 minutes to 6 hours, preferably one to two hours. The compounds of formula I in which R 4 is CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is as defined hereinbefore and R 8 is hydrogen and R 6 is CHR 9 COY in which R 9 is as defined hereinbefore and Y is hydroxyl, mainly, the corresponding acid derivatives of the aforementioned esters, are obtained by treatment of said corresponding esters with a hydrolyzing agent. Generally speaking, this conversion is most conveniently performed by employing a base as the hydrolyzing agent, although hydrolysis under acidic conditions is also applicable. It should be noted herein that when compounds of formula 1 in which R 4 is CHR 7 COOR 8 in which R 8 is lower alkyl and R 6 is CH 9 COY in which Y is lower alkoxy are subjected to the above hydrolyzing conditions a mixture of the corresponding diacid and 2,5-dioxopyrrolidine of formula III results. For basic hydrolysis a preferred embodiment involves subjecting the lower alkyl ester to the action of a strong base, for example, sodium or potassium hydroxide, in the presence of sufficient water to effect hydrolysis of the ester. The hydrolysis is performed using a suitable solvent, for example, methanol or ethanol. The reaction mixture is maintained at a temperature of from 0° C to the reflux temperature until hydrolysis occurs. Usually from 10 minutes to six hours is sufficient for this hydrolysis. The reaction mixture is then rendered acidic with an acid, for example, acetic acid, hydrochloric acid, sulfuric acid and the like, to obtain the corresponding free acid. The compounds of formula 1 in which R 4 is lower alkyl and R 6 is CHR 9 COY in which R 9 is as defined hereinbefore and Y is amino are obtained by treatment of the corresponding lower alkyl esters, described above, with ammonia according to standard amidation methods. Preferred conditions for this amidation include treatment of the appropriate ester of formula 1 with a saturated solution of ammonia in an inert solvent, for example, methanol, ether or tetrahydrofuran at 0° to 20° C for 6 hours to 5 days. The compounds of formula I in which R 3 is p-aminobenzoyl are obtained by treating the corresponding compounds of formula I, described above, in which R 3 is p-nitrobenzoyl with a reducing agent. In this case the use of hydrogen in the presence of a noble metal catalyst, for example, palladium, platinum and the like in a hydrogenation apparatus is a preferred and convenient method. Finally, the compounds of formula I in which R 3 is isocyanoacetyl (COCH 2 NC) are prepared directly from the aforementioned, corresponding compounds of formula I in which R 3 is N-formylglycyl. This transformation is effected readily with dehydrating agents known to be effective for transforming known formamides to corresponding isonitriles, see P. Hoffmann, et al., cited above. A preferred method in this case is the use of phosgene in the presence of triethylamine. The following examples illustate further this invention. EXAMPLE 1 Ethyl Levulinate Dimethyl Hydrazone A mixture of 21.5 g (0.15 mole) of ethyl levulinate and 15.0 g (0.25 mole) of anhydrous dimethylhydrazine in 35 ml of ethanol is heated at reflux for 4 hours. The solvent is removed and the residue fractionally distilled. The title compound is collected, b.p. 98°-100° C/15 mm., nmr (CDCl 3 δ 1.25 (t, J=7,3H), 1.95 (3H), 2.40 (6H), 2.53 (4H), 4.13 (q, J=7,2H). In the same manner but replacing ethyl levulinate with an equivalent amount of ethyl acetoacetate, ethyl acetoacetate dimethyl hydrazone, b.p. 88°-92° C/ 19-20 mm, ν max CHCl .spsb.3 3245, 3180 and 1728 cm -1 , is obtained. Similar replacement of the ethyl levulinate with ethyl α-phenylacetoacetate gives ethyl α-phenylacetoacetate dimethyl hydrazone, b.p. 138°-143° C/5 mm, nmr (CDCl 3 ) δ 1.13 and 1.30 (2t, J = 7, 3H), 1.47 (3H), 1.56(3H), 1.86 (3H). Similar replacement of the ethyl levulinate with cyclohexanone gives cyclohexanone dimethyl hydrazone, b.p. 80°-82° C/25 mm, nmr (CDCl 3 ) δ 1.66 (6H), 2.43 (10H). Similar replacement of the ethyl levulinate with 2-oxocyclohexanecarboxylic acid ethyl ester gives 2-oxocyclohexanecarboxylic acid ethyl ester dimethyl hydrazone, b.p.132° C/11mm. EXAMPLE 2 3-(Piperidinoimono)butyric Acid Methyl Ester A mixture of methyl acetoacetate (13 g. 0.10 mole) and 1-aminopiperidine (15 g, 0.15 mole) in absolute ethanol (30 ml) is heated at reflux for 4 hr. The solvent is removed and the residue fractionally distilled. The title compound has b.p. 125°-126° C/13 mm. In the same manner but replacing 1-aminopiperidine with an equivalent amount of 1-aminomorpholine, 3-(morpholinoimino)butyric acid ethyl ester, b.p. 150°-152° C/20 mm, ν max CHCl .spsb.3 3240, 3180, 1720, 1640, 1600 cm - 1 , is obtained. In the same manner but replacing ethyl acetoacetate with an equivalent amount of cyclohexanone, 1-(cyclohexylideneamino)piperidine, b.p. 124°-217° C/15-18 mm, is obtained. Reported b.p. for this compound is 76° C/0.4 mm, H. Boehlke and W. Kliegel, Arch. Pharm. 229, 245 (1966). EXAMPLE 3 Isobutyraldehyde Dimethyl Hydrazone A solution of isobutyraldehyde (43 g. 0.6 mole) and dimethylhydrazine (60 g, 1.0 mole) in benzene (500 ml) is heated at reflux temperature for 5 hr. using a Dean-Stark apparatus to collect the water. The solution is evaporated and the residue fractionally distilled. The hydrazone is obtained as a yellow oil, b.p. 120° C, ν max Film 1610, 1475, 1450 cm -1 . In the same manner but replacing isobutyraldehyde with an equivalent amount of isovaleraldehyde, isovaleraldehyde dimethyl hydrazone, b.p. 145° -149° C is obtained. Similar replacement of the isobutyraldehyde with an equivalent amount of propionaldehyde or hexaldehyde gives propionaldehyde dimethyl hydrazone and hexaldehyde dimethyl hydrazone, respectively. EXAMPLE 4 2-Isocyano-3-phenylpropionic Acid Methyl Ester A solution of phosgene (5.2 g, 0.052 mole) in dry methylene chloride (45 ml) is added dropwise to a stirred solution of N-formylphenylalanine methyl ester (10.0 g, 0.048 mole) and 1-methylmorpholine (13 g, 0.125 mole) in dry methylene chloride (25 ml) at -30° C. After completion of the addition the filtrate is concentrated under reduced pressure at room temperature. Benzene is added to the residue followed by filtration and concentration of the resulting solution. The residue is distilled to afford the title compound as a yellow oil, b.p. 97° C/0.3 mm, ν max CHCl .spsb.3 2150, 1746, 1595, 1578, 1489, 694 cm -1 . The starting material, N-formylphenylalanine methyl ester, is known; see R.G. Jones, J. Amer. Chem. Soc., 71, 644 (1949) for D L-form and F. Bergel, et al., J. Chem. Soc., 3802 (1962) for L-form. In the same manner but replacing the preceding starting material with an equivalent amount of N-formylmethionine ethyl ester, described in German Pat. No. 1,201,357, issued September 23, 1965 [Chem. Abstr. 63, 18260 (1965)], 2-isocyano-4-methylthiobutyric acid ethyl ester, b.p. 77°-79° C/ 0.1 mm, is obtained. EXAMPLE 5 N-cyclohexyl-3-(dimethylaminoformamido)-3-methylglutaramic Acid Ethyl Ester (1; R 1 and R 2 = CH 3 , R 3 = CHO, R 4 = CH 2 CH 2 COOC 2 H 5 , R 5 = CH 3 and R 6 = cyclohexyl) A solution of the hydrazone of formula II, ethyl levulinate dimethyl hydrazone (9.39 g, 0.05 mole), described in Example 1, and the isonitrile of formula R 6 NC, cyclohexyl isonitrile (5.45 g, 0.05 mole), in 10 ml of dry methylene dichloride is cooled in an ice bath and treated dropwise with the acid of formula R 3 X, formic acid (2.35 g, 0.05 mole). The mixture is stirred for 20 minutes in the cold and then stirred at room temperature until completion of the condensation. [In this case the condensation is complete after 3 hr. as determined by thin layer chromatography (tlc) using silica gel plates and a solvent system consisting of benzene-ethyl acetate (1:1)]. The reaction mixture is diluted with 4N sodium hydroxide and extracted with ethyl acetate. The extract is washed with water until neutral, dried (MgSO 4 ) and evaporated yielding a solid residue. The residue is crystallized from methylene dichloride-hexane to yield the title compound, m.p. 81.5°-83° C., ν max CHCl .spsb.3 3455, 3340, 1727, 1507 cm -1 . EXAMPLE 6 N-{[N-(Dimethylamino)-N-(N-formylglycyl)]-Dl-valyl}glycine Ethyl Ester (1; R 1 B. A. R 2 = CH 3 ; R 3 = COCH 2 NHCHO, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOC 2 H 5 ) The acid of formula R 3 X,N-formylglycine (15.4 g), described by R. S. Tipson and B. A. Pawson, J. Org. Chem., 26, 4698 (1961), is added dropwise to a solution of the hydrazone of formula 11, isobutyraldehyde dimethyl hydrazone (17.1 g), described in Example 3, and the isonitrile of formula R 6 NC, ethyl isocyanoacetate (16.0 g), in 50 ml of anhydrous methanol containing 20 g. of hydrated alkali-aluminum silicate (Molecular Sieves No. 4), cooled to 0° C. The mixture is stirred at room temperature until completion of the condensation. [In this case the condensation is complete after 24 hr. as determined by tlc using silica gel plates and a solvent system consisting of ethyl acetate-methanol (9:1)]. The mixture is filtered and concentrated. The residue is subjected to chromatography on silica gel. Elution with ethyl acetate-methanol (9:1) gives the title compound, nmr (CDCl 3 ) δ 0.91 and 1.02 (2d, J=6.5, 6H), 1.27 (t, J=7, 3 H), 2,53 (3H), 2.56 (3H), 3.03 (m, 1H), 3.44 (d, J = 11, 1H), 3.97 (2H), 4.20 (q, J = 7, 2H), 4.35 (2H), 6.62 (1H). EXAMPLE 7 N-[(N-Dimethylamino)-DL-valyl]glycine Ethyl Ester (1, R 1 and R 2 = CH 3 , R 3 = H,R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOC 2 H 5 ) A solution of the hydrazone of formula 11, isobutyraldehyde dimethylhydrazone (19.6 g, 0.172 mole) described in Example 3, water (17.2 ml), and methanol (28.6 ml) is stirred at ice-bath temperature. After 5 min., 12N HCl (14.5 ml) is added slowly. After an additional 2 min. the isonitrile, ethyl isocyanoacetate (19.4 g, 0.172 mol) is added. The solution is stirred at room temperature for 1.5 hr. The solution is diluted with methylene chloride (500 ml), and washed with 4N NH 4 OH (100 ml), water (50 ml), and a saturated solution of sodium chloride (100 ml). The organic phase is dried (Na 2 SO 4 ) and concentrated. The orange oil is distilled to yield the title compound, b.p. 124° C/0.1 mm, ν max CHCl .spsb.3 3380, 1730, 1660, 1510 cm -1 . By following the procedure of Example 5, 6 or 7 and using the appropriate hydrazone of formula 11, acid of formula R 3 X and isonitrile of formula R 6 NC then other compounds of formula II are obtained. Examples of such compounds of formula I are listed in Table I together with the hydrazone, acid and isonitrile required for their preparation. TABLE 1__________________________________________________________________________Hydrazone Acid of Isonitrile Product ofEx. of Formula 11 Formula R.sup.3 X (R.sup.6 NC) Formula 1__________________________________________________________________________8 ethyl aceto- formic acid cyclohexyl N-cyclohexyl-3-(dimethyl-acetate di- isonitrile aminoformamido)-3-methyl hydra- methylsuccinamic acidzone ethyl ester, m.p. 79.5 - 81° C, ν.sub.max CHCl.sub.3 1728, 1668 cm.sup.-.sup.1.9 ethyl levuli- benzoic acid cyclohexyl N-cyclohexyl-4-[N-(di-nate dimethyl isonitrile methylamino)benzamido]-hydrazone 4-methylglutaramic acid ethyl ester, m.p. 79 - 80.5° C, ν.sub.max CHCl.sub.3 1728, 1665, 1650 cm.sup.-.sup.1.10 ethyl aceto- formic acid 2-isocyano-3- N-(α-carboxyphenethyl)-acetate di- phenylpro- 3-[N-(dimethylamino)-methyl hydra- pionic acid formamido]-3-methyl-zone methyl ester succinamic acid ethyl (described in N-methyl diester, m.p. Example 4) 91 - 109° C, nmr (CDCl.sub.3) δ 1.24 (+, J=7,3H), 2.78 (6H), 2.82 (m,2H), 3.17 (d, J=6.5, 2H)11 isobutyral- formic acid 2-isocyano-3- N-[N-(dimethylamino)-N-dehyde di- phenylpro- formyl-DL-valyl]phenyl-methyl hydra- pionic acid alanine methyl ester,zone methyl ester ν.sub.max CHCl.sub.3 1735, 1640-1660cm.sup.-.sup.112 cyclohexanone formic acid 2-isocyano-3- N-{1-[N-(dimethylamino)-dimethyl hydra- phenylpro- formamido]cyclohexyl-zone pionic acid carbonyl}phenylalanine methyl ester methyl ester, m.p. 80 - 83° C13 cyclohexanone p-nitroben- 2-isocyano-3- N-{1-[N-(dimethylamino)-dimethyl zoic acid phenylpro- p-nitrobenzamido]cyclo-hydrazone pionic acid hexylcarbonyl}phenyl- methyl ester alanine methyl ester, m.p. 116 - 117° C14 isobutyralde- formic acid ethyl isocy- N-[N-(dimethylamino)-N-hyde dimethyl anoacetate formyl -DL-valyl]glycinehydrazone ethyl ester, b.p. 150 - 153° C/0.1 mm, ν.sub.max Film 3300, 1745, 1670 cm.sup.-.sup.1.15 cyclohexanone formic acid ethyl iso- N-{1-[N-(dimethylamino)-dimethyl cyanoacetate formamido]cyclohexyl-hydrazone carbonyl}ethyl - ester, m.p. 87 - 89° C ν.sub.max CHCl.sub.3 1732, 1658 cm.sup.-.sup.1.16 cyclohexanone N-carbobenzoxy- ethyl iso- N-[1-{1-[N-(carboxy-dimethyl glycylglycine cyanoacetate glycyl)glycyl]-2,2-di-hydrazone methylhydrazino}cyclo- hexylcarbonyl]glycine N-benzyl ethyl diester m.p. 138 - 139° C, ν.sub.max CHCl.sub.3 1720, 1655 cm.sup.-.sup.1.17 cyclohexanone benzoic acid ethyl iso- N-{1-[N-(dimethylamino)-dimethyl cyanoacetate benzamido]cyclohexyl-hydrazone carbonyl}glycine ethyl ester, m.p. 90 - 92° C, ν.sub.max CHCl.sub.3 1730, 1660, 1630 cm.sup.-.sup.1.18 cyclohexanone p-nitro- ethyl iso- N-{1-[N-(dimethylamino)-dimethyl benzoic acid cyanoacetate p-nitrobenzamido]cyclo-hydrazone hexylcarbonyl}glycine methyl ester, m.p. 86 - 88° C, ν.sub.max CHCl.sub.3 1730, 1660, 1640 cm.sup.- .sup.1.19 ethyl aceto- p-nitro- ethyl iso- N-(carboxymethyl)-3-acetate di- benzoic acid cyanoacetate [N-(dimethylamino)-p-methyl hydra- nitrobenzamido]-3-zone methylsuccinamic acid diethyl ester, m.p. 90 - 94° C, ν.sub.max CHCl.sub.3 1725, 1665 cm.sup.-.sup.1.20 cyclohexanone formic acid 2-isocyano-3- N-{1-[N-(dimethylamino)-dimethyl phenylpro- formamido]cyclohexyl-hydrazone pionic acid carbonyl}-DL-phenylala- - methyl ester nine methyl ester, m.p. 84-86° C, ν.sub.max CHCl.sub.3 1735, 1660 cm.sup.-.sup.1.21 isobutyralde- ±-butoxy- 2-isocyano-4- N-{N-[N-(carboxyglycyl)-hyde dimethyl carbonyl- methylthio- N-(dimethylamino-DL-valyl]}- hydrazone gly cine butyric acid DL-methionine N-±-butyl ethyl ester ethyl diester, nmr (CDCl.sub.3) (described in δ 0.90 (d, J=7,3H), 1.05 Example 4) (d, J=7,3H), 1.30 (2×t, J=7,3H), 2.10 (2×s,3H), 2.56 (2×s, 6H)22 isobutyral- formic acid 2-isocyano-4- N-[N-(dimethylamino)-N-dehyde dimeth- methylthio- formyl-DL-valyl]-DL-yl hydrazone butyric acid methionine ethyl ester, ethyl ester nmr (CDCl.sub.3) δ 0.95 N-{N-[- J=6.5,3H), 1.03 (d, J=6.5, }glycine 3H), 1.26 (+, J=7,3H). 2.10 (3H), 2.58 (6H)23 isovaleral- ±-butoxy- 2-isocyano-4- N-{N-[N-(carboxyglycyl)-dehyde di- carbonylgly- methylthio- N-(dimethylamino)-DL-methyl hydra- cine butyric acid leucyl]}-DL-methioninezone ethyl ester N-±-butyl ethyl diester, nmr (CDCl.sub.3 δ 0.98 (d, J=5,6H), 1.26 (2+, J=7, 3H), 1.46(9H), 2.11(2s, 3H), 2.56(6H)24 1-(cyclo- formic acid ethyl isocy- N-[1-(N-piperidinoform-hexylidene- anoacetate amido)cyclohexylcarbon-amino)piperi- yl]glycine ethyl ester,dine m.p. 119 - 120° C, ν.sub.max CHCl.sub.3 1730, 1655 cm.sup.-.sup.1.25 1-(cyclohex- p-nitro- ethyl iso-ylidene- benzoic acid cyanoacetate N-{1-[(p-nitro-N-piperid-amino)piperi- ino)benzamido]cyclohexyl-dine carbonyl}glycine ethyl ester, m.p. 133 - 135° C, ν.sub.max CHCl.sub.3 1730, 166026 isobutyral- cm.sup.-.sup.1. ±-butoxy- ethyl, so- N-{N-[N-(carboxyphenyl-dehyde dimeth- carbonyl- cyanoacetate alanyl)-N-(dimethyl-yl hydrazone phenylal- amino)-DL-valyl]}glycine anine N-±-butyl ethyl diester, separable into two isomers by chromatography (SiO.sub.2), isomer A: [α].sub.D.sup .25 = -66.9° (CHCl.sub.3), nmr (CDCl.sub.3) δ 0.91 & 1.04 (6H), 1.29 (3H); Isomer B: [α].sub.D.sup.24 = +40.0° (CHCl.sub.3), nmr (CDCl.sub.3) δ 0.75 & 1.03 (6H), 1.28 (3H).__________________________________________________________________________ EXAMPLE 27 3-[N-(Dimethylamino)formamido]-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester (III; and R 1 and R 2 = CH 3 , R 3 = CHO, R 5 =CH 3 and R 7 = H) A solution of the hydrazone of formula II, ethyl acetoacetate dimethylhydrazone (13.7g., 0.08 mole), the acid of formula R 3 X, formic acid (3.1 ml, 0.08 mole) and the isonitrile of formula R 6 NC, ethyl isocyanoacetate (9.1 g, 0.08 mole) in dry methylene chloride (25 ml) is stirred at room temperature until completion of the reaction. [In this case the reaction is complete after 21 hr. as determined by tlc using silica gel plates and a solvent system of benzeneethyl acetate (1:1)]. The mixture is diluted with ethyl acetate (200 ml) and 4N NH 4 OH (100 ml). The organic layer is separated, washed with water, dried (MgSO 4 ) and concentrated under reduced pressure. The oily residue is crystallized from hexane-methylene chloride to give the title compound, m.p. 89° - 92° C., ν max CHCl .spsb.3 1785, 1740, 1715, 1665 cm - 1 . EXAMPLE 28 3-(p-Chloro-N-piperidinobenzamido)-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester (III; R 1 and R 2 = (CH 2 ) 5 , R 3 = p-chlorophenyl, R 5 =CH 3 and R 7 = H) A solution of the hydrazone of formula II, ethyl acetoacetate piperidinehydrazone (21.2 g, 0.1 mole), ethyl isocyanoacetate (11.3 g, 0.1 mole) and p-chlorobenzoic acid (15.6 g, 0.1 mole) in dry methylene chloride (50 ml) are stirred at reflux temperature for 7 days. The solution is diluted with methylene chloride (50 ml), and washed with 0.5 N ammonium hydroxide (50 ml), water (50 ml), and saturated sodium chloride solution (50 ml). The organic phase is dried (Na 2 SO 4 ) and concentrated. The resulting oil and anhydrous potassium carbonate (20 g) in chloroform (200 ml) is heated at reflux temperature for 4 hr. The solution is filtered and the filtrate poured onto a column of silica gel (400 g). Elution with ethyl acetate-chloroform (1:3) affords the title compound having m.p. 153° - 155° C. after recrystallization from methylene chloride-hexane. EXAMPLE 29 3-(2,2-Dimethylhydrazino)-3-methyl-2,3-dioxo-4-phenyl-1-pyrrolidineacetic acid ethyl ester III; R 1 and R 2 = CH 3 , R 3 = H, R 5 = CH 3 and R 7 = phenyl) By following the procedure of Example 7 but replacing isobutyraldehyde dimethylhydrazone with an equivalent amount of ethyl-α-phenylacetoacetate dimethylhydrazone, described in Example I, then the title compound, m.p. 108° - 109° C., ν max CHCl .spsb.3 1770, 1738, 1700 cm -1 , is obtained. By following the procedures of Example 27, 28 or 29 and using the appropriate hydrazone of formula II, acid of formula R 3 X and isonitrile of formula R 6 NC then other compounds of formula III are obtained. Examples of such compounds of formula III are listed in Table II together with the hydrazone, acid and isonitrile required for their preparation. TABLE II__________________________________________________________________________ Hydrazone Acid of Isonitrile Product ofEx. of Formula II Formula R.sup.3 X (R.sup.6 NC) Formula III__________________________________________________________________________30 ethyl aceto- acetic acid ethyl iso- 3-[N-(dimethylamino)- acetate di- cyanoacetate acetamido]-3-methyl-2,5- methyl hydra- dioxo-1-pyrrolidine- zone acetic acid ethyl ester m.p. 112 - 115° C.31 ethyl aceto- benzoic acid ethyl iso- 3-[N-(dimethylamino)- acetate di- cyanoacetate benzamido]-3-methyl-2,5- methyl hydra- dioxo-1-pyrrolidine- zone acetic acid ethyl ester, m.p. 100 - 102° C.32 ethyl aceto- p-nitro- ethyl iso- 3-[N-(dimethylamino)- acetate di- benzoic acid cyanoacetate p-nitrobenzamido ]-3- methyl hydra- methyl-2,5-dioxo-1- zone pyrrolidineacetic acid ethyl ester, m.p. 179 - 182° C.33 ethyl aceto- p-chloroben- ethyl iso- 3-[p-chloro-N-(dimethyl- acetate di- zoic acid cyanoacetate amino)benzamido]-3-methyl- methyl hydra- 2,5-dioxo-1-pyrrolidine- zone acetic acid ethyl ester, m.p. 123 - 125° C.34 3-(piperi- formic acid ethyl iso- 3-methyl-2,5-dioxo-3-(N- dinoimino)- cyanoacetate piperidinoformamido)-1- butyric acid pyrrolidineacetic acid methyl ester ethyl ester, m.p. 89 - (described in 92° C. Example 2)35 3-(piperi- benzoic acid ethyl iso- 3-methyl-2,5-dioxo-3-(N- dinoimino)- cyanoacetate piperidinobenzamido)-1- butyric acid pyrrolidineacetic acid methyl ester ethyl ester, m.p. 140 - 144° C.36 3-(piperi- p-nitroben- ethyl iso- 3-methyl-3-[p-nitro-N- dinoimino)- zoic acid cyanoacetate piperidino)benzamido]- butyric acid 2,5-dioxo-1-pyrrolid- methyl ester ineacetic acid ethyl ester, m.p. 232 - 235° C.37 3-(morpholino- formic acid ethyl iso- 3-methyl-3-(N-morpho- imino)butyric cyanoacetate linoformamido)-2,5-dioxo- acid methyl 1-pyrrolidineacetic acid ester (des- ethyl ester, m.p. 148 - cribed in 149° C. Example 2)38 3-(morpholino- p-nitroben- ethyl iso- 3-[p-nitro-N-(morpho- imino)butyric zoic acid cyanoacetate lino)benzamido]-3-methyl- acid methyl 2,5-dioxo-1-pyrrolidine- ester acetic acid ethyl ester, (described in m.p. 237 - 238° C. Example 2)39 ethyl α-phenyl formic acid ethyl iso- 3-[N-(dimethylamino)- acetoacetate cyanoacetate formamido]-3-methyl-2,5- dimethyl dioxo-4-phenyl-1- hydrazone pyrrolidineacetic acid ethyl ester, m.p. 123 - 124° C.__________________________________________________________________________ EXAMPLE 40 3-[N-(Dimethylamino)-p-nitrobenzamido]-3-methyl-2,5-dioxo-1-pyrrolidineacetic acid ethyl ester III; R 1 and R 2 = CH 3 , R 3 = p-nitrophenyl, R 5 = CH 3 and R 7 H) A solution of the compound of formula I, N-(carboxymethyl)-3-[N-dimethylamino)-p-nitrobenzamido]-3-methylsuccinamic acid diethyl ester (15.74 g, 0.035 mole), described in Example 19, and anhydrous potassium carbonate (15.0 g) in chloroform (100 ml) is heated at reflux for 90 min. After filtering the mixture the filtrate is concentrated. The residue is recrystallized from ethyl acetate to afford the title compound, identical to the product of Example 32. The title compound is also obtained according to the procedure of this example in which the potassium carbonate is replaced by an equivalent amount of sodium carbonate or sodium or potassium hydroxide. By following the procedure of this example and using the appropriately substituted compound of formula I in which R 4 represents CHR 7 COO-(lower alkyl) and R 6 represents CH 2 C00-(lower alkyl) then the corresponding compounds of formula III, for example, those described in Examples 27 to 39, are obtained. EXAMPLE 41 N-Cyclohexyl-4-(dimethylaminoformamido)-4-methylglutaramic acid (I; R 1 and R 2 = CH 3 , R 3 = CHO, R 4 = CH 2 CH 2 COOH, R 5 = CH 3 and R 6 = cyclohexyl) To 5.10 g (0.015 moles) of the corresponding ethyl ester of the title compound, described in Example 5 in 50 ml. of dry methanol, a solution of 1.68 g (0.030 moles) of potassium hydroxide in 5 ml. of dry methanol is added. The mixture is stirred for 6 hr. at room temperature. The mixture is concentrated under reduced pressure, cooled and rendered acidic (pH = 4) with dil. HCl. The resulting gum is taken up in chloroform. The chloroform extract is washed with water, dried (MgSO 4 ), and concentrated. The residue is crystallized from methylene chloride-ether to afford the title compound, m.p. 221°-222° C. EXAMPLE 42 N-[N-(Dimethylamino)-N-(N-formylglycyl)]-DL-valyl}-glycine (I; R 1 and R 2 = CH 3 , R 3 = COCH 2 NHCHO, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOH) A mixture of N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester (6.618 g, 0.020 moles), described in Example 6, and IN NaOH (30 ml) is stirred at room temperature for 90 min. The solution is cooled, rendered acidic with dilute HCl and extracted with chloroform. The extract is washed with brine, dried (MgSO 4 ) and concentrated. The residue is purified by chromatography on silica gel using methanol-chloroform (8:2) as the solvent system. The eluate is concentrated and crystallization of the residue from acetone-isopropyl ether affords the title compound, m.p. 157° - 158° C. By following the procedure of Examples 41 or 42 other compounds of formula I in which the R 4 or R 6 radical includes an ester may be transformed to their corresponding acids. Examples of such acids prepared in this manner are listed in Table III. In these cases the ester used as starting material is indicated by the example in which it is prepared. TABLE III__________________________________________________________________________ No. of Example in Which Starting Material isEXAMPLE Prepared Product__________________________________________________________________________43 9 N-cyclohexyl-4-[N-(dimethyl- amino)benzamido]-4-methylglu- taramic acid, m.p. 118 - 119° C44 11 N-[N-(dimethylamino)-N- formyl-DL-valyl]phenylalanine, m.p. 133 - 136° C45 12 N-{1-[N-(dimethylamino)- formamido]cyclohexylcarbonyl}- phenylalanine, m.p. 156 - 157° C46 14 N-[N-(dimethylamino)-N- formyl-DL-valyl]glycine, m.p. 133 - 135° C47 15 N-}1-[N-(dimethylamino)- formamido]cyclohexylcarbonyl}- glycine, m.p. 139 - 142° C__________________________________________________________________________ EXAMPLE 48 N-{[N-(dimethylamino)-N-(N-formylglyclyl)]-DL-valyl}glycinamide (I; R 1 and R 2 = CH 3 , R 3 = COCH 2 NHCHO, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 CONH 2 ) A saturated solution of ammonia in anhydrous methanol (100 ml) is added with cooling to N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester (12.81 g) described in Example 6. The mixture is stirred at room temperature for 4 days. The solvent is removed and the residue subjected to chromatography on silica gel. Elution with chloroform-methanol (98.2) affords the title compound which, after crystallization from acetone, has m.p. 165° - 168° C. In the same manner but replacing N-{[N-dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester with an equivalent amount of N-[N-(dimethylamino)-N-formyl-DL-valyl]-DL-phenylalanine methyl ester (Example II), N-{N-[N-(carboxyglycyl)-N-(dimethylamino)-DL-leucyl]-DL-methionine N-t-butyl ethyl diester (Example 23), or N-[-(p-amino-N-piperidinobenzamido)cyclohexylcarbonyl]glycine ethyl ester Example 48), then N-[N-dimethylamino)-N-formyl-DL-valyl]-DL-phenylalaninamide, m.p. 147°-156° C, N-N-[N-(carboxyglycyl)-N-(dimethylamino)-DL-leucyl]}-DL-methioninamide N-t-butyl ester, separated by chromatography on silica gel into Isomer A, m.p. 84° - 89° C and Isomer B, m.p. 80°- 90° C, and 2-[1-(p-amino-N-piperidinobenzamido)cyclohexanecarboxamido]acetamide, m.p. 198° - 201° C, are obtained, respectively. EXAMPLE 49 N-{1 -[p-Amino-N-(dimethylamino)benzamido]cyclohexylcarbonyl-DL-phenylalanine methyl ester (1; R 1 and R 2 =CH 3 ; R 3 = p-aminobenzoyl, R 4 and R 5 = (CH 2 ) 5 and R 6 = CH(CH 2 C 6 H 5 )COOCH 3 ) N-{1-[N-(Dimethylamino)-p-nitrobenzamido]cyclohexylcarbonyl-phenylalanine methyl ester (9.5 g), described in Example 13, in 20 ml. of dry methanol is hydrogenated with 5% palladium on charcoal. Thereafter, the catalyst is collected on a filter pad. The filtrate is concentrated and the residue crystallized from acetone-isopropyl ether to give the title compound, m.p. 138°- 139° C. In the same manner but replacing N-{1-(dimethylamino)-p-nitrobenzamido]cyclohexylcarbonyl}glycine methyl ester (Example 18), or N-{1-[(p-nitro-N-piperidino)benzamido)]cyclohexylcarbonyl }glycine ethyl ester (Example 25), then N-{1-[p-amino-N-(dimethylamino)benzamido]cyclohexylcarbonyl} glycine ethyl ester, m.p. 69° - 71° C, and N-{1-(p-amino-N-piperidinobenzamido)cyclohexylcarbonyl}glycine ethyl ester, m.p. 92° - 96° C, are obtained, respectively. EXAMPLE 50 N-[N-(Dimethylamino)-N-(isocyanoacetyl)-DL-valyl]glycine ethyl ester (I; R 1 and R 2 = CH 3 , R 3 = COCH 2 NC, R 4 = CH(CH 3 ) 2 , R 5 = H and R 6 = CH 2 COOC 2 H 5 ) A solution of N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ethyl ester (4.0 g), described in Example 6, in dry methylene chloride (12 ml) is placed in a 3-neck flask fitted with mechanical stirrer, reflux condenser and drying tube (KOH). Redistilled triethylamine is then added (5.08 ml) followed by dropwise addition of a solution of phosgene in benzene (12 ml. of a 12.5% solution). The mixture is stirred an additional 30 min. at room temperature, the precipitate is then filtered off, the filtrate concentrated under reduced pressure to dryness (at temperature < 40° ). The residue is diluted with anhydrous benzene (40 ml) and filtered once more. The filtrate is evaporated to dryness and the residue purified by column chromatography using silica gel. Elution with benzene-ethyl acetate (1:l) provides the isonitrile as a yellow solid. To remove the color the material is dissolved in benzene and the solution is filtered through a short column of alumina (Activity II. The fractions containing the isonitrile are pooled and the solvent removed at low temperature (<40° ) under reduced pressure the residue if triturated with anhydrous diethylether to give the title compound, m.p. 119-120.5° C. By following the procedure of Example 50 but replacing N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-valyl}glycine ether ester with an appropriately substituted compound of formula I in which R 3 represents COCH 2 NHCHO, prepared by the procedure of Example 6 or 7, then the corresponding compounds of formula I in which R 3 is COCH 2 NC are obtained. For example, N-{[N-(dimethylamino)-N-(N-formylglycyl)]-DL-leucyl}-DL-methionine ethyl ester gives N-[N-(diethylamino)-4-(isocyanoacetyl)-DL-leucyl]-DL-methionine ethyl ester.
α-Hydrazinocarboxamide and α-(α'-acylhydrazino)-carboxamide derivatives of formula I ##STR1## in which R 1 and R 2 each are lower alkyl or R 1 and R 2 together with the nitrogen atom to which they are joined form a piperidino or morpholino radical; R 3 is hydrogen, lower alkanoyl, benzoyl, p-nitrobenzoyl, p-aminobenzoyl, p-chlorobenzoyl, isocyanoacetyl, or protected amino acyl radicals, for example, N-formylglycyl or ##STR2## (N-carbobenzoxyglycylglycyl); R 4 is lower alkyl, CHR 7 COOR 8 or CH 2 CH 2 COOR 8 wherein R 7 is hydrogen or phenyl and R 8 is hydrogen or lower alkyl; R 5 is hydrogen or lower alkyl; or R 4 and R 5 together with the carbon atom to which they are joined form a cyclohexylidene radical; and R 6 is a cyclohexyl or CHR 9 COY wherein R 9 is hydrogen or benzyl and Y is hydroxyl, lower alkoxy or amine, with the provisos that when Y is hydroxyl then R 8 is hydrogen, that when Y is lower alkoxy than R 8 is lower alkyl and that when Y is amino R 4 is lower alkyl, are disclosed herein along with the related α-hydrazino-carboxamide and α-(α'-acylhydrazino)carboxamide compounds of formula III ##STR3## in which R 1 , R 2 , R 3 , R 5 and R 7 are as defind above and Y is lower alkoxy. These compounds possess antibacterial activity. Methods for their preparation and use are disclosed also.
2
CROSS-REFERENCE TO RELATED APPLICATIONS Pursuant to 35 U.S.C. §120 and 37 CFR 1.78, this application is a continuation-in-part of, and claims the benefit of earlier filing date and right of priority to U.S. patent application Ser. No. 11/860,461, filed on Sep. 24, 2007, now U.S. Pat. No. 7,873,878 the content of which is hereby incorporated by reference herein in its entirety. COPYRIGHT & TRADEMARK NOTICES A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The owner has no objection to the facsimile reproduction by any one of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever. Certain marks referenced herein may be common law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is for providing an enabling disclosure by way of example and shall not be construed to limit the scope of this invention exclusively to material associated with such marks. FIELD OF INVENTION The present invention relates generally to data storage systems and, more particularly, to data validation in a data storage system. BACKGROUND Storing and retrieving data from large capacity storage systems (e.g., systems with a plurality of disk drives) generally requires certain safeguards against data corruption to ensure data integrity and system reliability. Certain disk behaviors contribute to corruption of data stored on a disk drive. During a write, the disk arm and head must align with very accurate precision on the track that comprises the physical block in order to deposit the new “bits” of write data. In the case of a write, two tracking errors can occur. Either the head can be misaligned so badly that the data is written to a completely unintended track or the head may be misaligned so that the data falls in a gap between two adjacent tracks. Both types of write errors are referred to as Undetected Write Errors because the disk drops the write data in the wrong location and does not itself detect the problem. Another type of error is a misaligned head placement when reading data. In this case, the head may read the data bits from a completely unintended track (i.e., Far Off-track Read) or from a gap between two tracks (i.e., Near Off-track Read) and return incorrect data to the user or application. Both of these errors are typically transient and are corrected when a subsequent read occurs to the same track. In addition, if the head reads tracks correctly but from the unintended target of a Far Off-track Write, incorrect data will be returned to the user or requesting application. In all the above scenarios, the drive typically does not detect a problem and returns a successful status notice to the user, host or application. Other error scenarios may also occur where the disk returns a success status while the user or application gets incorrect data. Such write or read errors can be referred to as Undetected Disk Errors (UDEs). Because a disk drive cannot independently detect UDEs, other methods need to be provided to detect such errors. Two main solution classes are available in the related art for verifying the accuracy of data read or written to disk drives. The first class is the file system or the application layer. For example, some file systems and many database systems use checksums on data chunks (e.g., 4 KB chunks) which are stored separate from the data chunks themselves. The checksums are read along with the data chunks; new checksums are recomputed from the read data chunks and are compared with the checksums read along with the data chunks. If the new checksum matches the old ones, then the read data chunk is assumed to be correct. The above method has two fundamental limitations. First, said method typically cannot recover from detected errors, unless they are also integrated with some additional data redundancy such as redundant array of independent disk drives (RAID). Second, said method is not always the source for every disk read, and so checking may not occur as often as necessary. For example, when the source of a disk read is not the file system or application layer, an underlying (and logically separate) layer in a RAID architecture may perform reads in the context of an application write (e.g., in a read-modify-write scenario). The application layer does not validate these types of reads. In such a case, the read may extract incorrect data from the disk and then use this incorrect data to update the RAID redundancy data. Thus, an error that goes undetected by the application may propagate errors in the underlying RAID layer, compounding the problem created by the drive. RAID is a disk subsystem that is used to increase performance and/or provide fault tolerance. RAID architecture comprises a plurality of disk drives and a disk controller (also known as an array controller). RAID improves performance by disk striping, which interleaves bytes or groups of bytes across multiple drives, so more than one disk is reading and writing simultaneously. Fault tolerance is also achieved in a RAID architecture by way of implementing mirroring or parity. A second class of methods to detect UDEs are implemented in the storage system itself, at a layer that is closer to the hardware layer so that every disk read and write that occurs in the system is monitored, whether the read or write is generated by the application layers or by the storage system layer itself. This class, however, cannot detect errors that occur in system layers that are higher than the storage system (e.g., in the network or internal host busses). It is desirable to have a method that not only detects a problem but also is capable of also locating where the error occurs and, further, to correct the errors if possible. There are a number of subclasses of methods that can be used within the storage system for detection of possible location and correction of UDEs. The first is based on parity scrubbing. RAID systems that protect against disk failures (such as RAID1 or RAID5) may use a method called “parity scrub” to detect these sorts of errors. For example, in a RAID5 system, the process involves reading the data and the respective redundancy data (i.e., parity data), recomputing the parity value and comparing the computed parity value with the parity value read from disk. If the two parity values do not match, then an error has occurred. Unfortunately, RAID5 does not provide a means to locate or correct an error detected in the above manner. More importantly, these parity scrubs may not detect errors that have been masked by other operations that were applied to data between the occurrence of a UDE and the parity scrub operation. For example, a UDE may occur during a write to a first disk in a RAID5 array that comprises four data disks and one parity disk. Subsequently, a write may be issued to the array for the second, third and fourth disks. Typically, an array will promote this operation to a full write by reading the data from the first disk, computing parity and writing out the new data to second, third and fourth disks and to the parity disk. After this operation, the data on the first disk is still incorrect, but the parity is now consistent with all the data (i.e., the parity now comprises the bad data on the first disk). As a result, a subsequent parity scrub will not detect the bad data. Another example of error propagation occurs when subsequent to a UDE, a successful and correct write (e.g., using a read-modify-write methodology) occurs to the same location. Such operation will leave the parity corrupted with the effects of the bad data. In effect, the bad data moves from the disk with the UDE to the parity disk. Such migration effects can occur whenever the bad data is read from the disk in order to perform any write operation to the stripe. Similar and even more complicated scenarios occur even with higher fault tolerant RAID algorithms such as RAID6. RAID6 is a fault tolerant data storage architecture that can recover from the loss of two storage devices. It achieves this by storing two independent redundancy values for the same set of data. In contrast, RAID5 only stores one redundancy value, the parity. A parity scrub on a RAID6 array can detect, locate and correct a UDE (assuming no disks have actually failed) but only if no operations were performed on the stripe that may have migrated or hidden the UDE. Parity scrubs are very expensive operations and are typically done sparingly. Consequently, the conditional assumption that no operations that migrated or failed to detect UDEs have occurred before the scrub rarely holds in practice. A location algorithm in the context of RAID6 (or higher fault tolerance) is disclosed in US Patent Application 2006/0248378, “Lost Writes Detection in a Redundancy Group Based on RAID with Multiple Parity.” This location algorithm must be used in conjunction with parity scrubs as an initial detection method. RAID parity scrub methods are incapable of reliably detecting and/or locating and correcting UDEs in an array. A second subclass of methods for addressing the problem of UDEs within the storage system is based on the write cache within the system. The method described in US Patent Application 2006/0179381, “Detection and Recovery of Dropped Writes in Storage Devices” uses the cache as a holding place for data written to disk. Only after the data is re-read from the disk and verified is the data cleared from the cache. This is an expensive method due to a number of factors. First, the discussed method requires using valuable cache space that could be used to improve read/write cache performance of the system. Second, it requires a separate read call (at some unspecified time) in order to validate the data on the disk. If that read occurs immediately after the data is written, Off-track Write Errors may not be detected because the head tracking system may not have moved. If the read occurs when the system needs to clear the cache (e.g., to gain more cache space for another operation), then a pending operation will be delayed until the read and compare occurs. Alternatively, the read could happen at intermediate times, but it will impact system performance with the extra IOs. A third subclass uses some form of metadata to manage the correctness of the data. The metadata is stored in memory and possibly on separate disks or arrays from the arrays the metadata represents. For example, US Patent Application 2005/0005191 A1, “System and Method for Detecting Write Errors in a Storage Device,” discloses a method for UDE detection. A checksum and sequence number for each block in a set of consecutive data blocks is stored in an additional data block appended immediately after. A second copy is stored in memory for the entire collection of blocks on the disk and this copy is periodically flushed to disk (which necessarily is a different disk) and preferably is stored on two disks for fault tolerance. A related scheme is found in U.S. Pat. No. 06,934,904, “Data Integrity Error Handling in a Redundant Storage Array” where only checksums are used, but no particular rule is defined for the storage of the primary checksum. US Patent Application 2003/0145279, “Method for using CRC as Metadata to Protect Against Drive Anomaly Errors in a Storage Array” discloses a similar checksum algorithm for detection together with a location algorithm. The above schemes suffer from the problems of high disk overhead and the additional IOs required to manage and preserve the checksum/sequence number data. Other examples of the third subclass are disclosed in U.S. Pat. No. 07,051,155, “Method and System for Striping Data to Accommodate Integrity Metadata.” The fourth subclass of storage based UDE detectors is similar to the third subclass in that the fourth subclass also uses some form of metadata to verify correctness of data read from disk. However, in the fourth subclass, the metadata is kept within the array and is collocated with the data or the parity in the array. For example, U.S. Pat. No. 07,051,155, “Method and System for Striping Data to Accommodate Integrity Metadata” discloses an embodiment where one copy of the stripe metadata is stored within the stripe. The above scheme provides a significant performance advantage when the system performs a read-modify-write to update data in the stripe. The method described in US Patent Application US2004/0123032, “Method for Storing Integrity Metadata in Redundant Data Layouts” uses extra sectors adjacent to the sectors of the parity strip(s) to store the metadata for the data chunks in the stripe. This method includes use of a generation number on the metadata, stored in NVRAM in order to verify the contents of the metadata. Other examples of the fourth subclass include the methods applicable to RAID5 arrays that are described in U.S. Pat. No. 04,761,785, “Parity Spreading to Enhance Storage Access;” US Patent Application 2006/0109792 A1, “Apparatus and Method to Check Data Integrity When Handling Data;” and U.S. Pat. No. 07,051,155, “Method and System for Striping Data to Accommodate Integrity Metadata.” In some disk storage systems, metadata is stored in non-volatile read access memory (NVRAM) or on rotating disks. The former has significant cost and board layout issues to accommodate the total volume of metadata that must be stored and managed, as well as the means to maintain the memory in non-volatile state. Furthermore, such memory takes a lot of motherboard real estate and this can be problematic. Particularly, in fault tolerant storage systems, with at least two coordinated controllers, the NVRAM must be shared between the two controllers in a reliable manner. This introduces complex shared memory protocols that are difficult to implement and/or have performance penalties. Rotating disks, on the other hand, have significant performance penalties and reliability issues. That is, a rotating disk has very low latency compared to memory, so accessing (e.g., reading or writing) the metadata can have a significant performance impact on the overall system. Additionally, rotating disks have a fairly low reliability record compared to memory. Consequently, vital metadata need to be stored at least as reliably as the data it represents. For example, when data is stored in a RAID6 array, wherein two disk losses may be tolerated, the metadata should also be stored in a manner that can survive two disk losses as well. Unfortunately, the above requirements impose significant additional costs and performance impacts, because the above-mentioned classes and subclasses for detecting and correcting UDEs are either inefficient or ineffective in uncovering sufficient details about a read or write error to help locate and fix a problem in many circumstances. Also, detecting and correcting UDEs may be very intrusive, especially with respect to RAID layers. Thus, systems and methods are needed to overcome the aforementioned shortcomings. SUMMARY The present disclosure is directed to a systems and corresponding methods that facilitate data validation in disk storage systems. For the purpose of summarizing, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages without achieving all advantages as may be taught or suggested herein. In accordance with one embodiment, a method for validating data in a data storage system is provided. The method comprises associating a first data chunk with a first check data calculated for the first data chunk, so that the first check data is accessed together with the first data chunk in a single input/output (I/O) operation directed to the first data chunk. A first data is stored across the storage devices in data chunks, so that the first data chunk and first check data are stored on a first storage device. One or more additional associated data chunks of the first data and associated additional check data are stored on at least one of the first storage device or one or more additional storage devices. At least a portion of the first check data and at least a portion of the additional check data are stored to a second storage device, so that the portion of the first check data is accessed together with the portion of the additional check data in a single I/O operation directed to the second storage device. The second storage device is distinct from the first storage device and the additional storage devices. I/O access to the second storage device is minimized by retaining at least a portion of the first check data and at least a portion of the additional check data in a readily accessible storage medium, during servicing of a first I/O request. In accordance with another embodiment, a system for validating data in a data storage system is provided. The system comprises one or more first storage devices for storing first data. The first data is comprised of data chunks, wherein each data chunk is associated with check data stored with the data chunk. A first data chunk and associated first check data are accessed in a single input/output (I/O) operation, and the first check data is used to validate the first data chunk. The system also comprises a second storage device for storing a portion of the first check data and a portion of additional check data associated with additional data chunks from among the data chunks. The stored portions are accessed in a single I/O operation, and the portion of the first check data is used to validate the first check data. One or more drive proxies are implemented to virtualize the first storage devices. The drive proxies also minimize I/O accesses to the second storage device when servicing I/O requests to access the stored portions of the first check data and the additional check data. In accordance with yet another embodiment, a computer program product comprising a computer useable medium having a computer readable program is provided. The computer readable program when executed on a computer causes the computer to perform the functions and operations associated with the above-disclosed systems and methods. One or more of the above-disclosed embodiments in addition to certain alternatives are provided in further detail below with reference to the attached figures. The invention is not, however, limited to any particular embodiment disclosed. BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the present invention are understood by referring to the figures in the attached drawings, as provided below. FIG. 1 is a block diagram of an exemplary data storage environment and its components, in accordance with one or more embodiments. FIG. 2 is a block diagram of an exemplary data layout for a data storage system, in accordance with one embodiment. FIG. 3 is a flow diagram of a method for checking validation data for a read request, in accordance with one embodiment. FIG. 4 is an exemplary block diagram for mapping check data on storage devices to copies in low latency non-volatile storage (LLNVS), in accordance with one embodiment. FIG. 5 is a flow diagram of an exemplary method for coordinating access to LLNVS, in accordance with one embodiment. FIGS. 6 and 7 are block diagrams of hardware and software environments in which the system of the present invention may operate, in accordance with one or more embodiments. Features, elements, and aspects of the invention that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects, in accordance with one or more embodiments. DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS In the following, numerous specific details are set forth to provide a thorough description of various embodiments of the invention. Certain embodiments of the invention may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects of the invention. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others. In accordance with one or more embodiments, systems and methods for detecting and correcting UDEs are provided. By way of example, certain embodiments are disclosed herein as applicable to a RAID architecture. It should be noted, however, that such exemplary embodiments should not be construed as limiting the scope of the invention to a RAID implementation. The principles and advantages disclosed herein may be equally applicable to other data storage environments. In accordance with one embodiment, data may be written to disk drives in conjunction with protection information. The term protection information as used here refers to information that can be used to detect whether data written to or read from a storage medium has been corrupted and to help restore the corrupted data when possible, as provided in further detail below. Depending on implementation, protection information may comprise parity information and check data (e.g., validity metadata (VMD) and atomicity metadata (AMD)) as provided in more detail in U.S. patent application Ser. No. 11/860,461 the content of which is incorporated by reference herein in entirety. VMD provides information (e.g., timestamp, phase marker, sequence number, etc.) that allows a storage system to determine whether data written to a storage medium has been corrupted. AMD provides information (e.g., checksum) about whether data and the corresponding VMD were successfully written during an update phase. Parity information is used to detect errors in a data storage environment by comparing parity bits for data before and after transmission using exclusive-or (XOR) calculations, for example. Referring to FIG. 1 , an exemplary data storage environment in accordance with one or more embodiments is provided. The data storage environment may comprise a storage system 110 connected to a host (e.g., computing system) 100 by way of host interface 130 . Storage system 110 provides host 100 with one or more virtual disks (not shown) that are mapped to one or more physical disk drives 180 . Array controller 120 may comprise a RAID I/O manager 140 , a RAID configuration manager 150 , and a disk interface 170 , for example. Array controller 120 services read and write requests and other input and output (I/O) requests for disk drives 180 by way of disk interface 170 . In some embodiments, array controller 120 may also comprise drive proxies 160 , which are mapped to disk drives 180 . Depending on implementation, RAID I/O manager 140 may forward I/O requests directly to drive proxies 160 . Or, RAID I/O manager 140 may forward I/O requests to disk interface 170 , and disk proxies 160 may intercept the requests. Drive proxies 160 are components that are included in storage system 110 component hierarchy between RAID I/O manager 140 and disk interface 170 . In other embodiments, array controller 120 may comprise a single drive proxy disk interface for disk drives 180 instead of drive proxies 160 . Drive proxies 160 intercept read and write operations to the physical disk drives 180 . For read operations, drive proxies 160 perform validation of the data returned by the disk drives 180 and provide validated data to the RAID I/O manager 140 . For write operations, drive proxies 160 accept new write data from RAID I/O Manager 140 and manage the preparation and storage of validation metadata before the user data is written to the physical disk drives 180 . RAID I/O manager 140 services I/O requests and manages data redundancy so that storage system 110 may continue to operate properly in the event of data corruption. RAID configuration manager 150 provides RAID I/O manager 140 with mapping information between the virtual disks and the disk drives 180 . Low-latency non-volatile storage (LLNVS) 190 (e.g., flash drives) may be utilized to store one or more copies of check data associated with data stored on disk drives 180 to provide further data redundancy and faster access. In this manner, data may be validated in more reliable and efficient manner in case an error is detected. Referring to FIGS. 1 and 2 , in accordance with one embodiment, storage system 110 may be implemented in a layered architecture with one or more of the following layers: virtual layer 210 , virtual drive layer 220 , and physical drive layer 230 . The use of multiple layers provides a logical abstraction that allows components of storage system 110 to be independent from each other, so that modification of one component does not require modification of all the other components in the system. In certain embodiments, virtual drive layer 220 provides an additional layer protection by utilizing drive proxies 160 that help keep data validation independent of the RAID implementation, thus minimizing intrusion into the RAID architecture when possible. Virtual layer 210 may comprise one or more virtual disks (e.g., virtual disk 1 ) that are accessible by host 100 . Data is written to the virtual disks in one or more virtual blocks (e.g., virtual block 1 , . . . , virtual block N). RAID configuration manager 150 provides RAID I/O manager 140 with mapping information so that RAID I/O manager 140 can map the data according to virtual drive data layout 225 . For example, virtual blocks 1 through 3 may be mapped to virtual drive block 1 , which is distributed across drive proxies 1 through 4 . Parity information for virtual blocks 1 through 3 may be stored in virtual drive block 1 on drive proxy 4 . Parity information for other sets of virtual blocks is distributed across drive proxies 1 through 4 so that storage system 110 can continue to operate properly if one of disk drives 180 fails or if data on one of the disk drives 180 is corrupted. As shown in FIGS. 1 and 2 , physical drive layer 230 may comprise one or more physical disk drives 180 , for example, corresponding to disk drives 1 through 4 . Drive proxies 160 , corresponding to drive proxies 1 through 4 , for example, may map virtual blocks to disk drives 180 and store parity information. The mapping scheme may be implemented in a similar way as implemented by RAID I/O manager 140 . Desirably, drive proxies 160 store check data associated with data stored on the respective disk drives 180 , in addition to the mapping information. Referring to the exemplary physical drive data layout 235 shown in FIG. 2 , each four blocks of data may be followed by a fifth block that includes the associated check data, in one implementation. Thus, the fifth block is utilized for storing the check data including protection information (e.g., VMD and AMD) needed for validation of data stored in the first four blocks. It is noteworthy that other physical drive data layouts are possible wherein check data is stored in every nth block such that it can be accessed, desirably, at the same time as the corresponding data (e.g., in a single read/write instruction) to maximize system performance. Referring to FIGS. 1 and 3 , in accordance with one embodiment, host 100 submits an I/O request for first data to RAID I/O manager 140 . One or more drive proxies 160 intercept the request (P 300 ), and validate the first data using check data stored in association with data in another data block (P 310 ). In some embodiments, the check data may not be accessible by RAID I/O manager 140 . Thus, instead of the RAID I/O manager 140 , drive proxies 160 may be used to validate the check data by comparing the check data or a subset of the check data with a copy of the check data stored in a storage device (e.g., LLNVS 190 ) (P 320 ). If validation of either the first data or the check data fails (P 325 ), drive proxies 160 return an error to RAID I/O manager 140 (P 330 ). If validation is successful (P 325 ), the request is serviced by RAID I/O manager 150 (P 340 ). Referring to FIGS. 1 and 4 , in accordance with one embodiment, check data or a subset of the check data stored in disk drives 180 is copied and stored in storage media or devices such as LLNVS 190 with high access rates. A high access rate means that data can be read or written to the storage media or device at a high rate of speed in comparison to slower storage media (e.g., tape drives, hard disk drives, etc.). As shown in the exemplary illustration in FIG. 4 , the contiguous blocks of non-shaded data are data chunks, and the shaded blocks following the data chunks are check data blocks. The two sets of data chunks and check data blocks on disk drives 1 through 4 may be referred to as a stripe. In certain embodiments, one or more check data blocks in a first stripe are copied to the first block of LLNVS 190 so that there is a one-to-one correspondence between a stripe on disk drives 180 and a block on LLNVS 190 . Such arrangement improves the performance of storage system 110 as RAID configuration manager 150 schedules read and write operations on a stripe by stripe basis. In the following, one or more embodiments are disclosed by way of example as utilizing LLNVS 190 as means for storing copies of check data. As discussed earlier, however, any other type of storage medium or device may be used. Depending on implementation, each stripe may comprise fewer or more data chunks than that provided in the suggested exemplary embodiments herein. The size of a data chunk may be configured so that an integral multiple of data chunks fit in a stripe, for example. Data on disk drives 180 may be stored such that check data associated with a stripe is stored contiguously on LLNVS 190 , so that the check data is read or written in conjunction with the associated data in a single operation, for example, and such that protection information stored on LLNVS 190 can be shared and made available to several drive proxies 160 as provided in further detail below. In one embodiment, RAID I/O manager 140 provides a coordination mechanism that enables drive proxies 160 to coordinate their accesses to LLNVS 190 . For example, upon receiving an I/O request that spans two or more virtual disks, RAID I/O manager 140 may append to each of the virtual disk I/O requests a data structure that indicates that these virtual disk I/O requests are related to the same stripe. Upon receiving these virtual disk I/O requests, drive proxies 160 examine the data structure and determine that the I/O requests are related. In this way, drive proxies 160 may coordinate their access to check data stored on LLNVS 190 to minimize the number of accesses to LLNVS 190 and make data validation more efficient. Referring to FIGS. 1 and 5 , in accordance with one embodiment, a first request is received to access check data on LLNVS 190 (P 500 ). At a same or subsequent time, a second request to access the check data may be received (P 510 ). In response, the check data is retrieved (P 520 ) and retained until each of the first and second requests are serviced (P 530 ). In accordance with another embodiment, an exemplary RAID5 storage system receives a small write request. Upon receiving the small write request, RAID I/O manager 140 generates four virtual disk I/O requests comprising of a request to read old data from a first virtual disk, a request to read old parity information from a second virtual disk, a request to write the new data to the first virtual disk, and a request to write new parity information for the new data to the second virtual disk. Each of the I/O requests to the virtual disks may involve accessing LLNVS 190 to read and update the VMD for the involved stripe. To assist drive proxies 160 , RAID I/O manager 140 associates or appends a data structure to each of the four virtual disk I/O requests before forwarding the requests to drive proxies 160 . The data structure may indicate (e.g., via pointers) that the four virtual disk I/O requests are related. Upon receiving the first read request, a first drive proxy 160 reads the VMD for the entire stripe once from LLNVS 190 . If the first drive proxy 160 determines that one or more second requests may need to access the VMD, the first drive proxy 160 may make the VMD available to one or more second drive proxies 160 that are handling the second requests by, for example, caching the VMD in a shared memory. Alternatively, the first drive proxy 160 may attach a pointer to the VMD onto the shared data structure provided by RAID I/O manager 140 . Thus, the second drive proxies 160 may avoid accessing LLNVS 190 to retrieve VMD for the same stripe and instead access the VMD directly from the shared memory or data structure. Upon receiving the first write request, a first drive proxy 160 updates the VMD for the written data. If the first drive proxy 160 determines that one or more second requests may need to access the VMD, the first drive proxy 160 does not write the updated VMD to LLNVS 190 until one or more second drive proxies 160 finish handling the second requests. Once drive proxies 160 determine that reads and updates to the VMD have completed, the VMD is written once to LLNVS 190 . Thus, reads and updates to LLNVS 190 are minimized, improving system performance. It is noteworthy that the coordination mechanism is not limited to the above-mentioned embodiments and can be implemented in any situation where coordination may reduce the number of accesses to LLNVS 190 to enable better overall system performance. Certain aspects and advantages of the invention are disclosed as applicable to an exemplary algorithm applied in the context of an exemplary host operation (e.g., a read operation). It is noteworthy, however, that the principles and advantages disclosed can be equally applied to other operations in accordance with other embodiments. In different embodiments, the invention can be implemented either entirely in the form of hardware or entirely in the form of software, or a combination of both hardware and software elements. For example, the error handlers may comprise a controlled computing system environment that can be presented largely in terms of hardware components and software code executed to perform processes that achieve the results contemplated by the system of the present invention. Referring to FIGS. 6 and 7 , a computing system environment in accordance with an exemplary embodiment is composed of a hardware environment 600 and a software environment 700 . The hardware environment 600 comprises the machinery and equipment that provide an execution environment for the software; and the software provides the execution instructions for the hardware as provided below. As provided here, the software elements that are executed on the illustrated hardware elements are described in terms of specific logical/functional relationships. It should be noted, however, that the respective methods implemented in software may be also implemented in hardware by way of configured and programmed processors, ASICs (application specific integrated circuits), FPGAs (Field Programmable Gate Arrays) and DSPs (digital signal processors), for example. Software environment 700 is divided into two major classes comprising system software 702 and application software 704 . System software 702 comprises control programs, such as the operating system (OS) and information management systems that instruct the hardware how to function and process information. In one embodiment, the data validation processes noted above may be implemented as application software 704 executed on one or more hardware environments to facilitate error detection and data recovery in storage system 110 , Application software 704 may comprise but is not limited to program code, data structures, firmware, resident software, microcode or any other form of information or routine that may be read, analyzed or executed by a microcontroller. In an alternative embodiment, the invention may be implemented as computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer-readable medium can be any apparatus that can contain, store, communicate, propagate or transport the program for use by or in connection with the instruction execution system, apparatus or device. The computer-readable medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid-state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk read only memory (CD-ROM), compact disk read/write (CD-R/W) and digital video disk (DVD). Referring to FIG. 6 , an embodiment of the application software 804 can be implemented as computer software in the form of computer readable code executed on a data processing system such as hardware environment 600 that comprises a processor 602 coupled to one or more memory elements by way of a system bus 604 . The memory elements, for example, can comprise local memory 606 , storage media 608 , and cache memory 616 . Processor 602 loads executable code from storage media 608 to local memory 606 . Cache memory 616 provides temporary storage to reduce the number of times code is loaded from storage media 608 for execution. A user interface device 612 (e.g., keyboard, pointing device, etc.) and a display screen 614 can be coupled to the computing system either directly or through an intervening I/O controller 610 , for example. A communication interface unit 618 , such as a network adapter, may be also coupled to the computing system to enable the data processing system to communicate with other data processing systems or remote printers or storage devices through intervening private or public networks. Wired or wireless modems and Ethernet cards are a few of the exemplary types of network adapters. In one or more embodiments, hardware environment 600 may not include all the above components, or may comprise other components for additional functionality or utility. For example, hardware environment 600 can be a laptop computer or other portable computing device embodied in an embedded system such as a set-top box, a personal data assistant (PDA), a mobile communication unit (e.g., a wireless phone), or other similar hardware platforms that have information processing and/or data storage and communication capabilities. In some embodiments of the system, communication interface 1108 communicates with other systems by sending and receiving electrical, electromagnetic or optical signals that carry digital data streams representing various types of information including program code. The communication may be established by way of a remote network (e.g., the Internet), or alternatively by way of transmission over a carrier wave. Referring to FIG. 7 , application software 704 can comprise one or more computer programs that are executed on top of system software 702 after being loaded from storage media 708 into local memory 706 . In a client-server architecture, application software 704 may comprise client software and server software. For example, in one embodiment of the invention, client software may be executed on host 100 and server software is executed on storage system 110 . Software environment 700 may also comprise browser software 808 for accessing data available over local or remote computing networks. Further, software environment 700 may comprise a user interface 706 (e.g., a Graphical User Interface (GUI)) for receiving user commands and data. Please note that the hardware and software architectures and environments described above are for purposes of example, and one or more embodiments of the invention may be implemented over any type of system architecture or processing environment. It should also be understood that the logic code, programs, modules, processes, methods and the order in which the respective steps of each method are performed are purely exemplary. Depending on implementation, the steps can be performed in any order or in parallel, unless indicated otherwise in the present disclosure. Further, the logic code is not related, or limited to any particular programming language, and may comprise of one or more modules that execute on one or more processors in a distributed, non-distributed or multiprocessing environment. Therefore, it should be understood that the invention can be practiced with modification and alteration within the spirit and scope of the appended claims. The description is not intended to be exhaustive or to limit the invention to the precise form disclosed. These and various other adaptations and combinations of the embodiments disclosed are within the scope of the invention and are further defined by the claims and their full scope of equivalents.
A method for validating data in a data storage system comprising associating a first data chunk with first check data and storing the first data chunk and the first check data on a first storage device. Additional associated data chunks of the first data and associated additional check data are stored on at least one of the first storage device or one or more additional storage devices. At least a portion of the first check data and at least a portion of the additional check data are stored to a second storage device, which is distinct from the first storage device and the additional storage devices. I/O access to the second storage device is minimized by retaining at least a portion of the first check data and at least a portion of the additional check data in a readily accessible storage medium, during servicing of a first I/O request.
6
PRIOR APPLICATION DATA [0001] The present application claims priority from prior UK application 0606965.2 filed Apr. 6, 2006, incorporated by reference herein in its entirety. FIELD OF THE INVENTION [0002] The present invention relates to video processing and display. For example, some embodiments aim to provide a viewer with a wider field-of-view—leading to a greater sense of immersion than a traditional video presentation—without requiring a larger television or display screen. BACKGROUND OF THE INVENTION [0003] Traditional television viewing in domestic environments usually includes a single, television monitor. In some situations, a flat-screen display or projector may be used to provide a larger viewing area. It is reasonably common for viewers to choose to augment or replace the audio capabilities of the display with an external stereo or surround sound hi-fi system. [0004] One known system (Philips Ambilight FlatTV TM) includes a built in soft light, which emanates onto the wall surrounding the television and aims to provide a more relaxed viewing environment as well as to improve the perceived picture detail, contrast and color. The color of the surrounding light may be adjusted in line with prevailing colors in the screen image, but there is no further image information. Thus this may improve perception but does not provide any real sense of enhanced “immersion” in the scene, as it occupies only a small proportion of the viewer's visual field, and is only very weakly related to the picture content. [0005] Watching a broadcast television program or a DVD film in the home thus provides a very different experience from viewing ‘real world’ scenes. The angle subtended by the video image to the eye is only a few degrees at either optimum or typical viewing distances. Much of the field of view of the eye is filled with the viewing environment—the living room furniture, wall decoration, and so on. [0006] Conventional methods for achieving a wide-angle display, such as IMAX, require a very high-definition camera and display system, and are unsuitable for use in a domestic environment. The data rate required to deliver such a high-definition image over a broadcast link makes deploying such a system impractical. [0007] Furthermore, were such a system to be set up in a domestic environment, any conventional TV set would have to be removed to make space, interfering with viewing of conventional TV. SUMMARY OF THE INVENTION [0008] Embodiments of the present invention seek to provide an improved viewing system alleviating the drawbacks of the above-mentioned systems. Advantageously, embodiments may be backwards compatible with existing television equipment. [0009] In one aspect, an embodiment of the present invention includes a method of providing a video display comprising the steps of providing a primary video display in a primary display region; providing a surround video display in a region surrounding the primary display region, wherein the surround video display is of lower quality than the primary video display. [0010] The primary video display may be provided by a primary display device having a dedicated screen area. The primary video display may be provided by a device having an active screen. The surround video display may be provided by projection onto at least one object surrounding the primary display device. An embodiment may compensate the projected surround video display based on the geometry of an object. Apparent motion of at least one object in the primary video display may be extrapolated into the surround video display. [0011] In another aspect, an embodiment of the present invention includes a method of providing a video display comprising providing a primary video display in a primary display region; and providing a surround video display in a region surrounding the primary display region, wherein the surround video display is of lower resolution than the primary display and wherein the surround video display extends over a substantially larger field of view than the primary display. [0012] The primary video display may be provided on a primary display device and the surround video display may be provided by projection onto at least one object surrounding the primary display device. An embodiment may receive at least one encoded video signal and provide a primary signal to cause the primary display device to display the primary video and a surround signal to cause a surround video projector to display the surround video. The surround signal may include information for use in synthesizing surround information based on the primary video signal Synthesizing at least a part of a surround video signal based on the content of a primary video signal may be performed Apparent motion of at least one object in the primary video display may be extrapolated into the surround video display. A surround video signal may be provided by transforming generic surround images in real time based on the geometry of the surroundings of the primary video display. [0013] A primary representation may include a primary video signal and a surround representation may include a surround video signal which is more coarsely quantized or encoded at a lower bit rate than the primary video signal. In another aspect, an embodiment of the present invention includes a method of distributing video content, comprising supplying a primary representation of a first view of a scene which representation is decodable to provide a primary video display; and supplying a surround representation of a second view of the scene, being a wider angle view than said first view, which surround representation is separately decodable to provide a surround video display in a region surrounding the primary display region. [0014] In another aspect, an embodiment of the present invention includes a method of distributing video content, comprising supplying a primary representation of a first view of a scene which representation is decodable to provide a primary video display; and supplying surround information which surround representation is separately decodable to provide a surround video display in a region surrounding the primary display region such that apparent motion of at least one object in the primary video display is extrapolated into the surround video display. [0015] In another aspect, an embodiment of the present invention includes video processing apparatus comprising an input stage for receiving a video input; a primary display driver connected with the input stage and adapted to provide a primary video signal for a primary display on a screen in a room; and a surround video processor connected with the input stage and adapted to provide a surround video signal for a surround display projected onto surfaces of the room adjacent the screen, the surround video processor being adapted to hold geometrical parameters of said surfaces and to compensate in said surround video signal for said parameters. [0016] The surround video processor may for example mask the area of the screen in the surround video signal. A masking area corresponding to the primary video display may be defined. [0017] In another aspect, an embodiment of the present invention a includes video processing apparatus comprising an input stage for receiving a video input; a primary display driver connected with the input stage and adapted to provide a primary video signal for a primary display; a surround video processor connected with the input stage adapted to provide a surround video signal for a surround display in which the trajectory of moving objects represented in the primary display is extrapolated into the surround display. [0018] In another aspect, an embodiment of the present invention includes a method of calibrating a video display apparatus including a primary video display and a surround video projector, the method comprising registering the projector and primary video display so that the projected surround video surrounds but does not substantially overlap the primary video display. [0019] In another aspect, an embodiment of the present invention includes a method of calibrating a video display apparatus including a primary video display and a surround video projector, the method comprising storing data indicative of the geometry and/or reflectivity and/or color of the surroundings of the primary video display for use in modifying a surround video image to be projected onto the surroundings. [0020] In another aspect, an embodiment of the present invention includes video processing apparatus means for receiving video information; means for outputting a signal to a primary video display; surrounding object information storage means, store, or memory; image transformation means for transforming surround video image data based on the stored surrounding object information and means for outputting a surround video signal to a surround projector. [0021] In another aspect, an embodiment of the present invention includes a system comprising a primary display driver for outputting a signal to a primary video display; a surrounding object information store or memory; an image transformation processor for transforming surround video image data based on the stored surrounding object information; a surround video display driver for outputting a surround video signal; and a surround projector receiving the surround video signal. [0022] In another aspect, an embodiment of the present invention includes video capture apparatus comprising; primary video capture means for capturing primary video corresponding to at least one broadcast standard for a primary field of view; surround video capture means for capturing surround video for a surround field of view surrounding the primary field of view. The surround video capture means may capture video overlapping with or encompassing the primary field of view. [0023] In another aspect, an embodiment of the present invention includes a processor, computer program or computer program product or logic or video processing hardware configured to perform a method comprising the steps of receiving at least one encoded video signal; providing a primary signal to generate a primary video display on a primary display device; providing a surround signal to generate a surround video display by projection onto at least one object surrounding the primary display device wherein apparent motion of at least one object in the primary video display is extrapolated into the surround video display. [0024] It will be appreciated that there is considerable correspondence between capture and playback and processing features. For conciseness features are generally identified herein in a single context; method features may be provided as apparatus features (or computer code or program features) and vice versa and features of the capture system may be applied to the playback system and vice versa unless otherwise explicitly stated or clearly implied by context. [0025] Embodiments may fill a large portion of the eye's view—both the central and peripheral vision areas—and thereby increase the sense of immersion in the presented scene. [0026] In a preferred embodiment it is proposed that, a secondary (high definition) camera fitted with a wide angle or fish-eye lens is associated with and, typically, rigidly mounted to the main camera. While the main camera records action as usual, the secondary camera records the surrounding scene. The fish eye lens may have close to 180° field of view. The precise field of view and other characteristics of the secondary camera are not critical to this invention. [0027] Both main and secondary recordings may be made available as two separate but synchronous video streams. Those viewers with the required playback equipment can use the second ‘surround’ video stream to project an image onto the walls, floor and ceiling of their viewing environment and substantially fill their field of view. Real-time image manipulation software is preferably provided to remove the distortion imposed on the image by the geometry (or other characteristics) of the room. The portion of the projected image that would fall on the normal TV display is typically blanked, but may be at a lower intensity so as not to be problematic. [0028] Thus, a high-resolution video image is displayed on a smaller screen in the centre of the viewer's gaze. The second ‘surround’ video is displayed over a much larger area filling the viewer's peripheral vision. Because of the large surface area over which the secondary stream is displayed, it is perceived as a lower resolution image. [0029] Those with only regular viewing equipment are free to watch the standard video stream as usual. [0030] In cases where it is impossible or impractical to capture a contemporaneous “surround” video recording (or for use with archive or other video that was not captured using a secondary camera as described above), embodiments of the present invention contemplate analysis of the main video image (and possibly also the audio soundtrack) to synthesize a surround video stream, which is related to the main video image spatially, by color and by motion (of main camera or of objects in the scene) as examples. [0031] The ‘surround’ video image will generally be of lower quality than the main image: it will almost certainly be of lower spatial resolution, it is likely to be dimmer, and is likely to show some residual distortion due to failures to accurately compensate for the geometry of the walls. However, since the programme being viewed will have been shot so as to put the main focus of interest on the conventional display (as the programme will generally be shot to look sensible for viewers without the benefit of the surround image), the viewer's attention will usually be concentrated on this display. The main task of the ‘surround’ image is to provide information for the viewer's peripheral vision, where requirements for resolution and other aspects of image quality are generally lower. [0032] A mode selector may allow selecting at least one synthetic surround video signal or no signal in the absence of received or stored information providing the surround video signal. BRIEF DESCRIPTION OF THE DRAWINGS [0033] The principles and operation of embodiments of the present invention may be better understood with reference to the drawings, and the following description, it being understood that these drawings are given for illustrative purposes only and are not meant to be limiting, wherein: [0034] FIG. 1 shows a capture system; [0035] Fig. 2 shows a playback system; [0036] FIG. 3 shows a recording and delivery system; [0037] FIG. 4 illustrates extrapolation from a primary image; and [0038] FIG. 5 illustrates alternative extrapolation from a primary image. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0039] The following description is presented to enable one of ordinary skill in the art to make and use the invention as provided in the context of a particular application and its requirements. Various modifications to the described embodiments will be apparent to those with skill in the art, and the general principles defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the particular embodiments shown and described, but is to be accorded the widest scope consistent with the principles and novel features disclosed. In some cases, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention. [0040] Referring to FIG. 1 , two cameras 10 and 11 are used which are rigidly mounted together in a frame. The cameras can be handheld, mounted on a tripod or supported in any other appropriate manner. The main camera 10 is free to be moved to frame shots as usual; the second camera 11 may be fitted with a fish-eye lens, such that it captures a very much wider field of view than the main camera and is used to record the surround video stream The surround video stream captures the environment in which the scene was recorded, putting it into better context. [0041] The cameras are frame-synchronized. A clapperboard may be used, as is common in television and film productions; the synchronism could equally be provided electronically using genlock and time code. [0042] Referring to FIG. 2 , an existing video playback system (which is assumed to comprise of a video display, with internal or external audio capabilities) is supplemented with a projector The standard display system is used to present the main video stream, as usual. This may comprise a “conventional” television, which term is intended to encompass without limitation a cathode ray tube, plasma screen, liquid crystal display and may be analogue, digital, high definition. It may also include a video projection screen onto which an image is projected by a video projector, which may or may not be integrated with the projector to be described below. [0043] In one example of a system according to this invention, a projector 20 is used to project the wide field-of-view video stream onto the walls ( 40 a - d ), ceiling and floor of the viewing environment. The wide-angle projection is obtained by using a conventional video projector 20 and a curved mirror 21 . [0044] Referring to FIG. 3 , there is provided a system for recording a surround video stream, delivering said stream to a user and displaying the stream The image capture system comprises two cameras as before—one for the main image 10 and a second 11 , with a fish-eye lens; this provides the video stream The video is then processed in editing and post-production 41 . When the zoom of the main camera changes, the scale factor for the surround image may be adjusted accordingly. Image-based analysis 42 can occur by, for example: [0045] i analyzing the main and surround images in order to deduce their relative scale factors (many techniques in the field of image processing are known which could be used for this task, for example correlation-based methods, object matching or recognition, or motion estimation) or [0046] ii analyzing data from sensors attached to the camera lenses that indicated their focal length. [0047] Similar techniques could be used to determine or specify the relative positioning of the main and surround video (for example, the surround video may be centered on the main image, or it may be centered a little way above, to give a more extensive view of objects above the camera rather than below). This analysis could also be carried out later at the end-user. The video stream is delivered via broadcast or physical media 50 to the user. Upon delivery, geometric correction is performed to correct distortions due to the viewing environment 43 ; in addition image-based analysis may be carried out, especially in cases where no surround video stream was recorded. Real-time video manipulation software may be used to remove the distortion imposed on the image by the fixed geometry of the room. This software performs additional scaling of the surround image, such that it correctly matches the scale of objects shown in the main video. Re-timing of the two video streams occurs 44 in order to compensate for processing delays. The main image is displayed on a video display 30 such as an LCD monitor. The peripheral image is projected onto the viewing environment 40 by a projector 20 or projecting system as depicted in FIG. 2 . [0048] For cases where no surround video stream was recorded, the video may be analyzed to synthesize a surround video stream. A number of example algorithms are suggested here; any one of these or combinations or modifications may be used. [0049] 1. Edge Color Extrapolation [0050] To provide a wider surround view from existing video material it is proposed to synthesize a surround video signal. This signal contains aspects of the motion and the predominant color from the edges of the original image. The use of the predominant edge color allows the extended view to match the background color in the video and so providing a basic sense of being surrounded by the scene Motion in the original image is represented in the synthesized view to give extra movement cues to the viewer so that movement on the. conventional display is also represented on the surrounding view. [0051] To extract basic motion and color from the edges of the conventional image, the average color is taken from blocks of pixels from around the edge of the image and replicate them to fill the larger surround image. [0052] Referring to FIG. 4 , this averaging process is done for each pixel along a border 33 within the edge of the image 31 . This border is smaller than the picture size to take into account any letterboxing or pillar boxing black borders of the image. For each pixel along the line of this border the n×n block of pixels 32 containing the border pixel is averaged together to find the average color for the block. The resulting color for the block is then replicated within the surround video image 32 across a line 35 from where original pixel lines up within the larger surround image to the edge of the projected view. [0053] The area within the surround image that the conventional display fills is then set to black in the image This stops light from the projected surround image landing on the conventional display. The brightness of the synthetic image can also be adjusted so that pixels get darker the further they are from the centre of the image to fade out the surround view. [0054] This approach works well for the sides of the display. Motion within the synthetic view matches well with the original image and appears somewhat like the change of reflected light caused by the movement of the foreground objects. The extent to which motion and textural detail are represented in the surround view can be controlled by the size of the averaging blocks. The sizing of the averaging border also can be used to control the extent to which objects within the foreground of the scene occur within the surround image. [0055] However, this approach may have limitations at the corner areas of the surround view as a single pixel block value is replicated to fill an entire corner area of the larger image. To minimize the effect of this, filtering may be performed on the entire synthesized view to the smooth the transition between the sides and the corners of the surround image. [0056] 2. Radial Color Extrapolation [0057] An alternative synthesis algorithm—presented in FIG. 5 —uses the averaging technique as described above, but generates the ‘Surround Video’ image 32 by extrapolating the location of each pixel in the ‘Surround’ image back to the centre of the original video image 31 and coloring it according to the color of the pixel on the edge of the original image which lies closest to the line 36 extrapolated between the centre pixel and the ‘Surround Video’ pixel. [0058] 3. Measurement of Object or Camera Motion to Render a Moving Texture Pattern [0059] Motion cues can be one of the more important cues to come from peripheral vision. Therefore one method of synthesizing the surround video is to generate an image with motion properties that match those of the main image. For example, a pseudo-random texture could be generated, which is moved in accordance with the estimated movement of the camera. Thus, when the camera pans left, the texture is moved to the left at a rate that matches the movement in the main image. Alternatively, instead of using a pseudo-random texture, some features of the image (such as fine detail) could be extracted and replicated to fill the surround image, in such a way that motion in the main image results in the replicated texture moving at a matching speed in the surround image. [0060] By taking just the fine detail from the image, the replication process can be substantially hidden, resulting in a texture with an apparently random appearance, but which moves in largely the same way as the content of the main image. The low frequencies in the surrounding image could be synthesized using one of the color extrapolation methods described above. [0061] 4. Extrapolation of Image Texture Using Object or Camera Movement [0062] Having analyzed object movement in a video image (extracting object size and position over time to derive its speed, direction and possibly its acceleration), a representation of moving objects can be synthesized in the surround video image. [0063] The analyzed movement properties are applied to the object being rendered in the surround image, giving the impression that it continues traveling off to the sides (or top or bottom) of the main image. Similar techniques could be applied to camera rather than object movement (that is, by measuring the apparent movement of the background), to build up a wide-angle image using a method similar to the well-known ‘image stitching’ approach used to build panoramic images from a series of overlapping still images. This kind of processing would preferably process an entire image sequence before producing any synthesized surround video, because information for a given frame may usefully be taken from both preceding and following points in time. It thus may be more applicable as a pre-processing stage, implemented by the broadcaster to generate a surround video channel before the video was delivered. Alternatively, the processing could take place using stored content in a domestic device (such as a PC with a DVD drive) to generate the surround video for a programme or film before viewing it [0064] An example of the steps involved in this image synthesis process is as follows: 1. For each video frame, segment it into objects having different motions. Methods are known to achieve such segmentation, see for example Chung, H Y. et al “Efficient Block-based Motion Segmentation Method using Motion Vector Consistency”. In Proc. IAPR Conference on Machine Vision Applications (MVA2005), pages 550-553, Tsukuba Science City, Japan, May 2005 (http://www csis.hku.hk/˜kykwong/publications/hychung —mva 05.pdf) 2. For each object, look through the list of objects that have been seen before, and identify a corresponding object, by matching parameters such as object size, location, and direction of movement. Update the stored motion vector, size, shape and image information associated with the matching object, using the information from the current frame. If parts of the object are no longer visible due to having moved outside the image or having moved behinds another object, leave the shape and image information for these parts unchanged. If no corresponding object has been seen before, create a new object on the list of observed objects. 3. For all objects in the list, delete those that were expected to be seen in the current frame and were not. For those that were not expected to be seen (i.e. those that lie wholly outside the image), update their location by assuming they continue moving at constant velocity. 4 Synthesize an initial surround video image using one of the methods mentioned earlier, such as Edge Color Extrapolation. 5. For each object in the list that lies partly or wholly outside the image, draw the object using its stored location and image data at the appropriate position into the synthesized surround video image. Optionally, the objects may be drawn with a transparency level or degree of low-pass filtering that increases in accordance with the length of time since the object disappeared from the main image, or the distance it has traveled. [0070] A number of alternative implementations are possible and the embodiments described above are in no way exhaustive or limiting. Some possibilities for modification include: Using a projector rather than CRT or flat-screen display to present the main video stream. Using a projector with a wide angle lens to present the surround video image Using any other future video display device (such as electronic wallpaper) to show either the main or surround video image. In the case of proposals such as electronic wallpaper (which can be based on liquid crystal display technology), driving of the wallpaper shall be construed as “projection” onto the surrounding objects. Using a single high-resolution camera with wide-angle lens to capture the footage, and electronically extracting a centre portion to create the main video stream. [0075] Other known techniques could be incorporated to enhance a projection-based surround video system. For example, methods are known to perform accurate compensation of projected images when projecting onto irregular surfaces with varying reflectivity, such as may be found in a typical home environment. An example of such a method is described in “Bimber, O et al. Enabling View-Dependant Stereoscopic Projection in Real Environments., Fourth International Symposium on Mixed and Augmented Reality, October 5-8, Vienna, Austria, pp. 14-23”. [0076] To apply such a method, one approach would be to use a camera to capture images of a series of projected calibration patterns. The camera should preferably be placed at the position of a typical viewer's head (e.g. someone sitting in the middle of the sofa in a living room), although alternatively for convenience it could be integrated into the projector unit. The calibration patterns could consist of a series of lines, dots or squares in different positions in the projected image. By analyzing the captured image of each projected pattern, it is possible to calculate the geometric, brightness and color corrections that should be applied to the projected image in order to compensate for the non-ideal geometry and reflectivity of the walls onto which the image is being projected. The captured images could also be analyzed to determine the location and size of the main display screen, which would allow the scaling and positioning of the projected image to be adjusted to match. [0077] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be appreciated by persons skilled in the art that many modifications, variations, substitutions, changes, and equivalents are possible in light of the above teaching. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
To supplement a video display on a conventional television, a surround video stream may be projected onto wall and other surfaces adjacent the television. The surround video stream may derive from a wide angle lens camera positioned alongside the main camera. The surround video stream may be processed in a local processor to compensate for departures from planar geometry in the wall surfaces. Where no surround video stream is received, a video processor may synthesize a surround video stream from the main video signal. Moving objects represented in the main video signal may be synthesized in the surround video to provide the perception of movement across the viewer's full field of view.
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DESCRIPTION 1. Technical Field This invention relates to elevator drive motors, in particular, geared elevator drive motors and, specifically, traction elevators employing elevator drive motors that use a worm gear. 2. Background Art Geared elevator drives are very common. With few, if any, exceptions, geared elevator drives use a worm gear that engages a gear wheel that is attached to a shaft to which the elevator sheave is attached. The worm gear or worm as it is often called is rotated by an AC electrical motor, usually single or two speed, but, in some more recent systems, variable frequency AC to offer continuously variable motor speed control. The sheave, it is commonly known, engages the elevator ropes and usually supports the elevator car and counterweight, a considerable shaft load. In this "traction" elevator system, the traction between the rotating sheave and the rope propels the car. Manufacture and assembly of geared elevator drives is notable in that it is expensive, complicated, and not always done in a way that maximizes longevity of the shaft bearings. Construction techniques have focused ostensibly on simplifying the insertion of the shaft and the wheel gear as a single subassembly in the motor housing or case, an objective that has led to the uniform use of two-piece gear housings or cases. Typically, the shaft subassembly with the bearings on the shaft is inserted into one gear case half. Semicircular bearing seats are milled into each half; these should be perfectly aligned with the shaft axis and should be perfectly circular because, when the two halves are joined, they form the bearing bore that supports each of the shaft bearings, of which there are two usually, one, just next to the sheave, the other, at the opposite end of the shaft. A seal is placed on the bottom of the case, and the two halves are bolted together. The two halves are separated to service the gear wheel and the worm. The vertical load on the shaft, which may be substantial, the combined weight of the cab and counterweight and ropes, exerts forces on the case that tends to distort the alignment of the two case halves. In reality, the stresses on the case halves or sections, is more complex than that because the load is entirely on one side of the shaft in all but a few geared traction elevators. The effect is that it is difficult to maintain precise bearing alignment over the life of the drive, which is typically many years, and the bearings may wear prematurely, creating annoying mechanical noise in the drive. Sometimes the stresses cause leaks in the case seal, allowing gear oil to escape. DISCLOSURE OF INVENTION An object of the present invention is to provide a far more reliable, durable type of geared elevator drive. According to the present invention, the gear case is made of a single piece. An access port is provided on the side of the case to insert the gear wheel. The bearing bore or holes for the shaft ball bearings are drilled simultaneously, ensuring that the shaft bearings, when inserted, are coaxial. According to the invention, the gear wheel is placed inside the case and then one end of the shaft inserted through one bearing hole towards the opposite bearing hole. The gear wheel is placed on the shaft. A ball bearing is inserted in the bore furthest from the shaft end that supports the sheave. A fitting on the end of the shaft is tightened to push the gear wheel onto the shaft by pushing the inner race of the bearing towards the gear wheel. The outer race of this bearing is pushed against a seat in the bearing bore by tightening a case cap that covers the bearing and the end of the shaft. The worm engages the gear wheel and is rotated to thread it down into a thrust bearing on the bottom of the case. A ball or roller bearing on the worm is held in place by a retainer or collar that is tightened (bolted) to the case from the top of the case with the motor removed. Among the features of the present invention is that it allows for a very rapid assembly and disassembly of the motor; the bearings are optimally aligned and the alignment will not change; and the only gasket is for the access port, which does not sustain any loading. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is an elevational view of a worm gear elevator drive of the "vertical type", the worm gear is vertical and the motor is on the top of the gear housing or case. FIG. 2 is a sectional view of part of the gear case as seen from the same direction as in FIG. 1; it exposes the gear wheel, shaft, shaft bearing components and other parts inside the case. FIG. 3 is a partial sectional view, as seen from the direction 3--3 in FIG. 1, and exposes the worm and its bearings and bearing retainer. BEST MODE FOR CARRYING OUT THE INVENTION As stated previously, FIG. 1 shows a "vertical" worm gear elevator drive motor. This drives contains a sheave 10 which is rotated by a motor 12 through a gear assembly (not visible) within a gear case 14. On the top of the motor 12 is a drum brake 16, simplistically shown being that it is commonly used in elevators. The operation of the brake is not germane to the invention; still it may be helpful to appreciate that a typical brake would have a drum that is bolted or otherwise attached to the motor shaft. The brake is operated when an elevator car is at a floor. Attached by a plurality of bolts to the case, a cover plate 16 closes access to the interior of the case. Assembly of the interior gear case components is conveniently made through the access provided when the plate is removed. Not shown, there is a gasket between the plate and the case. The sheave has been deleted in FIG. 2, which shows the internal components within the case 14, among them a circular gear wheel 20. Several features need to be observed. The shaft 22 is tapered and contains a key 26. The gear wheel, of course, fits tightly onto the taper and has a slot to receive the key. As in many drives, the gear teeth 28 are attached to the outside of the gear wheel, which acts more like a hub on which a rim, containing the teeth, is attached. These teeth are engaged by a worm 30, which is also visible in FIG. 3. The worm 30 extends upward partially through the motor. By means of a plurality of bolts 31 that extend down through the brake, the motor shaft and the brake and the worm are mechanically connected together. At the "sheave end" of the shaft 22, there is a ball bearing 32 that is held in place by a retainer ring 34. At the opposite end of the shaft, there is also a ball bearing 36. The bore holes for each of these ball bearings are on the same axis, that is, they are coaxial, having been machined by rotating the case or drilling the holes on a common axis. Special attention should be given to the way in which the bearing 36 is installed in the case and also to its relationship to the gear wheel. The way it is installed makes it possible to "hand assemble" the wheel gear on the shaft within the case; final assembly is achieved by positioning and adjusting externally accessible components. The size of the access hole into the case is minimized as access for tools is not required. Specifically, the bearing 36 is lightly pushed into the bore around the shaft, but between the bearing 36 and the gear wheel 20 is a thrust ring 38. The inner race of the bearing 36 is pushed against the thrust ring 38 as a thrust plate 40 is "tightened down" onto the end of the shaft. This pushes the thrust ring against the gear wheel, forcing the gear wheel tightly on the tapered portion of the shaft. The outer race 36.1 of the bearing 36 is held in place by a cover plate 42, and it contains an inner flange 44. That flange fits snugly in the bearing bore or hole, and pushes the outer race 36.1 into its seat when the cover plate is tightened down with the bolts 45. The gear teeth 28 are held on the gear wheel 20 by means of bolts. These bolts are not shown, but it should be understood that this type of attachment is common. However, access to the bolts is conveniently provided by removing the cover plate 42, exposing the holes 50, through which the bolts can be reached. Assembly of the motor and, for that matter, disassembly and repair is especially convenient. Using the single piece case 14, that is, with the bore holes for the bearings coaxially and simultaneously machined, the gear 20 with the gear teeth 28 thereon is first inserted into the side of the machine through the space provided by the removed plate 15. Holding the gear wheel 20 in one hand, the installer then inserts the shaft 22 through the right side of the case, directing the tapered end and the keyhole through the interior of the gear wheel 20. Then the spacer ring 38 is slid over the end of the shaft, passing through the interior of the bore hole. It is placed lightly against the gear wheel 20. The bearing 36 is then placed over the end of the shaft within the bore hole, an action which, as stated before, forces the inner race against the retainer ring and thereby holds the gear wheel 20 securely in place on the shaft. The worm is then separately installed from the top of the case 14 by rotating it so that it is "threaded down" by the wheel gear that it engages. As FIG. 3 shows, the worm is supported on two roller or ball bearings 56, 60. The bearing 56 rests in a seat 58 in the top of the case. The lower end of the worm 30 contains a narrow shaft area that fits into the bearing 60, a thrust roller or ball bearing. A retainer ring 64 is fastened in place onto the case, securing the bearing in place by pressing the outer race of the bearing into the seat 58. The worm contains a collar 70 which butts up against the inner race of the bearing 56. The worm 30 extends all the way up through the case. The motor, with the brake attached to the motor shaft, is installed on the case, and the motor shaft is attached to the worm. The worm 30 contains a key 72. The motor 14 drive shaft, which is not visible in the drawing, is hollow or tubular, a typical configuration, and the key registers with a keyway inside the shaft. The assembly is finally completed when the motor is then bolted in place on top of the motor and the motor and brake shaft is secured through bolts 31 to the worm 30. Then the cover plate 15 and the gasket 15.1 between it and the case are then installed using bolts 14.1. The foregoing is a description of the best mode for carrying out the invention, but it will be obvious to one skilled in the art that modifications and variations therein may be made in whole or in part without departing from the true scope and spirit of the invention.
An elevator drive has an electric motor 12 which drives a worm 30 that drives a gear 20,28 on a shaft 22, at right angles to the worm 30. The output shaft is in the horizontal plane, and an elevator rope sheave 10 is attached to this shaft 22. The shaft 22 is mounted on two bearings 32,36, at opposite ends of a single piece case 14. The drive is assembled by first inserting the gear 20,28 through the side of the case 14, then inserting the shaft 22 through one end of the case through the gear 20,28 and into the bearing 36. Then a thrust plate 40 is tightened down on the end of the shaft 22 to hold the shaft in place on the bearing's inner race and also thrust the gear 20,28 onto the shaft 22. The worm 30 is then inserted through the top of the case 14. Both shaft support bearings 32,36 are machined on the same axis.
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BACKGROUND OF THE INVENTION [0001] 1. Technical Field [0002] The invention relates to graphical user interfaces. More particularly, the invention relates to displaying forms and content in a browser. [0003] 2. Related Art [0004] The Internet has radically changed both the content and speed at which companies disseminate information. The Internet has also provided a means by which companies can assist their clients through the use of posting relevant information on the companies' web sites. The clients later visit the web sites and retrieve and or submit information from to the companies. [0005] The Internet has seen processing to specify and sometimes manipulate this information shift in location from being handled on the server providing a web site to the actual client computer (referred to herein as the client). One way of accomplishing scripting content for use on a client is through the use of Java. [0006] Java applets are small programs that run in the memory of a client. Despite developers striving to provide highly integrated content between the standard HTML and Java, conventional implementations of Java and HTML force a user to use various windows and different graphical user interfaces (GUIs) as HTML and Java are not tightly integrated. For example, FIG. 1 shows how a browser (for example, Netscape from Netscape, Inc. or Internet Explorer 5.5 from the Microsoft Corporation) handles HTML and Java. As is known in the art, the browser executes on a computer system comprising a processor and a display. FIG. 1A shows incoming HTML 101 being displayed in a browser 102 . FIG. 1B shows a Java applet 103 being received and run in browser 102 . While Java applets contain text, they do not normally contain HTML content. Any text in an applet is generally displayed as in a window 104 separate from that of the display of the running Java applet 105 . While most experienced users would not mind the opening and closing of various windows, novice users may become flustered. [0007] Further, Java applets are dynamically run on a user's machine. Because of the failure to store persistence information relating to previous interactions with the Java applet, navigation away from then back to the Java applet will re-execute the applet thereby replacing any previously entered information. [0008] A further problem that needs to be overcome when forms are displayed as a result of activating an HTML hyperlink is that navigating away from the form then back to the form can be difficult. If the Java form was treated as HTML content is conventionally treated, then the form may be lost in a long history of visited pages. Further, with Java applets, only one form is generally opened at a time as only one applet is normally active. Navigating to a new page or new form shuts down the previously running applet and fails to save previously entered information. FIG. 2 shows a user initiating an applet 202 from browser 201 . Prior to completing the interaction with applet 202 , a user may choose to navigate to new page 203 or back to page 201 . Attempting to re-navigate to applet 202 may completely refresh the running of the applet and destroy all previously entered information. For long forms, a user will quickly tire of needing to reenter previously entered information [0009] Accordingly, tighter integration between forms and content is needed. SUMMARY [0010] A system and method for integrating forms and content is disclosed. By integrating both forms and content, the drawbacks of the prior art are reduced. The present invention includes a container that houses an applet that displays both forms and HTML content. In other words, the present invention displays static HTML data and dynamic Java form data in a single window. The invention permits a user to interact with a form created by a Java applet, navigate away, and have the form content maintained in the applet as the applet is not shut down. Also, as the invention maintains the content of the form with its incorporated HTML content, a user may open a new form without concern that the previous form and content will be deleted. [0011] In one embodiment, the user may navigate static HTML hyperlinks to open new Java forms. The new form may be added to the running applet with a tab or other easy way of accessing the new form added to the graphical user interface displaying the forms. The user may navigate to HTML content from inside the running Java applet. Multiple forms may be opened simultaneously and may be accessed by tabs. In a further embodiment, an icon is displayed that, when activated, retrieves all forms and entered data. Activating the icon displays a graphical user interface that shows all open forms. The presence of this icon and its functionality assures a user that open forms and entered data may always be retrieved. By providing a way to access all open forms, the forms are not lost through a string of HTML navigations. [0012] The invention also allows integration of HTML content and Java forms by enabling the user to open a new form by clicking an HTML hyperlink. New HTML content may also be displayed by navigating links in the displayed forms. These links or buttons may include Help buttons and the like. Activating these links or buttons redirects the applet to display the content of the HTML page associated with the button or link. In this regard, the applet is not shut down but rather the content of the new page is displayed in the applet housed by the container. [0013] These and other aspects of the invention will be apparent from the following drawings and description. BRIEF DESCRIPTION OF DRAWINGS [0014] [0014]FIGS. 1A and 1B show conventional methods of displaying content and forms in browsers. [0015] [0015]FIG. 2 shows conventional navigation between forms and HTML pages. [0016] [0016]FIG. 3 shows the combination of forms and content in accordance with embodiments of the present invention. [0017] [0017]FIG. 4 shows the display of form content in response to user input in accordance with embodiments of the present invention. [0018] [0018]FIG. 5 shows an architecture for supporting the present invention. [0019] [0019]FIG. 6 shows a method for performing the present invention. DETAILED DESCRIPTION [0020] The present invention relates to displaying both forms and content in a common graphical user interface. The present invention may be embodied as a Java applet that, when retrieved and run in a browser, the invention displays a form or forms to a user. The Java applet is housed in a container. A container is an application program or subsystem in which the program building block known as a component is run. For example, a component—such as a button or other graphical user interface or a small calculator or database requester—may be developed using JavaBeans that can run in Netscape containers such as browsers and in Microsoft containers such as Internet Explorer, Visual Basic®, and Word. [0021] [0021]FIG. 3 shows a form displayed in accordance with embodiments of the present invention. Form 302 is a form displayed in display 301 . The contents of the form 302 are generated by a Java applet 304 . The applet also contains HTML information 303 . This information is also displayed in form 302 . The Java applet may be downloaded from the Internet, retrieved locally, or obtained by any other means of retrieving information known in the art. While FIG. 1 displays the content of a Java applet apart from the content of browser 102 as window 104 , the present invention combines both the HTML content and forms content together in a display of the form. [0022] The browser display 301 includes back button 305 and icon (or button) 306 . Activation of back button 305 directs the browser to display previously displayed content. As is known in the art, as one navigates HTML pages, links to the pages are stored in a history stack (not shown for simplicity). By activating the back button 305 , the browser is redirected to the top link in the history stack. The present invention includes the ability to add links to forms in the history stack. [0023] As an example, the browser 301 displays pane 302 comprising a form. The form includes HTML text 307 and buttons 311 and 312 . The form also includes form fields 308 and 310 . As shown in FIG. 3, the form may be used as forms are normally used including in ordering books on-line, in e-commence in general, in configuring systems (like a system gateway for a computer system), and other form related applications as are known in the art. [0024] The system uses Java-based classes including JEditorPane to control when a form is displayed. The form may include a variety of information as is known in the art. The system also instantiates objects from HTMLEditorKit classes to control the display of the HTML content 303 received from applet 304 . Finally, the system uses HyperLinkListener to monitor for operation of hyperlinks in pane 302 . While browser 301 may navigate to new content based on the activation of hyperlinks in it, operation of hyperlinks in pane 302 need to be controlled so as to not refresh the content of any dynamic forms in pane 302 . This is performed by having new forms or pages displayed in the running Java applet, rather than permitting the applet to be completely replaced by the browser's redirection to new content. With the use of the applets described here, one may use conventional browsers to realize the present invention. [0025] In one embodiment, the present invention displays HTML content by instantiating javax.swing.text.html.HTMLEditorKit and javax.swing.JeditorPane. The javax.swing.event.HyperlinkListener interface is implemented by the classes in the invention. The various classes are described in additional detail in respect to FIG. 5. [0026] HyperEvents with the description field starting with “http:// “ cause the corresponding HTML page to be displayed in area 302 . HyperlinkEvents with the description field starting with “form://” cause the container (specifically the workbench container 302 of FIG. 4) to be displayed in the browser and the corresponding form to be added as a new tab in the container 302 . [0027] The invention may be practiced using Java Developer Kit 1.2.2-001 available from Sun Microsystems, Inc. This developer kit contains the Java Runtime Environment 1.2.2-001. [0028] [0028]FIG. 4 shows browser 301 having multiple active forms in pane 302 . The forms are represented by tabs 401 , 402 , and 403 . A new tab 405 is shown in broken lines. The contents of each tab are shown in display region 404 once the tab is selected. The content of each form, represented by tabs 401 , 402 , and 403 , is separately maintained. Accordingly, navigation in window 404 does not refresh the currently displayed form or other forms (unless specified by, for example, navigation of a “reset” or “close” button as is known in the art). The Java forms get and set persistence information by communicating with a server process using one of the known communication protocols (for example, CORBA, RMI, or JDBC). [0029] [0029]FIG. 5 shows an architecture for supporting the invention. Applet 501 is from a class extending javax.swing.Japplet. Event manager 502 is a class implementing java.awt.event.ActionListener. History stack 503 is a stack class extending java.util.Stack. Workbench button 504 is a short cut button that, when activated, extends javax.swing.Jbutton. The action command field of this button is set to “wb://wb”. Workbench 505 is a class extending javax.swing.JtabbedPane (resulting in the tabbed panes of FIG. 4). Form factory 506 is a factory class as is known in the art that creates forms based on a string reference in the applet. Forms 507 and 508 are form classes extending javax.swing.JPanel. [0030] HTML Panel 509 is a class for displaying HTML content extending javax.swing.JEditoryPane with a javax.swing.text.html.HTMLEditorKit object set as the current editor kit. This class also implements javax.swing.event.HyperlinkListener. [0031] Back Button 510 is a navigation button extending javax.swing.JButton. The action or command field of this button is set to “back://back”. [0032] The flow of events are described as follows. All hyperlinks in the HTML content displayed in HTML Panel 509 are handled by the Panel 509 . When the Panel 509 receives a javax.swing.event.HyperlinkEvent, Panel 509 creates a java.awt.event.ActionEvent with the command field of the ActionEvent set to the description of the HyperlinkEvent. Panel 509 next forwards the ActionEvent to event manager 502 . Workbench 505 listens to events from controls (or buttons operable by the user) on open form objects ( 507 and 508 ). The workbench 505 may also perform some filtering by eliminating events that do not need additional action. All events that cause a new form or HTML page to become visible are forwarded to event manager 502 . All other events are ignored. Finally, event manager 502 listens to events from buttons 504 and 510 . [0033] When a relevant event occurs, event manager 502 determines what action to take in response to a java.awt.event.ActionEvent by examining the command field associated with the event. If the command field starts with “wb://”, then the follow steps occur: [0034] 1) If the HTML panel 509 is visible, then it is hidden; and, [0035] 2) If the Workbench 505 is hidden, it is made visible. [0036] If the command field starts with http://, then the following steps are taken: [0037] 1) If the HTML panel 509 is hidden, then it is made visible; [0038] 2) If the Workbench 505 is visible, it is hidden; [0039] 3) The current page of the HTML Panel is set to the command field; and, [0040] 4) A new entry is placed in stack 503 with the contents of the command field. [0041] If the command field starts with “form://” then the following steps are taken: [0042] 1) If the HTML panel 509 is visible, then it is hidden; [0043] 2) If the Workbench 505 is hidden, it is made visible; [0044] 3) The contents of the command field are passed to form factory 506 to create a new form object (for example, 507 and 508 ); [0045] 4) The newly created form object is added to the workbench 505 ; and [0046] 5) A new entry is placed in stack 503 with the contents set to “wb://wb”. [0047] If the command field starts with “back://”, then the following steps are taken: [0048] 1) The top entry (or other entry) of stack 503 is removed (or popped as is known in the art); and, [0049] 2) The contents of the newly removed stack entry are used to set the command field of the current ActionCommand and the ActionCommand is reprocessed. [0050] [0050]FIG. 6 shows a method of creating and navigating form content in accordance with the present invention and graphically shows the addition of a new form and HTML. In step 601 , a Java applet is run. In step 602 , the applet instructs a browser to open a display window and populates the window with form information, in step 603 . In step 604 , the Java applet retrieves HTML content and forwards the content to the browser for display in the window. In step 605 , the Java applet running in the browser monitors navigation commands. These commands may take the form of events generated through selection of hyperlinks or other actions as are known in the art (including activation of buttons, icons, and the like). In step 606 , the system determines if a new form is to be created. If so, the system adds a link to the currently displayed form or HTML page to the history stack (in step 607 ), displays the workbench container (in step 608 ) and adds a new tab ( 405 ) in the workbench container for accessing the new form (in step 609 ). [0051] In step 610 , the system determines if new HTML content is to be displayed. If so, the system adds a link to the current form or HTML page to the history stack (in step 611 ), hides the workbench container if visible (in step 612 ), and shows the new HTML page (in step 613 ). [0052] Otherwise, the system continues to monitor for new actions or commands. [0053] Various embodiments have been described. It is appreciated that various modifications of the embodiments are known to those of skill in the art and are considered within the scope of the present invention. For example, instead of using Java, one may use ActiveX controls to implement the current invention. Also, instead of using horizontally arranged tabs, one may use vertically arranged tabs. Further, one may substitute frames or a combination of frames and tabs to display forms. [0054] The scope of the invention is intended to be limited only by the following claims.
The present invention relates to a system and method for presenting both forms and content in a browser. The invention includes a Java applet having a graphical user interface that receives and projects HTML content to the user. By being able to combine both forms and non-forms content in a single interface, a tighter integration of information is achieved. Further, form content is maintained during navigation though storing active forms in a workbench.
6
INCORPORATION BY REFERENCE [0001] The disclosure of Japanese Patent Applications No. 2010-255737 filed on Nov. 16, 2010 and No. 2011-097123 filed on Apr. 25, 2011 including the specification, drawings and abstract is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates to a lock device and an electric power steering system. [0004] 2. Description of Related Art [0005] Conventional lock devices are described in, for example, Japanese Patent Application Publication No. 2010-219816 (JP 2010-219816 A) and Japanese Patent Application Publication No. 2002-308049 (JP 2002-308049). [0006] JP 2001-219816 describes a column-type electric power steering system provided with a steering lock device. An engagement portion is formed at a worm shaft side (input side), the worm shaft transmitting the rotation of an electric motor to a speed reducer, or at an electric motor output shaft side. A locked state is achieved by inserting a lock member into the engagement portion, and an unlocked state is achieved by removing the lock member from the engagement portion. [0007] The lock member is advanced or retracted with the use of an elastic member that urges (advances) the lock member toward the engagement portion and an actuator that attracts the lock member to remove (retract) the lock member from engagement portion. The lock member is advanced or retracted in the following manner. When an ignition key is turned on, electric current application to a solenoid that serves as the actuator and that is fixed to a casing is controlled. Thus, an attraction force that counteracts an urging force generated by the elastic member is generated to retract the lock member provided with a moving core so that the lock member is removed from the engagement portion. As a result, the unlocked state is achieved. When the ignition key is turned off, attraction of the moving core by the solenoid is stopped, and the lock member is advanced toward the engagement portion by an urging force generated by the elastic member. As a result, the lock member is engaged with the engagement portion, whereby the locked state is achieved. [0008] As described above, the locked state and the unlocked state are achieved at the electric motor output shaft side or at the worm shaft side that is the input side of the speed reducer (i.e., at a stage prior to output of assist torque based on the torque applied to a steering wheel). Thus, in the locked state where the lock member is engaged with the engagement portion, a large force based on the torque applied to the steering wheel is no longer applied directly to the lock member, which enables downsizing of the lock member. [0009] However, when the ignition switch is on, electric current is applied to a coil to retract the lock member from the engagement portion. Therefore, if, for example, breakage of a harness, disconnection of a connector, or an instantaneous reduction in battery voltage occurs, electric current application to the coil is stopped. As a result, the lock member is advanced and engaged with the engagement portion due to an urging force generated by the elastic member. In some cases, the steering wheel may be locked while a vehicle is traveling. With this regards, there is still room for improvement. [0010] JP 2002-308049 describes a structure in which a key portion and a lock mechanism portion of a steering shaft are unitized so as to be mechanically linked to each other. In the structure, a cam member that rotates together with a key rotor is provided between the key rotor and the lock mechanism portion of the steering shaft and extends to the lock mechanism portion coaxially with the key rotor. A locking lever that is linked to insertion and removal of the key is provided. When the key is turned from ACC position to LOCK position, the cam member is operated. In accordance with the operation of the cam member, the lock member that is provided at the lock mechanism on the steering shaft side is operated and is brought to a state where the lock member can be locked with the steering shaft. When the key is removed from LOCK position, the locking lever is operated. In accordance with the operation of the locking lever, the lock member is operated to be inserted in a groove of the steering shaft. Thus, the locked state is achieved. [0011] JP 2002-308049 A describes the structure in which the key portion and the lock mechanism portion of the steering shaft are unitized so as to be mechanically liked to each other. Therefore, if the key portion is provided at an instrument panel at a driver's seat, the lock mechanism portion is located in front of the knee of a driver, which may impose restrictions on the strength and installation position of the lock mechanism portion. [0012] In order to address this problem, the following configuration may be employed. An operation portion such as a key device and an actuator portion such as a lock mechanism are separated from each other. A lock member at the lock mechanism is moved to the lock position by a spring member. When the key is inserted and turned to ACC position (when locking is cancelled), the fact that the key is turned to ACC position is detected by, for example, detection unit, and drive unit such as a motor is driven based on a detection signal to move the lock member to the locking cancellation position. [0013] A device is required which maintains the locking cancellation state so that the locking operation is not erroneously performed in the locking cancellation state where locking by the lock member is cancelled. Conventionally, the key portion and the lock mechanism portion of the steering shaft are mechanically linked to each other. Therefore, as long as the key rotor is at a predetermined rotation position, the locking cancellation state where locking by the lock member is cancelled is maintained by the cam member. [0014] In the above-described structure where the operation portion such as the key device and the actuator portion such as the lock mechanism are separated from each other, there is no cam member. Accordingly, it is necessary to provide a device that maintains the locking cancellation state, at the actuator portion. For example, a locking cancellation maintaining member is attached to a plunger of a solenoid, which is an electric drive unit. An electric signal is generated based on the operation of the operation portion, the solenoid is driven according to the electric signal, and the locking cancellation state in which locking by the lock member is cancelled is maintained by the locking cancellation maintaining member. However, in the structure in which the locking cancellation maintaining member is operated by electric drive unit such as a solenoid, malfunction due to an electrical problem (e.g., breakage of a harness, disconnection of a connector, or an instantaneous reduction in battery voltage) may occur. In this regard, there is still room for improvement. SUMMARY OF THE INVENTION [0015] It is an object of the invention to provide a lock device that is able to reliably maintain the locked state with low power consumption while operating a lock cancellation maintaining member using an electric drive unit without being affected by an electrical trouble. [0016] An aspect of the invention relates to a lock device that restricts movement of a movable body. The lock device includes: a lock member that is engageable with an engagement portion formed at the movable body; an urging member that urges the lock member in a direction away from the engagement portion; and an actuator that moves the lock member toward the engagement portion to engage the lock member with the engagement portion against an urging force generated by the urging member. [0017] With the configuration described above, even if electric current application to a coil or electric current application to the actuator is stopped due to an electrical trouble, for example, breakage of a harness, disconnection of a connector or an instantaneous drop in battery voltage, it is possible to maintain the disengaged state by moving the lock member using the urging member. [0018] As a result, even if electric current application is stopped, the lock member is maintained in the disengaged state. BRIEF DESCRIPTION OF THE DRAWINGS [0019] Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein: [0020] FIG. 1 is an overall view of an electric power steering system according to an embodiment of the invention; [0021] FIG. 2 is a partial sectional view which is taken along the line II-II in FIG. 1 , and from which a steering wheel and a universal joint are omitted; [0022] FIG. 3 is a sectional view taken along the line III-III in FIG. 2 ; [0023] FIG. 4 is a view showing the structure of a steering lock device; [0024] FIG. 5 is an electrical diagram for the steering lock device; [0025] FIG. 6 is a graph showing the relationship between a stroke of a lock pin of the steering lock device and forces that act on the lock pin while electric current is not applied; [0026] FIG. 7 is a graph showing the relationship between a stroke of the lock pin of the steering lock device and forces that act on the lock pin while electric current is applied to achieve the locked state; [0027] FIG. 8 is a graph showing the relationship between a stroke of the lock pin of the steering lock device and forces that act on the lock pin while electric current is applied to achieve the unlocked state; [0028] FIG. 9 is a view showing the state where the lock pin of the steering lock device is about to start advancing from the unlock end; [0029] FIG. 10 is a view showing the state where the lock pin has advanced from the unlock end in FIG. 9 and a lock detection switch is turned on; [0030] FIG. 11 is a view showing the state where the lock pin has further advanced and come close to the lock end; [0031] FIG. 12 is a view showing the state where the lock pin is about to start retracting from the lock end; [0032] FIG. 13 is a state where the lock pin has retracted from the lock end in FIG. 12 and the lock detection switch is turned off; [0033] FIG. 14 is a state where the lock pin has further retracted and come close to the unlock end; and [0034] FIG. 15 is a flowchart showing an operation of the steering lock device. DETAILED DESCRIPTION OF EMBODIMENTS [0035] Hereafter, an embodiment of the invention will be described with reference to the accompanying drawings. As shown in FIG. 1 and FIG. 2 , an input shaft 1 of an electric power steering system is rotatably supported by a steering column 2 . The input shaft 1 includes an upper shaft 4 and a lower shaft 6 . A steering wheel 3 is attached to the upper shaft 4 . The lower shaft 6 is fitted in a tubular portion 5 formed at a lower end portion of the upper shaft 4 such that relative rotation between the lower shaft 6 and the tubular portion 5 is restricted and such that relative displacement between the tubular portion 5 and the lower shaft 6 in the axial direction is allowed if an axial force equal to or larger than a predetermined value is applied. Accordingly, if a driver hits the steering wheel 3 upon a vehicle collision and an axial force equal to or larger than the predetermined value is applied to the input shaft 1 , the upper shaft 4 is displaced relative to the lower shaft 6 in the axial direction. Thus, impact energy is absorbed. [0036] The steering column 2 includes a tubular upper column 8 and a tubular lower column 9 . The upper column 8 rotatably supports the upper shaft 4 via a bearing 7 . The lower column 9 is fitted at its upper end portion to the inner periphery of a lower end portion of the upper column 8 . An upper bracket 10 is used to fit the upper column 8 to a vehicle body. If a vehicle collision occurs and the upper column 8 is moved forward due to an impact, the upper bracket 10 is removed from the vehicle body, thus allowing the upper column 8 and the upper shaft 4 to move forward. [0037] A housing 11 is fixed to a lower end of the lower column 9 , and fitted to the vehicle body via a lower bracket 12 . An output shaft 13 is an output member rotatably supported by the housing 11 , and is connected to the lower shaft 6 via a torsion bar 14 . The output shaft 13 is connected to steered wheels 18 via, for example, a universal joint 15 , an intermediate shaft 16 , and a rack and pinion mechanism 17 . A torque detector 19 detects a steering torque that is applied to the input shaft 1 via the steering wheel 3 . The steering torque is detected by electrically measuring a minute relative rotational displacement between the input shaft 1 and the output shaft 13 , which is proportional to torsion of the torsion bar 14 due to the steering torque. [0038] As shown in FIG. 3 , a wheel gear 21 of a speed reducer 20 is fixed to the output shaft 13 . A worm shaft (input member of the speed reducer 20 ) 22 is rotatably supported by the housing 11 at both ends via bearings 23 , and is in mesh with the wheel gear 21 . An electric motor 24 is fixed to the housing 11 . An output shaft 25 that serves as a rotational output member of the electric motor 24 is spline-connected to the worm shaft 22 . A ring 31 having a plurality of lock holes (engagement portions) 29 in its periphery is fitted to the output shaft 25 . A steering lock device (lock device) 35 is fixed to the housing 11 . The steering lock device 35 places the output shaft 25 in the locked state by inserting a lock pin (lock member) 26 into the lock hole 29 formed in the ring 31 fitted to the output shaft 25 , and places the output shaft 25 in the unlocked state by removing the lock pin 26 from the lock hole 29 . [0039] Next, the structure of the steering lock device 35 will be described with reference to FIG. 4 . The steering lock device 35 includes an actuator 30 and the ring 31 . The actuator 30 causes the lock pin 26 to advance toward the lock hole 29 or to retract from the lock hole 29 . The ring 31 is fitted to the output shaft 25 of the motor 24 , and has the multiple lock holes 29 in its periphery. [0040] The actuator 30 has a plunger 51 that is secured to the lock pin 26 so as to move together with the lock pin 26 . The plunger 51 is formed of a magnet with one pole pair. For example, as shown in FIG. 4 , the left side portion of the plunger 51 is the south pole, and the right side portion of the plunger 51 is the north pole. [0041] A coil 52 is wound around the plunger 51 to generate an electromagnetic force for advancing or retracting the lock pin 26 . The coil 54 is surrounded by a yoke 53 that serves as a magnetic path for an electromagnetic force generated by the coil 54 . [0042] Two bushes 55 are provided between the plunger 51 and the coil 54 . Thus, the plunger 51 is smoothly advanced or retracted by an electromagnetic force generated by the coil 54 . [0043] A front portion of the actuator 30 is covered with a front cover 56 . A compression spring (urging member) 28 , which is used to remove the lock pin 26 from the lock hole 29 formed in the ring 31 fitted to the output shaft 25 of the electric motor 24 , is provided between the front cover 56 and the left end of the plunger 51 . [0044] A rear portion of the actuator 30 is covered with a rear cover 57 . A lock detection switch (lock detection unit) 45 , which detects the state of engagement of the lock pin 26 with the lock hole 29 based on the position of the plunger 51 , is provided between the rear rover 57 and the yoke 53 . [0045] Next, the electrical configuration of the steering lock device 35 will be described with reference to FIG. 5 . A control unit for the steering lock device 35 includes an ECL 40 that is a main control portion, a battery 46 , an ignition switch 44 , the lock detection switch 45 , and the actuator 30 . [0046] The ECU 40 includes a CPU 41 that executes control processes, an input interface (I/F) 42 , and an output interface (I/F) 43 . The input interface 42 receives signals from the ignition switch 44 and the lock detection switch 45 . The output interface 43 outputs electric current to the actuator 30 . [0047] Next, the operations of the steering lock device 35 and the ECU 40 for the steering lock device 35 will be described with reference to FIGS. 6 , 7 and 8 . [0048] With regard to the ordinate axis in FIG. 6 , the upward arrow represents a retraction force Fr for retracting the lock pin 26 from the lock hole 29 (placing the lock pin 26 in the disengaged state), and the downward arrow represents an advance force for advancing the lock pin 26 toward the lock hole 29 . [0049] The abscissa axis represents a stroke of the lock pin 26 . When the lock pin 26 is in the state shown in FIG. 4 , the stroke is zero. The stroke in this state is indicated by an unlock end (retraction end) P 1 . As the lock pin 26 moves toward a lock end (advance end), the value of stroke shifts rightward on the abscissa axis. [0050] L 1 indicates the relationship between the stroke of the lock pin 26 and a retraction force Fr, generated by the compression spring 28 , for retracting the lock pin 26 from the lock hole 29 . L 2 indicates an attraction force that acts between the magnet with one pole pair, which constitutes the plunger 51 , and the yoke 53 . The attraction force acts as an advance force Fa for advancing the lock pin 26 toward the lock hole 29 . [0051] L 3 indicates a resultant of L 1 and L 2 while electric current is not applied to the coil 54 , that is, a resultant of the retraction force Fr generated by the compression spring 28 and the attraction force (advance force) Fa that acts between the plunger 51 and the yoke 53 . P 3 indicates a balance point at which the retraction force Fr generated by the compression spring 28 and the advance force Fa that acts between the plunger 51 and the yoke 53 cancel out each other. P 10 indicates a position to which the lock pin 26 is allowed to be advanced maximally by the resultant of the retraction force Fr generated by the compression spring 28 and the attraction force Fa that acts between the magnet of the plunger 51 and the yoke 53 . Note that, the lock pin 26 is configured to mechanically stop at the lock end (advance end) P 2 , therefore, the lock pin 26 never reaches P 10 . [0052] Between P 1 and P 3 , the retraction force Fr is larger than the advance force Fa, and therefore a force for retracting the lock pin 26 acts on the lock pin 26 . Between P 3 and P 10 , the advance force Fa is larger than the retraction force Fr, and therefore a force for advancing the lock pin 26 acts on the lock pin 26 . [0053] As a result, when the value of stroke is on the left side of P 3 , the lock pin 26 is pushed by the retraction force Fr generated by the compression spring 28 such that the lock pin 26 is directed toward the unlock end (retraction end) P 1 . That is, the unlocked state is achieved. [0054] Next, as indicated by L 4 in FIG. 7 , a lock pin advancing current Ia is applied to the coil 54 of the actuator 30 by the ECU 40 to apply the advance force Fa that overcomes the retraction force Fr generated by the compression spring 28 to the lock pin 26 . Then, the lock pin 26 is advanced by a resultant (indicated by L 5 ) of the advance force Fa indicated by L 4 and the retraction force Fr indicated by L 3 . [0055] The lock pin advancing current Ta is shut off at a stroke (e.g., P 4 ) at which the lock pin 26 is able to be advanced even when electric current is not applied to the coil 54 of the actuator 30 by the ECU 40 as shown by L 3 . Then, the advance force Fa is shifted from the advance force Fa indicated by L 5 to the advance force Fa indicated by L 3 at P 4 . However, the advance force Fa continuously acts on the lock pin 26 to bring the lock pin 26 to the lock end (advance end) P 2 at which the lock pin 26 mechanically stops, and the lock pin 26 is maintained at the lock end P 2 (engaged state). That is, the locked state is achieved. As described later in detail (see FIG. 15 ), whether the lock pin 26 has reached P 4 is determined based on a signal from the lock detection switch 45 and a value indicated by a lock pin advance checking timer Tr 1 . More specifically, when the lock pin 26 reaches P 4 , the lock pin 26 is in an immediately-before engaged state that is a state achieved immediately before the engaged state where the tip of the lock pin 26 reaches the lock end of the lock hole 29 formed in the ring 31 . As a result, the lock pin advancing current Ia is shut off at P 4 . Therefore, steering lock is achieved in the electric power steering system with lower power consumption. [0056] As indicated by L 6 in FIG. 8 , a lock pin retracting current Ib is applied to the coil 54 of the actuator 30 by the ECU 40 to apply the retraction force Fr that overcomes the resultant of the compressing spring force and the attraction force that acts between the magnet that constitutes the plunger 51 and yoke 53 . With the resultant, steering lock has been maintained. Then, the lock pin 26 is retracted by a resultant (indicated by L 7 ) of the retraction force Fr indicated by L 6 and the advance force Fa indicated by L 3 . [0057] The lock pin retracting current Ib is shut off at a stroke (e.g., P 5 ) at which the lock pin 26 is able to be retracted even when electric current is not applied to the coil 54 of the actuator 30 by the ECU 40 as shown by L 3 . Then, the retraction force Fr is shifted from the retraction force Fr indicated by L 7 to the retraction force Fr indicated by L 3 at P 5 . However, the retraction force Fr continuously acts on the lock pin 26 to bring the lock pin 26 to the unlock end (retraction end) P 1 at which the lock pin 26 mechanically stops, and the lock pin 26 is maintained at the unlock end P 1 . As described later in detail (see FIG. 15 ), whether the lock pin 26 has reached P 5 is determined based on a signal from the lock detection switch 45 and a value indicated by a lock pin retraction checking timer Tr 2 . [0058] Next, transition of the steering lock device 35 from the unlocked state to the locked state and transition of the steering lock device 35 from the locked state to the unlocked state will be described with reference to FIG. 9 to FIG. 14 . [0059] As shown in FIG. 9 , in the state where the plunger 51 secured to the lock pin 26 so as to move together with the lock pin 26 is standstill at the unlock end P 1 , electric current is applied to the coil 54 of the actuator 30 by the ECU 40 . Electric current is applied to the coil 54 of the actuator 30 in such a direction that the north pole is formed in the left side portion of the yoke 53 and the south pole is formed in the right side portion of the yoke 53 (see Ia in FIG. 5 ). Thus, the south pole of the plunger 51 is attracted to the north pole formed in the yoke 53 , and the plunger 51 is advanced toward the lock hole 29 . [0060] When the plunger 51 is advanced to a predetermined position (P 4 in FIG. 7 ), the lock detection switch 45 is turned on as shown in FIG. 10 . Therefore, based on a signal from the lock detection switch 45 and a value indicated by the lock pin advance checking timer Tr 1 , electric current application to the coil 54 of the actuator 30 is stopped by the ECU 40 . The south pole of the plunger 51 has been attracted to the north pole formed in the yoke 53 , and thus the plunger 51 has been advanced. However, the north pole that has been formed in the yoke 53 disappears when electric current application to the coil 54 is stopped. [0061] However, even if electric current application to the coil 54 of the actuator 30 is stopped by the ECU 40 when the lock pin 26 reaches the predetermined position (P 4 in FIG. 7 ), a magnetic force acts between the plunger 51 formed of the magnet with one pole pair and the yoke 53 made of magnetic material. Thus, the lock pin 26 is advanced to the lock end P 2 against a spring force of the compression spring 28 , and the lock pin 26 is maintained at the lock end P 2 (see FIG. 11 ). The lock pin advancing current Ia is shut off at P 4 . Therefore, it is possible to achieve steering lock in the electric power steering system with lower power consumption. [0062] Next, if the ignition switch 44 is turned on when the plunger 51 is stopped at the lock end P 2 as shown in FIG. 12 , electric current is applied to the coil 54 of the actuator 30 by the ECU 40 . Electric current is applied to the coil 54 of the actuator 30 in such a direction that the south pole is formed in the left side portion of the yoke 53 and the north pole is formed in the right side portion of the yoke 53 (see Ib in FIG. 8 ). Then, the south pole of the plunger 51 repels the south pole formed in the yoke 53 , and the spring force of the compression spring 28 is added to the repelling force. With this force, the lock pin 21 secured to the plunger 51 is retracted from the lock hole 29 . [0063] When the plunger 51 is retracted to a predetermined position (P 5 in FIG. 8 ), the lock detection switch 45 is turned off as shown in FIG. 13 . Therefore, based on a signal from the lock detection switch 45 and a value indicated by the lock pin retraction checking timer Tr 2 , electric current application to the coil 54 of the actuator 30 is stopped by the ECU 40 . However, at this time, the plunger 51 is retracted to the unlock end P 1 by a resultant of a spring force of the compression spring 28 and a magnetic force that acts between the plunger 51 and the yoke 53 (see FIG. 14 ). [0064] Next, the operations of the steering lock device 35 and the ECU 40 will be described in detail with reference to a flowchart shown in FIG. 15 . First, it is determined whether the ignition switch 44 is off (step 101 ). If it is determined in step 101 that the ignition switch 44 is off (YES in step 101 ), the lock pin advance checking time Tr 1 is reset (step 102 : Tr 1 =0). [0065] Next, electric current is applied to the coil 54 of the solenoid 30 in such a direction that the lock pin 26 is advanced (step 103 : apply current Ia). Further, the lock pin advance checking timer Tr 1 is incremented (step 104 : Tr 1 =Tr 1 +T 1 ). [0066] Next, it is determined whether the value indicated by the lock pin advance checking time Tr 1 is equal to or larger than a predetermined value (step 105 : Tr 1 ≧Tr 01 ). If the value indicated by the lock pin advance checking timer Tr 1 is equal to or larger than the predetermined value (YES in step 105 : Tr 1 ≧Tr 01 ), it is determined whether the lock detection switch 45 is on (step 106 ). [0067] If the lock detection switch 54 is on (YES in step 106 ), electric current application to the coil 54 of the actuator 30 is stopped (step 107 : stop application of current Ia), after which the process ends. Thus, the lock pin 26 is engaged with the lock hole 29 , whereby the locked state is achieved. If the value indicated by the lock pin advance checking time Tr 1 is smaller than the predetermined value (NO in step 105 : Tr 1 <Tr 01 ), or if the lock detection switch 45 is off (NO in step 106 ), step 103 is executed again to apply electric current to the coil 54 of the actuator 30 in such a direction that the lock pin 26 is advanced (step 103 :apply current Ia). [0068] If it is determined in step 101 that the ignition switch 44 is on (NO in step 101 ), the lock pin retraction checking time Tr 2 is reset (step 108 : Tr 2 =0). [0069] Then, electric current is applied to the coil 54 of the actuator 30 in such a direction that the lock pin 26 is retracted (step 109 : apply current Ib). In addition, the lock pin retraction checking time Tr 2 is incremented (step 110 : Tr 2 =Tr 2 +T 2 ). [0070] Next, it is determined whether the lock detection switch 45 is off (step 111 ). If the lock detection switch 45 is off (YES in step 111 ), it is determined whether the value indicated by the lock pin retraction checking time Tr 2 is equal to or larger than a predetermined value (step 112 : Tr 2 ≧Tr 02 ). If the value indicated by the lock pin retraction checking time Tr 2 is equal to or larger than the predetermined value (YES in step 112 : Tr 2 ≧Tr 02 ), electric current application to the coil 54 of the actuator 30 is stopped (step 113 : stop application of current Ib), after which the process ends. Thus, the lock pin 26 is disengaged from the lock hole 29 , whereby the unlocked state is achieved. [0071] If the lock detection switch 45 is on (NO in step 111 ), or if the value indicated by the lock pin retraction checking timer Tr 2 is smaller than the predetermined value (NO in step 112 : Tr 2 <Tr 02 ), step 109 is executed again to apply electric current to the coil 54 of the actuator 30 in such a direction that the lock pin 26 is retracted (step 109 : apply current Ib). [0072] According to the present embodiment, the following operations and effects are obtained. The steering lock device 35 is configured such that, when the ignition switch is turned on, electric current is applied to the coil 54 of the actuator 30 in such a direction that the lock pin 26 secured to the plunger 51 moves away from the ring 31 that has a plurality of lock holes 29 in its periphery and that is fitted to the output shaft 25 of the electric motor 24 . In addition, the urging member for increasing a force for moving the lock pin 26 away from the ring 31 is provided. [0073] With the configuration described above, when the ignition switch 44 is on, in other words, when the steering wheel 3 is being operated, the unlocked state is maintained by a spring force of the urging member. [0074] With the configuration described above, even if electric current application to the coil is stopped due to an electrical problem (for example, breakage of a harness, disconnection of a connector, or an instantaneous drop of battery voltage), it is possible to maintain the disengaged state by retracting the lock member using the urging member. [0075] As a result, even if electric current application is stopped, the lock member is maintained in the disengaged state. [0076] In addition, the steering lock device 35 is configured such that, when the ignition switch is turned off, electric current is applied to the coil 54 of the actuator 30 by the ECU 40 in such a direction that the lock pin 26 secured to the plunger 51 is engaged with the ring 31 that has a plurality of lock holes 29 in its periphery and that is fitted to the output shaft 25 of the electric motor 24 . [0077] When the lock detection switch 45 that detects the position of the plunger 51 secured to the lock pin 26 is turned on, electric current application is stopped based on a signal from the lock detection switch 45 and a value indicated by the lock pin advance checking timer Tr 1 . After that, the lock pin 26 is advanced by a magnetic force acting between the yoke 53 of the actuator 30 and the magnet with one pole pair, which is fitted to the plunger 51 , and then engaged with the engagement portion formed in the rotational output member of the electric motor 24 . [0078] With the configuration described above, when the lock pin 26 is advanced beyond P 4 and approaches P 2 , even if electric current application to the coil 54 of the actuator 30 is stopped, the lock pin 26 is engaged with the engagement portion formed in the rotational output member of the electric motor 24 by a magnetic force between the plunger 51 formed of the magnet with one pole pair and the yoke 53 made of magnetic material. [0079] As a result, steering lock in the electric power steering system is maintained with lower power consumption. [0080] In the present embodiment, the ring 31 is provided at the output shaft 25 of the motor 24 . Accordingly, the engagement force of the lock device 35 is increased by the speed reducer 20 . As a result, steering lock is achieved with lower power consumption. [0081] The present embodiment may be modified as follows. [0082] In the present embodiment, the invention is applied to a column assist-type EPS. Alternatively, the invention may be applied to a rack assist-type EPS or a pinion assist-type EPS. [0083] In the present embodiment, the steering lock device is actuated based on the on/off state of the ignition switch. However, how the steering lock device is actuated is not limited to this. The steering lock device may be actuated by a remote controller that uses radio waves or infrared rays. [0084] In the present embodiment, the left side portion of the plunger 51 is the south pole, and the right side portion of the plunger 51 is the north pole. However, as a matter of course, the right side portion of the plunger 51 may be the south pole and the left side portion of the plunger 51 may be the north pole. [0085] In the present embodiment, a magnet with one pole pair is used as the plunger 51 . Alternatively, a magnet with two or more pole pairs may be used as the plunger 51 . [0086] If the steering lock device according to the present embodiment is applied to a hybrid vehicle, a plug hybrid vehicle or a electric vehicle having a large-capacity battery, it is possible to maintain steering lock state for a long period of time. [0087] According to the invention, it is possible to provide a lock device that is able to maintain a lock member in the disengaged state and to reliably maintain the locked state with low power consumption while operating a lock cancellation maintaining member using an electric drive unit without being affected by an electrical trouble.
A lock device that restricts movement of a movable body includes: a lock member that is engageable with an engagement portion formed at the movable body; an urging member that urges the lock member in a direction away from the engagement portion; and an actuator that moves the lock member toward the engagement portion to engage the lock member with the engagement portion against an urging force generated by the urging member.
8
BACKGROUND OF THE INVENTION This invention relates to the opening of a gap for the passage of the needle thread between the nonrotating bobbin case of a rotary sewing machine loop taker and the rotation restraining means for the bobbin thread case. The gap between the position finger and the bobbin case, through which the thread has to pass just prior to stitch setting, tends to be closed due to the frictional forces caused by the rotating loop taker body during operation. This results in an interference with passage of the thread loop which can cause several sewing malfunctions, for example, the formation of loops in the resulting stitches, imperfect stitch setting, and thread breakage. It is known in the sewing machine art to provide a bobbin thread case opener for the purpose of allowing the passage of the needle thread between the bobbin thread case and the bobbin case rotation restraining means. Conventional bobbin case opener employs two spaced bobbin case rotation restraining means relatively movable so as to be alternately effective and thus to provide for an escapement. In such conventional bobbin case opener mechanism, the timing of the opener drive is critical, and the spaced rotation restraining means double the chance of a problem arising as the thread passes there through. SUMMARY OF THE INVENTION It is the object of this invention to provide an improved bobbin thread case opener effective to allow the passage of the needle thread loop past the bobbin thread case rotation restraining means in a sewing machine. This is accomplished by restraining the bobbin thread case in only one place, and vibrating the restraining means at a frequency greater than four complete cycles for each revolution of the loop taker. DESCRIPTION OF THE DRAWINGS The accompanying drawings illustrate a preferred form of this invention in which: FIG. 1 represents a front elevational view of a lock stitch sewing machine loop taker showing the bobbin thread case opener and portions of the sewing machine frame as well as the needle and needle thread; FIG. 2 is a top plan view of the loop taker and bobbin thread case opener of FIG. 1 with the sewing machine frame shown in section; FIG. 3 is a cross section taken substantially along line 3--3 of FIG. 1. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 3 of the drawings, 10 illustrates a bobbin case which includes a bobbin case base 12 which is formed with a bearing rib 14 journaled in a raceway 16 formed in the rotary loop taker 18. The rotary loop taker 18 is mounted on a loop taker shaft 22 in the machine frame 24. A loop seizing beak 26 formed on the rotary loop taker serves to engage and draw out loops of needle thread manipulating such needle thread loops about an under thread supply in the bobbin case in the formation of each stitch. By providing a gap 28 in the bearing rib 14 and a gap 30 in the rotary loop taker raceway 16, and by preventing the base 12 from rotating with the rotary loop taker 18 so that the gaps 28 and 30 may periodically overlap, it will be appreciated that the needle thread loop can enter between the base 12 and the rotary loop taker 18 when the gaps 28 and 30 overlap, and after being drawn completely about the bobbin, the needle thread loop may be withdrawn from between the base 12 and the rotary loop taker 18 when the gaps 28 and 30 again overlap. The bobbin case 10 is also provided with a bobbin case cover 32 which can serve many purposes such as that of latching the bobbin in place on the base 12, that of providing a smooth, snag-free outer shell over which the needle thread loop can pass, and that of supporting a bobbin thread tensioning means. The cover 32 and the base 12 together thus provide a bobbin case 10 which is required to be restrained against rotation with the rotating loop taker. To provide for such rotation restraint as best illustrated in FIG. 1, the bobbin case 10 is formed with a pair of spaced abutments 34 and 36 each disposed substantially radially of the path of motion of the rotary loop taker and arranged facing each other. Cooperating with the spaced abutments 34 and 36 to provide the sole rotation restraint for the bobbin case is a rotation restraining arm 38 formed with a laterally extending stop member 40 arranged to extend between the spaced abutments 34 and 36 with a gap or clearance therebetween. Because of the frictional drag exerted by the rotating loop taker on the bearing rib 14, the abutment 34 will be forced against the stop member 40. The rotation restraining arm 38 is formed integral with a bracket 42 which is slidably restrained between guide elements 44 secured to the frame 24. The bracket 42 is also formed with a vertical slot 45 which accommodates an eccentric pin 46 mounted on a drive shaft 48. The drive shaft 48 has a gear 50 mounted thereto, meshing with a gear 52 mounted on the hook shaft 22. Preferably the gearing 50, 52 will rotate the drive shaft 48 at a speed greater than four revolutions to every one revolution of the hook shaft 22. Therefore, the eccentric 46, which is arranged in the vertical slot 45 of the bracket 42, will drive the rotation restraining arm 38 in an reciprocatory motion at the same frequency at which the drive shaft 48 rotates. The laterally extending stop member 40, which is disposed with clearance between the spaced abutments 34 and 36, will thus vibrate between the spaced abutments 34 and 36 preferably at an amplitude less than the gap or clearance. At very low sewing speeds, the bobbin case 10 can follow the oscillatory movements of the stop member 40 so that the abutment 34 will remain in contact therewith. Since the friction force will be exceedingly low at slow speeds, however, no serious impediment to thread loop passage will be experienced. At higher sewing speeds, on the contrary the inertia of the bobbin case 10 will impede its movement so that the abutment 34 will no longer follow and remain in contact with the stop member 40. Instead, the spaced abutments 34 and 36 will oscillate relatively to the stop member repeatedly opening gaps therebetween through which the needle thread loop may pass freely. Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. For instance, the stop member 40 may be driven from an electrical oscillator rather than from a mechanical drive connection to the drive shaft 22. Since no timed relation between the stop member vibration and loop taker movement would then exist, an oscillator should be chosen with a frequency at least four times greater than the maximum possible loop taker speed. In order to keep the required driving energy small for parts oscillating with high frequency, it is of advantage to operate oscillating systems at or near the natural frequency (resonance frequency) of the bobbin thread case opener mechanism. In mechanically driven systems for oscillating the stop member to serve as a gap opener for a high speed lock stitch machine which depend on the operating speed of the sewing machine, the natural frequency can be varied by changing the length or the mass of the member 40 functionally coupled with the mechanical drive shaft 48. For an electro-magnetically driven oscillating system using a selected oscillator for constant high frequency, it will be required to adjust the ratio of the driving frequency to the oscillating frequency electrically whereby this ratio will be kept substantially at 1 for obtaining the resonance frequency and also for optimizing the oscillating amplitude. Such electrical adjustment of the oscillating frequency may become necessary in order to compensate for variations in frictional forces and to maintain stable operating conditions.
A lock stitch sewing machine having a rotary loop taker adapted to carry a loop of thread about a stationary bobbin thread case. The bobbin thread case is restrained from rotation by a finger which is disposed between abutments in the bobbin thread case for opening a passage to allow the needle thread loop past the bobbin thread case rotation restraining means, the rotation restraining finger is vibrated at a frequency greater than four cycles per rotation of the loop taker.
3
BACKGROUND [0001] The present invention relates to a packaging for a consumer product. [0002] Many consumer products are scented. Often, a consumer wishes to sample the scent before purchasing the product in a store. When the product is a product such as an anti-perspirant or deodorant composition winch is sold in a roll-on or stick format, there is a problem that a user may remove the cap protecting the roll-ball or stick to try to sample the scent of the composition within the container. Other consumer products, such as liquid soap and detergents may have a seal that would have to be removed in order to sample the scent. [0003] Historically, shoppers of roll-on products tend to remove the cap to smell the packaged product, often spinning the ball with their finger in order to wet the finger with the product, and then replace the cap. Shoppers of stick products also tend to open the cap to smell the packaged product, often causing the dome, or factory finish, which temporarily protects the underlying stick and allows for filling during manufacture, to fall out. The dome is sometimes referred to as the “factory finish” by those skilled in the art. The primary purpose of the dome is to allow filling of the container with the product when the container is in an inverted position, a secondary purpose being to protect the stick prior to use. Replacing the dome and/or touching the product compromises the presentation of the package and renders it potentially unsealable. [0004] Similarly, shoppers of other consumer products may also compromise package presentation. In consumer products like liquid soap or detergent, the shopper may remove a seal to smell the product. If the shopper decides to purchase the product, they often pick an untampered package, but replace the product which they sampled back onto the shelf, which can cause the now compromised product to be damaged and be potentially unsaleable. SUMMARY [0005] The present invention aims to provide a consumer product which is packaged to allow shoppers to sample the scent of the product without opening the package or compromising the package's factory-fresh presentation. [0006] The cap is typically located at the top of the container, but alternatively the cap may be located at the bottom of the container, for example on a secondary cap which seals the bottom of the container after a filling step in which the container is inverted. Typically, the manually deformable pan comprises a flexible membrane. In a preferred embodiment, in which the cap is located at the top of the container, the manually deformable part is disposed at an upper surface of the cap. Optionally, the manually deformable part comprises a majority of the upper surface of the cap. Correspondingly, in an alternative embodiment, in which the cap is located at the bottom of the container, the manually deformable part is disposed at a lower surface of the cap, and for example comprises a majority of the lower surface of the cap The manually deformable part may be composed of a thermoplastic elastomer. Typically, the orifice is composed of an elastic material which maintains the orifice in a substantially closed condition in the absence of a pressure differential across the orifice. The orifice may be provided in a thermoplastic elastomer. In one embodiment, the manually deformable part and the orifice are provided in a common body of thermoplastic elastomer. Optionally, the manually deformable part has an external surface shaped with a recess for receiving a finger of a user. [0007] The present invention accordingly provides a consumer product comprising a container for containing a scented composition and a cap fitted to the container, the cap and the container defining a cavity therebetween, the cap having an orifice, for communicating between the cavity and an exterior of the cap, and a manually deformable part which is adapted to be displaceable thereby to displace air from an internal location within the cavity outwardly through the orifice. [0008] Typically, the manually deformable part comprises a flexible membrane. In a preferred embodiment, the manually deformable part is disposed at an upper surface of the cap. Optionally, the manually deformable pan comprises a majority of the upper surface of the cap. The manually deformable part may be composed of a thermoplastic elastomer. Typically, the orifice is composed of an elastic material which maintains the orifice in a substantially closed condition in the absence of a pressure differential across the orifice. The orifice may be provided in a thermoplastic elastomer. In one embodiment, the manually deformable part and the orifice are provided in a common body of thermoplastic elastomer. In another embodiment, the manually deformable part and the orifice are provided in a common body of injection moldable or blow moldable resin, for example polypropylene. Optionally, the manually deformable pan has an external surface shaped with a recess for receiving a finger of a user. [0009] The consumer product may further comprise a tamper evident element connecting together the container and the cap. [0010] In some embodiments, the container is a roll-ball container containing a liquid composition. In other embodiments, the container contains a solid stick of the composition. Typically, the composition is an anti-perspirant or deodorant composition. [0011] The present invention also provides a packaged consumer product comprising a container containing a scented personal care composition, selected from a liquid and a solid personal care composition, and a scent sampler for displacing air which contains the scent from an internal location within the package to outside the package without opening the package. [0012] Typically, the scent sampler comprises a manually deformable part and an orifice, the manually deformable part being adapted to be displaceable thereby to displace air from the internal location outwardly through the orifice. The packaged consumer product may further comprise a tamper evident element sealing the package. In one embodiment, the container is a roll-ball container containing a liquid antiperspirant or deodorant composition. In another embodiment, the container contains a stick of a solid anti-perspirant or deodorant composition. In a further embodiment, the container contains a soap or body wash composition. In a yet further embodiment, the container contains a detergent or fabric softener. [0013] The present invention further provides a method of packaging a consumer product, the method comprising the steps of: [0014] (a) disposing a scented composition in a container, the composition being selected from a liquid and a solid composition; [0015] (b) applying a cap to the container to seal the container, the cap including a manually actuatable scent sampler for displacing air located between the cap and the container to outside the package without opening the package; and [0016] (c) permitting scent from the composition to become infused in the air located between the cap and the container. [0017] The present invention yet further provides a method of sampling the scent of a consumer product, the method comprising the steps of: [0018] (a) providing a packaged consumer product comprising a container for containing a scented composition, selected from a liquid and a solid composition; and [0019] (b) displacing air which contains the scent from an internal location within the package to outside the package without opening the package. [0020] Accordingly, the embodiments of the invention can provide that the scent of the packaged composition can be sampled by a prospective purchaser by sampling the scent of the actual packaged product but without opening the package, exposing the packaged product, or compromising the integrity of the packaging or the packaged consumer product. BRIEF DESCRIPTION OF THE DRAWINGS [0021] FIG. 1 is a schematic perspective view of an upper portion of a roll-on container for a personal care product such as an antiperspirant or deodorant composition in accordance with a first embodiment of the present invention; [0022] FIG. 2 is a schematic side view of the roll-on container of FIG. 1 when used to provide a scent preview to a user; [0023] FIG. 3 is a schematic perspective view of a cap for a container for a consumer product in accordance with a second embodiment of the present invention; and [0024] FIG. 4 is a schematic perspective view of a cap for a container for a consumer product in accordance with a third embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0025] Referring to FIG. 1 , there is shown a schematic perspective view of an upper portion of a roll-on container 2 in accordance with a first embodiment of the present invention. [0026] The container 2 includes a body portion 4 and a cap 6 which is removably mounted thereon, for example by conventional helical threads (not shown). The body portion 4 packages a consumer product such as an antiperspirant or deodorant composition. The cap 6 covers and protects a roll-ball 14 (shown in phantom in FIG. 1 ) Which is mounted in conventional manner at an end 7 of the body portion 4 . The cap 6 includes a flexible portion 8 , in the form of a membrane, which can he manually depressed by a user. Typically, the flexible portion 8 is located in an upper wall 9 of the cap 6 and takes up the major proportion of the upper surface of the cap 6 . A surrounding skirt 11 of the cap 6 depends downwardly from the upper wall 9 and is threadably fitted to the end 7 of the body portion 4 . A flexible insert 10 defining an outlet orifice 12 is located in the skirt 11 . The outlet orifice 12 is typically maintained in a substantially closed condition by the elastic properties of the flexible insert 10 in the absence of a pressure differential across the outlet orifice 12 . Therefore, when the packaged container is not being handled manually to sample the scent as described below, the cap is substantially sealed. The cap 6 defines a closed cavity 15 above the roll-ball 14 which is infused with scent from the consumer product packaged within the container 2 . [0027] The cap 6 on the one hand, and the flexible portion 8 and insert 10 an the other hand, may be composed of a two plastic materials, and are typically bi-injection molded, with the flexible portion 8 and the insert 10 being composed of a relatively flexible material, such as a thermoplastic elastomer, and the upper wall 9 and the skirt 11 being composed of a relatively rigid material, such as polypropylene. The flexible portion 8 and the insert 10 may be separated, as shown, or connected together. Alternatively, the cap 6 , flexible portion 6 and insert 10 may be composed. of a single plastic material, with the flexible portion 8 having a thinner wall thickness as compared to the upper wall 9 and skirt 11 to provide the required flexibility for the flexible portion 8 and an orifice 12 sufficiently small in cross-section or sealed so that the scent is retained within the cavity 15 prior to sampling, as described below. Optionally, a flexible hinge (not shown may be provided between the flexible portion 8 and the upper wall 9 . [0028] As shown in FIG. 2 , when a shopper wishes to sample the scent of the consumer product packaged within the container 2 , the shopper can manually depress the flexible portion 8 with their finger F. This causes the flexible portion $ to be flexed inwardly, thereby reducing the volume of the closed cavity 15 , which in turn causes a corresponding volume of the scent-infused air within the closed cavity 15 to he displaced. outwardly through the orifice 12 , to form a scent-release S from the cavity 15 . The pressure differential across the orifice 12 causes the flexible insert 10 to deform thereby temporarily to open up the orifice 12 to permit the scent release. The scent can then be sampled by the shopper. The scent can be sampled without removing the cap 6 of the packaged product, and so the package is not opened to sample the scent. Moreover, the scent of the packaged product itself may be sampled, and not the scent of a separately provided sample which may differ perceptibly from the actual packaged product. [0029] After the manual pressure is released, the flexible portion 8 and the insert 10 , which are resilient or elastic, return to their initial configuration. This permits the scent of the product to be sampled again by a subsequent shopper. [0030] In order to direct the shopper to the scent sampling feature, the product may be labeled with printed information to highlight the scent sampling flexible portion 8 to the customer. Furthermore, the container 2 may be provided with a tamper evident feature to discourage a shopper from removing the cap 6 in store to test the product. Such a tamper evident feature may be selected from, for example, a shrink band, an extended shrink label, a pressure sensitive and/or geometry molded into the packaging components, i.e. the body portion 4 and the cap 6 , to achieve the goal of keeping the package uncompromised prior to the sale of the product to a customer. FIG. 2 illustrates a tamper evident feature in the form of a pressure sensitive label 13 bridging the body portion 4 and the cap 6 . The provision of such a tamper evident feature would inhibit the consumers' typical behavior of unscrewing the cap 6 at the point of sale. In fact, hindering the opening of the cap 6 would prompt the user to take a closer look at the product and notice the scent preview feature of the present invention. [0031] Accordingly, the consumer product is packaged to allow shoppers to sample the scent of the product without compromising the package's factory-fresh presentation. [0032] The cap 16 is adapted for removable snap- or push-fitting over a container (not shown) for a personal care product such as a roll-on anti-perspirant or deodorant. The cap 16 covers and protects the roll-ball. The cap 16 includes a relatively flexible substantially planar top wall 18 mounted on a relatively rigid skirt 20 which is shaped and dimensioned to fit onto a container. The top wall 18 is typically composed of a thermoplastic elastomer and the skirt 20 is typically composed of polypropylene. The top wall 18 includes an orifice 22 extending therethrough which is surrounded by an annular depression 24 constituted by a thinning of the material of the top wall 18 . As illustrated in FIG. 3 , the orifice 22 is located on an annular side surface 26 of the top wall 18 above the skirt 20 . [0033] Referring to FIG. 3 , there is shown a schematic perspective view of a cap 16 for a consumer product container in accordance with a second embodiment of the present invention. [0034] The cap 16 is adapted for removable snap- or push-fitting over a container (not shown) for a consumer product such as an anti-perspirant or deodorant stick. The cap 16 could also contain threads for threaded coupling with a container (not shown) for a consumer product such as a body wash, liquid soap, fabric softener, detergent and the like. The cap 16 covers and protects the free end of a container knot shown). The cap 16 includes a relatively flexible substantially planar top wall 18 mounted on a relatively rigid skirt 20 which is shaped and dimensioned to fit onto a container. The top wall 18 is typically composed of a thermoplastic elastomer and the skirt 20 is typically composed of polypropylene. The top wall 18 includes an orifice 22 extending therethrough which is surrounded by an annular depression 24 constituted by a thinning of the material of the top wall 18 . As illustrated in FIG. 3 , the orifice 22 is located on an annular side surface 26 of the top wall 18 above the skirt 20 . [0035] As for the embodiment of FIGS. 1 and 2 , manual pressure acting on the top wall 18 can flex the top wall, thereby to reduce the volume of the closed cavity between the cap 16 and the container, which in turn causes a corresponding volume of the scent-infused air within the closed cavity to be displaced through the orifice 22 , to form a scent-release from the cavity. [0036] FIG. 4 shows a schematic perspective view of a cap 26 for a consumer product container in accordance with a third embodiment of the present invention, which is a modification of the cap of the second embodiment shown in FIG. 3 . [0037] The cap 26 is, again, adapted for removable snap-fitting over a container (not shown) for a consumer product such as an anti-perspirant or deodorant stick, body wash, liquid soap, detergent, fabric softener and the like. The cap 26 could alternatively comprise threads for mating with threads on a neck of a container (not shown). The cap 26 includes a relatively flexible top wall 30 mounted on a relatively rigid skirt 34 which is shaped and dimensioned to fit onto a container. The top wall 30 includes a central depression or recess 36 surrounded by an annular upwardly inclined surface 38 terminating in an annular ridge 40 around the cap 26 . The top wall 30 is typically composed of a thermoplastic elastomer and the skirt 34 is typically composed of polypropylene. The top wall 30 includes an orifice 32 extending therethrough which is surrounded by an annular depression 42 constituted by a thinning of the material of the top wall 30 . As illustrated in FIG. 4 , the orifice 32 is located, on an annular side surface 44 of the top wall 30 above the skirt 34 . [0038] The shaping of the top will 30 to include the central depression 36 provides the user with an easy to use structure for finger location above the flexible membrane for sampling the scent of the personal care product within the container. [0039] The caps of the previous embodiments may readily be modified so as to be suitable for removable snap-fitting over a container (not shown) for a personal care product such as an anti-perspirant or deodorant in the form of a stick. For example, the shape of the cap may be modified so as to have a cross-section corresponding to that of the packaged stick, for example an oval cross-section, with correspondingly modified dimensions. The cap accordingly covers and protects the free end of a stick. [0040] In another modification, when the container is for a stick product, the cap may be a secondary cap located at the bottom of the container, the cap sealing the bottom of the container after filling thereof with the stick composition. In such a modification, the manually deformable part may be disposed at a lower surface of the cap, and for example comprises a majority of the lower surface of the cap. Other features described earlier for the structure of the cap, when located at the top of the container, may be incorporated into such a secondary lower cap. [0041] In a modification of any of the embodiments described, the deformable part and the orifice may be provided in a common body of injection-molded or blow-molded resin, for example polypropylene. [0042] Other modifications to and embodiments of the present invention will be apparent to those skilled in the art.
A consumer product comprises a container for packaging a composition having a scent. A removable cap is fitted to the container, with the cap and the container defining a cavity therebetween. The cap has an orifice, for communicating between the cavity and an exterior of the cap, and a manually deformable part which is adapted to be displaceable thereby to displace air from an internal location within the cavity outwardly through the orifice.
1
TECHNICAL FIELD [0001] The present invention relates to elongated hollow building elements that are combined to form a wall or panel and more particularly to such building elements that are extruded for plastics material and are secured together by snap engagement. The building elements can be used in the construction of basement walls, liquid and granular storage tanks and other like structures. BACKGROUND OF THE INVENTION [0002] The present invention relates to the building element described in U.S. Pat. No. 7,703,248. [0003] Where walls are exposed to moisture, such as walls of water storage tanks and building walls below ground level, typically waterproofing is applied to the walls that are exposed to the moisture. In the construction of conventional concrete and reinforced masonry walls, the walls need to be protected from moisture as exposure to moisture over time will cause degradation of the concrete and corrosion of the steel. A still further problem is mould, mildew and fungus and bacterial development on the walls. To address this issue typically a waterproof membrane is applied to inhibit water reaching the concrete or reinforced masonry wall. It is also not unusual to provide a gap between an earth surface and the wall to enable a water proofing membrane to be applied. Typically the gap can be a metre. This gap can be considered a safety issue for workers. [0004] The above construction of walls that are to exist in a damp environment has a number of disadvantages in that if the waterproofing fails then the wall will degrade. A further disadvantage is the loss of floor area should a gap be required between the wall and an earth surface. OBJECT OF THE INVENTION [0005] It is the object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages. SUMMARY OF THE INVENTION [0006] There is disclosed herein an extruded hollow longitudinally elongated building element into which concrete is to be poured, the element being extruded so as to be integrally formed and comprising: [0007] a pair of longitudinally extending spaced walls which are generally longitudinally coextensive and longitudinally parallel; [0008] a plurality of longitudinally extending spaced transverse webs joining the side walls, the webs including a first and a second web; [0009] a pair of longitudinally extending grooves, each of the grooves being formed in a respective one of the side walls; [0010] a pair of longitudinally extending end flanges, each of the end flanges extending from a respective one of the walls; [0011] a pair of longitudinally surfaces that diverge from the first web toward the grooves; [0012] a sealing projection extending from each flange and extending longitudinally thereof; and wherein [0013] the end flanges and grooves are positioned and configured to engage a respective one of the grooves of a respective one of the flanges of a like element, and the end flanges are resilient deformed by engagement longitudinal surface of the like element so as to be resilient deformed such that, when the end flanges are moved in a transverse direction relative to the diverging surfaces of the like element, there is a resilient deformation of the end flanges to allow snap engagement of each end flange in a respective one of the grooves to thereby secure the elements together by snap engagement, and the sealing projections extend transversely from their associated flange toward the other element to aid in sealingly connecting the. elements. [0014] Preferably, each end flange includes a first portion extending transversely from the first wall, and a second portion extending generally transverse relative to the first portion so as to project into the associated groove of the like element. [0015] In one preferred form, said sealing element projects from said portion. [0016] In a further preferred form, said sealing projection extends from said second portion. [0017] Preferably, each groove is provided by a groove providing portion extending longitudinally of the element, the groove providing portion having a sealing projection extending longitudinally of the element and extending into the groove so as to be operatively associated with the sealing element of the second portion to aid in sealingly connecting the elements. BRIEF DESCRIPTION OF THE DRAWINGS [0018] Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings wherein: [0019] FIG. 1 is a schematic top plan view of the walls of a building basement; [0020] FIG. 2 is a schematic top plan view of portion of one of the walls of FIG. 1 ; [0021] FIG. 3 is a schematic top plan view of a further portion of one of the walls of FIG. 1 ; [0022] FIG. 4 is a schematic top plan view of a building element used to form the walls of the basement of FIG. 1 ; [0023] FIG. 5 is a schematic top plan view of a further building element used in forming the walls of FIG. 1 ; [0024] FIG. 6 is a schematic enlarged view of portion of the elements used to form the walls of FIG. 1 ; and [0025] FIG. 7 is a schematic top plan view of an alternative portion of FIG. 6 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0026] In FIG. 1 of the accompanying drawings there is schematically depicted the basement 10 of a building. The basement 10 may be below ground level. [0027] The basement 10 includes walls 11 that may be straight or curved. Each of the walls 11 is formed by a plurality of elongated building elements 12 . Each building element 12 is hollow and is extruded from plastics material. Each element 12 has a pair of longitudinally extending side walls 13 that are longitudinally parallel. In FIG. 3 the element 12 illustrated has the walls 13 also transversely parallel and generally flat. The element 12 of FIG. 5 has longitudinally extending side walls 14 and 15 that provide for the construction of curved walls and corners, with the walls 11 inclined by a desired angle 29 . The inner wall 15 is of a shorter transverse width relative to the outer wall 14 . [0028] Each of the elements 12 has a plurality of transverse webs 16 and end webs 17 and 18 . The webs 16 of the element 12 of FIG. 4 is joined to the side walls 13 by connecting webs 19 . The connecting webs 19 are inclined so as to converge from their connection with the side walls 13 to the associated web 16 . [0029] The end web 18 has extending from it longitudinally extending ramp surfaces 20 that diverge from the web 18 toward the side walls 13 , 14 and 15 . The surfaces 20 extend to longitudinally extending grooves 21 . [0030] Extending from the end web 17 are flanges 22 that in the embodiment of FIG. 4 are generally parallel and coextensive. [0031] Like elements 12 are connected by transverse relative movement between the elements 12 . In particular the flanges 22 of one of the elements 12 moves transversely across the surfaces 20 so as to be resiliently deflected apart, with the flanges 22 then snap engaging within the recesses 21 to thereby connect adjacent elements 12 . [0032] As best seen in FIGS. 6 and 7 each flange 22 includes a first flange portion 23 that extends from the web 17 , and a second flange portion 24 that extends from the first flange portion 23 . The second portion 24 is to be located in the recess 21 . The portions 23 of each element 12 are generally parallel and coextensive and extend generally transverse to the associated web 17 . The second portion 26 projects from the first portion 23 in a direction generally parallel to the web 17 . [0033] Each groove 21 is provided by a groove providing portion 25 , the portions 25 of each element 12 being generally parallel and coextensive. The portions 25 are of a “U” shaped transverse cross section so as to receive the portion 24 . [0034] In the embodiment of FIG. 6 , the first flange portion 23 is provided with a longitudinally extending seal projection 26 that is shaped like a barb. The projection 26 extends from the first portion 23 toward the other element 12 . The projection 26 may actually engage the other element 12 or be slightly spaced therefrom. In such instances, wet concrete delivered to the cavities 30 would sealingly connect each sealing projection 26 to the adjacent element 12 . The projection 26 aids in sealingly connecting engaged elements 12 . [0035] When elements 12 , as shown in FIG. 6 , are connected, the second portion 24 would move along the surface 20 so as to cause resilient outward deflection of the first portions 22 until the second portions 24 were aligned with the groove 21 so as to snap engage therein. [0036] In the embodiment of FIG. 7 , there is provided a pair of sealing projections 27 and 28 . The projection 27 extends from the second portion 24 while the projection 28 extends from the recess providing portion 25 . The projections 27 and 28 engage, or are located adjacent each other so that the gap therebetween is sealed by wet concrete. [0037] The projections 26 , 27 and 28 extend the entire longitudinal length of each of the elements 12 .
A building element that is an elongated extrusion of plastics material. The element can be used to form straight or curved walls. Like elements are secured together by transverse relative movement and snap engagement of flanges in recesses. En one embodiment the element has a longitudinally extending seal projection that aids in sealingly connecting engaged elements.
4
Background of the Invention The present invention relates to the high speed conveying of discreet sheets of material, such as sheets of corrugated paperboard and, more particularly, to a system for changing the speed of conveyed sheets while holding the same in register. In the high speed handling of individual sheets of corrugated paperboard or similar sheet materials, sheets of uniform size are often conveyed in "register" such that a uniform spacing is maintained between sheets. Uniform edge to edge spacing or pitch spacing of the sheets is necessary so that the sheets may be fed serially and accurately into timed downstream processing equipment such as may be used, for example, to cut or fold the sheet. Corrugated paperboard sheets may be conveyed at speeds of 1,500 feet per minute and, in order to maintain register, the sheets are typically conveyed between upper and lower conveying means which hold the positions of the sheets. It is also often necessary or desirable to change the speed of sheets being conveyed while maintaining accurate sheet register. Correspondingly, it may be desirable to increase or decrease the spacing between sheets, but again on a uniform basis such that register is maintained. With slow moving sheet materials a change in speed and spacing may be effected by moving the sheets from an upstream conveyor operating at a first speed to a downstream conveyor operating at a second speed via an intermediate speed change conveyor utilizing variable speed drives, clutch mechanisms or the like to change the speed of the sheets from the first to the second speed. Such a variable speed drive for changing the pitch spacing and speed of conveyed sheets is shown in U.S. Pat. No. 3,827,545. The mechanical speed changing mechanism of the intermediate transfer conveyor, though satisfactory for sheet materials conveyed at relatively low speeds, is wholly unsatisfactory for handling corrugated board at high speeds. U.S. Pat. 2,580,469 also shows a device for changing the speed of conveyed sheets. That device utilizes a pair of counterrotating cams between which the sheet is fed from a first conveyor such that the increase or decrease in the radius of the cam surfaces causes a corresponding increase or decrease in the speed of the sheet being conveyed therebetween. Although satisfactory for relatively slow moving sheets, the extreme variation in the radii of the cams as they rotate in contact with the sheet results in a severe vertical deflection of the sheet which is totally unacceptable in a high speed handling situation where such deflection would tend to bend, break or otherwise damage relatively fragile corrugated board stock. It would be desirable, therefore, to have a system which is capable of changing the speed and spacing of corrugated board sheets being conveyed at high speed while maintaining the register thereof. Such a system would preferably eliminate the need for complex mechanical speed changing mechanisms or the use of speed changing cams imparting severe vertical deflection to the conveyed sheets. SUMMARY OF THE INVENTION In accordance with the present invention, sheets of material being conveyed in register are accelerated or decelerated to a second speed while maintaining register by utilizing an intermediate speed changing belt operating at a constant linear speed, but specially configured to change the speed of the sheet received from the upstream conveyor to the speed of the downstream conveyor and to retain hold of and prevent the board from slipping during the speed change and sheet transfer. The speed changing belt operates via positive driving engagement around a pulley positioned tangent to the surface of the sheets and rotating in the direction of sheet movement. At least a portion of the length of the speed changing belt comes into tangent contact with the sheets as the belt travels around the pulley. The speed changing belt operates at a constant linear speed which is established to provide an instantaneous velocity at the outer belt surface as it travels around the pulley and makes initial contact with the sheet which velocity is equal to the speed of the infeed conveyor. A flexible holding means is disposed on the opposite side of the sheets from the pulley and is positioned to contact the surface of the sheets and to form with the belt and pulley a nip for receiving sheets from the infeed conveyor. The speed changing belt includes a speed change lobe which presents a region of continuously changing radius as the lobed region of the belt operates around the pulley, such that the outer surface of the belt including the lobe at the tangent contact with the sheet operates at a continuously changing speed which varies from the speed of the infeed conveyor to the speed of an outfeed conveyor. When utilized in its preferred manner as a system for accelerating sheets and increasing the spacing thereof, the acceleration lobe comprises a length along the belt of uniformly increasing belt thickness. The speed change lobe need only have a length equal to a portion of the length of a sheet such that the increase in thickness is gradual enough to allow an increase in the contacting radius to accelerate the sheets without slippage. The resilient holding means may comprise a low inertia idler roll positioned with its axis of rotation parallel to the axis of the pulley. The axis of the low inertia idler roll is fixed and the outer surface which contacts the sheets is resilient so that the upward deflection of the sheets as the radius of the speed changing belt increases around the belt pulley may be accommodated. Alternatively, the resilient holding means may comprise a flexible finger mechanism which is biased into engagement with the sheets. In the case of the flexible finger mechanism, the resilient holding means must be provided with a coefficient of surface friction substantially lower than that of the pulley and the speed changing belt such that non-slipping conveying engagement may be maintained between the pulley/speed change belt combination and the sheets. In the presently preferred embodiment, the acceleration belt is positioned below the plane of the sheets such that it contacts the bottom surfaces thereof. In one of two preferred embodiments, the pulley includes a peripheral surface portion which provides initial tangent contact with the sheets, while they are still simultaneously held by the infeed conveyor, and the acceleration belt is recessed in the peripheral surface of the pulley, except for the acceleration lobe which extends radially beyond the pulley surface as the lobe passes around the pulley. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation of a schematic representation of the speed changing system of the present invention. FIG. 2 is an enlarged side elevation of the speed changing mechanism showing the conveyed sheet in its FIG. 1 position operating at the speed of the infeed conveyor. FIG. 3 is a side elevation view similar to FIG. 2 showing a sheet leaving the speed changing mechanism at the increase velocity of the outfeed conveyor. FIG. 4 is a view similar to FIGS. 2 and 3 showing an alternate construction for the flexible holding means operating in conjunction with the speed changing pulley and belt. FIG. 5 is a top plan view showing another embodiment of a combined pulley and acceleration belt of the speed changing system, FIG. 6 is a side elevation of the apparatus of FIG. 5. FIG. 7 is an enlarged side elevation similar to FIG. 2 showing an embodiment of the speed change belt for decreasing the speed of the sheets. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring first to FIG. 1, a series of sheets 10 are shown being conveyed on a first infeed conveyor 11 at a velocity V 1 . The infeed conveyor 11 may be of any suitable type, including a driven belt or live roll conveyor, and includes at its downstream end a pair of driven rolls 12 and 13 which maintain positive hold of the sheet 10 and, with similar sheet engaging upstream rollers (not shown), maintain a uniform equal spacing S 1 between the sheets 10. In other words, the sheets are maintained in register as they are conveyed over the infeed conveyor 11. The system of the present invention includes an intermediate speed change mechanism 14 which accelerates (or decelerates) sheets received from the infeed conveyor 11, increases (or decreases) the speed of the sheets to that at which a second outfeed conveyor 15 is operating, and simultaneously increases (or decreases) the spacing S 2 therebetween. The downstream outfeed conveyor 15 may also be of any suitable construction which will positively hold the sheets 10 and maintain them in register. As such, the outfeed conveyor 15 may include a series of pairs of driven rolls 16 and 17, only the upstream-most pair of which is shown in the drawing. The description of the speed change mechanism 14, set forth hereinafter, relates specifically to a mechanism for accelerating the sheets 10 to a higher velocity and increasing the spacing therebetween. However, with suitable changes, the speed change mechanism can be adapted to decelerate sheets and decrease the spacing therebetween. Also, when used as a sheet acceleration mechanism, the system of the present invention can handle corrugated paperboard sheets or other similar sheet materials which are disposed on the infeed conveyor 10 in abutting end to end relation (no spacing S 1 ). Referring also to FIGS. 2 and 3, the speed change mechanism 14 of the system of the present invention is positioned downstream from the end of the infeed conveyor 11 (as defined by the driven rolls 12 and 13) by a distance substantially less than the length of a sheet 10. Thus, a sheet 10 passing between driven rolls 12 and 13 will enter the speed change mechanism while it is still engaged by the rolls 12 and 13. The speed change mechanism includes an acceleration belt 18 which is driven at a constant speed around a pulley to provide a radially outer surface speed at the point of intiial contact with the sheet equal to the speed V 1 of the infeed conveyor 11 as will be described in more detail hereinafter. The belt 18 is preferably constructed in the manner of a conventional timing belt to include a ribbed or toothed configuration 20 on its underside adapted to engage a similar toothed drive sprocket 21 driven by a drive motor 22. The acceleration belt 18 also operates about an upper pulley 23 which may also be provided with teeth to be engaged by the tooth pattern 20 on the belt to prevent slipping of the pulley with respect to the belt. The belt 18 has a flat outer surface 24 over the greater portion of its length and it is synchronized with the sheets incoming from the infeed conveyor 11 of the pulley 23 such that, as it passes around the pulley, the surface of the belt is either at or slightly below the periphery of the pulley defined by the radius R 1 (FIG. 2). Alternately, the uniform outer surface portion 24 of the belt may extend slightly beyond the outer periphery of the pulley 23. Thus, either or both of the outer surface of the pulley or the radial outer surface of the belt traveling around the pulley may provide initial tangent contact with an incoming sheet 10 and, because the speed of the tangent contact surface belt is set to coincide with the speed of V 1 of the infeed conveyor 11, the sheet 10 will initially pass through the speed change mechanism 14 at the initial speed V 1 . As is well known in the art, the pitch line L P of the belt 18 (FIG. 2) inherently lies some distance below the outer surface 24 of the belt. In other words, the pitch line radius R P is less than the radius R 1 to the outer surface of the belt. Therefore, the outer surface of the belt as it travels around pulley 23 and in contact with the sheet will be moving at a velocity greater than the radially inner pitch line speed. As a result, the linear speed of the belt must be established and set at a speed less than V 1 . Specifically, the pitch line speed V P is less than V 1 by a factor equal to the ratio of the radii R P /R 1 (see FIG. 2). Similarly, as the belt 18 makes a complete revolution around pulleys 21 and 23, the total motion or distance of travel of the outer surface of the belt will exceed the total pitch line distance or pitch length of the belt by approximately the factor R 1 /R P . As will become apparent from the example set forth below, the distance of travel by the outer surface of the belt in one revolution is greater than the pitch spacing (repeat length) of the sheets (L+S 1 ) by an amount dependent on the magnitude of the length and thickness of the speed change lobe, the function of which will be described. A resilient low inertia idler roll 25 is positioned above the pulley 23 and in engagement with the upper surface of the sheet 10. The belt 18 and pulley 23 make tangent contact with the lower surface of the sheet and the idler roll 25 makes tangent contact with the upper surface of the sheet to define therebetween a nip for holding and conveying the sheets through the speed change mechanism. In addition to being of light weight and low inertia, the idler roll 25 comprises an interior having a series of generally radially extending flexible fins 26 which interconnect a central hub 27 and a flexible outer cylindrical surface portion 28. The idler roll thus provides means for resiliently holding the sheet in contact with the belt 18 and pulley 23 to maintain register between the belt and the sheet. The entire outer surface of the belt 18 and the outer peripheral surface of the pulley 23 (if the latter is constructed to engage the sheet) are provided with a high coefficient of friction surface to maintain positive driving contact with the sheet. A portion of the length of the acceleration belt 18 is provided with an acceleration lobe 30 which is shaped to define a continuously increasing radius at the point of tangent contact between the belt and the sheet 10 as the belt travels around the pulley 23. Referring particularly to FIGS. 2 and 3, the acceleration lobe 30 comprises a portion raised from the outer surface 24 of the belt which increases in thickness from the belt surface uniformly to an upstream end 31 of maximum thickness. As the acceleration lobe 30 travels around the pulley 23 the radius at the point of tangent contact with the sheet increases from the minimum R 1 (FIG. 2) to a maximum R 2 (FIG. 3) as the upstream end 31 of the lobe reaches the top of the pulley in engagement with the sheet. Therefore, the velocity of the outer surface of the lobe and the sheet being conveyed thereon will increase from the incoming velocity V 1 to the second speed V 2 . The acceleration lobe 30 is constructed to provide uniform acceleration and has a length and register with the sheet such that the upstream edge 32 of the sheet 10 coincides with the upstream end 31 of maximum lobe thickness and radius R 2 , as shown in FIG. 3. As an example, assume that it is desired to increase the speed V 1 of incoming sheets to a speed V 2 which is 120% of V 1 . Assume also sheets 10 which are 48 inches long and spaced from one another by two inches, thereby comprising a sheet pitch spacing or repeat length of 50 inches. The acceleration lobe 30 on the belt 18 is constructed to provide a radius R 2 which is 120% of the radius R 1 and, as previously indicated, belt 18 is operating at constant linear speed to provide a peripheral speed at the outer belt surface on pulley 23 equal to V 1 . If the transition from R 1 to R 2 is provided with an acceleration lobe 30 having a length of 10 inches, the sheet 10, from its FIG. 2 to its FIG. 3 position, will travel 11 inches, because the average increase in the effective radius of the lobe at the point of contact with the sheet is 10%. The acceleration of the sheet over its last 11 inches of travel over the lobe 30 results in a one inch increase in the space from the trailing edge 32 to the leading edge 33 of the following sheet. Thus, the sheet spacing increases from S 1 of two inches in FIG. 2 to an intermediate spacing of three inches in FIG. 3. At this point, leading sheet 10 is traveling at V 2 while trailing sheet 10 is still traveling at V 1 . This difference in velocities between the two sheets will continue until the trailing sheet reaches the position shown in FIG. 2 (where its trailing edge 32 is 11 inches from the acceleration belt nip). Thus, the trailing sheet must move through a distance of 40 inches (the three inch spacing plus the initial 37 inches of the sheet) before it begins to accelerate. In the meantime, the leading sheet 10 has been traveling at a speed which is 120% greater and, therefore, the spacing between trailing and leading edges 32 and 33 of these adjacent sheets will continue to increase at a constant rate. However, as the trailing sheet begins to accelerate (from the FIG. 2 to the FIG. 3 position), the rate of increase in the space will slow until the trailing edge 32 of the trailing sheet has been fully accelerated to speed V 2 (FIG. 3 position). At this point, the final spacing S 2 and the pitch spacing of the sheets is established. In the present example, the pitch spacing or repeat length is 60 inches (120% of 50 inches) and the sheet spacing S 2 is, therefore, 12 inches (60 inches minus 48 inches). The driven rolls 16 and 17 at the inlet to the outfeed conveyor 15 are spaced from the nip of the speed change mechanism 14 by a distance equal to or just slightly less than the length of the sheet. In this manner, the sheet is positively held at all times in one or the other of the conveyor nips so that sheet register is maintained. In order to handle runs of sheets of a different length, rolls 16 and 17 are adjustable in the direction of travel to vary their distance from the speed change mechanism 14. Referring again to FIG. 3, as the leading sheet 10 leaves the nip formed by the acceleration belt 18 and idler roll 25 and is traveling at speed V 2 , the leading edge 33 of the following sheet is approaching the nip. By the time the leading edge of the following sheet reaches the nip, the maximum thickness upstream end 31 of the acceleration lobe 30 will have traveled past the tangent contact point and the uniform flat surface 24 of the belt 18 is positioned to engage the following sheet 10. The following sheet, like the sheet immediately preceding it, will be engaged in the nip and continue to travel at the speed V 1 until it is engaged by the acceleration lobe 30, as shown in the FIG. 2 position, whereafter it is accelerated in an identical manner previously described. In accordance with the system of the present invention, sheets may be readily accelerated (or decelerated) to a different speed and spacing and maintained in absolute register utilizing an acceleration belt which travels at a constant linear speed and, therefore, requires no complex speed changing mechanism. Correspondingly, no massive inertial changes in machine drive components are required and only the mass of the sheet 18 and the idler rool 25 are subject to acceleration (or deceleration) forces. Another important feature of the present invention is that the acceleration lobe 30 requires only a fairly nominal increase in the radius from R 1 to R 2 which does not result in any significant vertical displacement of the sheet or board as it is being accelerated. For example, a four inch diameter pulley 23 would require only a 0.4 inch maximum lobe thickness to effect a 120% increase in sheet velocity. By comparison, utilization of a prior art speed change device utilizing a rotating cam would require a roller having approximately a 16 inch diameter to accommodate sheets with a 50 inch pitch spacing. To effect a 20% increase in speed, the cam surface radius would have to increase from about eight inches to about 9.6 inches which would result in a vertical displacement of the sheet or board likely to cause bending or other damage and which would be intolerable. As shown in FIG. 4, an alternate flexible holding means to the idler roll 25 of the preferred embodiment comprises a flexible finger 34 or series of such fingers which are attached to an upper support structure 35 and extend laterally across the sheet 10. The fingers 34 are biased into engagement with the sheet and will readily accommodate the upward vertical displacement thereof as the acceleration lobe 30 moves around the pulley 23 and under the sheet. The surfaces of the fingers 34 in contact with sheet 10 should have a low coefficient of friction so as not to interfere with the frictional engagement between the belt 24 and/or the pulley 23 with the sheet 10. FIGS. 5 and 6 show another embodiment of an acceleration belt and pulley combination believed to be as effective as the embodiment of FIGS. 1-3. In this configuration, the acceleration belt 18 comprises a pair of spaced belts 36 which operate synchronously in recessed portions 37 in the pulley 23. The pulley 23 includes a series of spaced outer peripheral portions 38 defining the recessed portions 37 therebetween, which outer peripheral portions engage the sheet 10 over the incoming length thereof until the sheet is engaged by the acceleration lobes 30 on the spaced belts 36. As the lobes 30 travel over the pulley 23 and into tangent contact with the sheet 10, the lobes 30 rise radially out of the recessed portions 37 to engage and accelerate the sheet, as previously described. The thickness of the lobes 30 may be chosen to provide the desired increase in sheet velocity, as also previously described. The resilient idler rolls 25, which are shown in phantom in FIG. 5 so as not to obscure the construction of the modified pulley 23, are longer axially than the recessed portions 37. In this manner, the rolls 25 overlie the edges of the larger diameter outer peripheral portion 38 to hold the sheet in contact therewith until the sheet is engaged by the lobes 30. In FIG. 7, there is shown a deceleration belt 40 which may be utilized to reduce the speed of sheets and the spacing thereof. The belt 40 has a generally enlarged uniform thickness along the greater portion of its length, beginning with a leading lobe 41 which is synchronized to make tangent contact with the leading edge 33 of the incoming sheet. The uniform thickness portion of the belt will maintain the sheet at its incoming velocity until the end portion 42 of the belt 40 reaches the top tangent portion of the pulley 23. The end portion is tapered to provide a uniformly decreasing belt thickness and, correspondingly, a uniformly decreasing radius as the end portion travels over the pulley and in tangent contact with the sheet. In a manner opposite the acceleration embodiment previously described, the sheet will decelerate from the incoming speed V 1 to a lower speed V 2 and the initial spacing S 1 between sheets will be correspondingly reduced to a smaller spacing S 2 . Various modes of carrying out the present invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.
A system for changing the speed of conveyed sheets while maintaining the sheets in register includes a speed changing belt operating at a constant speed to present a radial outer surface portion which travels over a pulley and into tangent contact with the surface of the sheet traveling at a speed equal to the velocity of the incoming sheets. A portion of the speed changing belt includes an acceleration lobe positioned to engage the trailing portion of the sheet and to provide a continuously increasing radius at the tangent contact portion as the belt travels around the pulley whereby the outer surface velocity of the lobe and the sheet in contact therewith continuously increase from the incoming speed to a desired second speed. The constant velocity speed changing belt requires only a simple constant speed drive and the speed change lobe attached to the belt requires only a relatively small increase in the effective radius of the belt around the pulley such that unacceptable vertical displacements of the sheet from the plane of travel are obviated. Only the mass of the sheet or board being conveyed (and an upper holddown idler roll if used) is subject to acceleration (or deceleration) forces as all the machine drive components run at constant velocity during the speed change, thereby minimizing the overall inertial effects.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a fuel control apparatus for an internal combustion engine. 2. Prior Art A wide variety of fuel control apparatuses have been used for providing optimum air-fuel ratioes. FIG. 7 shows one such prior art fuel control apparatus described in Japanese Patent Preliminary Publication No. 60-212643. A crank angle sensor 7 outputs a reference position pulse for each reference position of crank angle (every 180 deg. for four-cylinder engine and every 120 deg. for six-cylinder engine) and a unit angle pulse for each unit angle (eg. one degree). Thus, the crank angle can be determined by counting the unit angle pulses after the reference position pulse is inputted into a control apparatus 12. Further, the rotational speed of the engine can be determined by measuring the frequency or period of the train of unit pulses. In FIG. 7, the crank angle sensor 7 is provided in the distributor. The control apparatus 12 is formed of, for example, CPU, RAM, ROM, and I/O interface. The control apparatus 12 receives an intake-air flow rate signal S1 from an air flow meter 2, a water temperature signal S2 from a water temperature sensor 6, a crank angle signal S3 from the crank angle sensor 7, an exhaust signal S4 from an exhaust sensor 9, and a battery voltage signal and a fully-closed throttle signal (not shown), and calculates a fuel amount to be injected on the basis of these signals to provide an fuel injection signal S5. A fuel injection valve 10 is actuated by the fuel injection signal S5 to supply the engine with a required amount of fuel. The fuel injection Ti to be injected is calculated by the control apparatus 12 using the following equation. Ti=Tp (1+Ft+KMR/100) β+Ts (001) Tp=KQ/N where Tp is a basic injection amount, Q is an intake air flow rate, N is a rotational speed of the engine, and K is a constant. Ft is a correction factor dependent on the temperture of cooling-water of the engine, which is increasingly large with decreasing temperature. KMR is a correction factor when the engine is heavily loaded, and is read through table-look-up from a data table in which sets of data dependent on the basic injection amount Tp (ms) and the rotational speed N (rpm) are stored in advance as shown in FIG. 8. Ts is a correction factor for correcting fluctuation of the voltage which drives the fuel injection valve 10. β is a correction factor dependent on the exhaust signal S4 from the exhaust sensor 9. Through the use of 62 , the air-fuel ratio of the mixture can be feedback-controlled to a predetermined value, for example, a value close to the theoretical air-fuel ratio of 14.6. Where feedback control based on the exhaust siganl S4 is underway, the air-fuel ratio of the mixture is controlled to a constant value, in which case the corrections for the cooling-water and heavy load are meaningless. Thus, the feedback control using the exhaust signal S4 is carried out only when the correction factors Ft and KMR are zero. FIG. 9 illustrates the relation between the various sensors and the respective corrections calculated on the outputs of these sensors. For example, the signal from the air flow meter 2 is used to calculate the basic injection amount, the heavy load correction, and an injection amount when the engine is just started. In the prior art fuel control apparatus described above, the intake air flow rate Q is measured by the air flow meter 2, and is then divided by the rotational speed N to obtain the basic injection Q. Thus the air flow meter 2 plays a fundamental role in the fuel control apparatus. The prior art apparatus suffers from the following drawbacks. (1) An air flow meter is normally installed upstream of a surge tank. Therefore, during transient period in which the throttle opening changes abruptly, it measures not only the intake-air flow rate of the air flowing into the engine but also variations of the amount of air trapped in the inlet pipe (i.e., amount of air flowing into the inlet pipe), causing a difficulty in measuring an actual amount of air flowing into the engine and therefore disturbing the control of the air-fuel ratio. (2) A large air flow meter is required, which is not preferable from a point of view of space factor. (3) The output of the air flow meter is directly used to determine the fuel injection. This requires an accurate air flow meter. Japanese Patent Preliminary Publication No. 59-221433 discloses a procedure for measuring the pressure in a combustion chamber to calculate an amount of air charged into the combustion chamber. As is apparent from FIG. 11, the air charge amount Ga is in a linear relation with the pressure difference ΔP within the cylinder, where ΔP is the pressure difference within the cylinder between the bottom dead center (BDC) and 40 deg. before the top dead center (BTDC 40 deg.) as shown in FIG. 10. The air charge amount is calculated on the basis of ΔP by using this relation. However, this procedure suffers from a drawback that the measurement accuracy is directly dependent on the gain of the sensor since a change in gain causes a change in the pressure difference ΔP for the same air charge amount. SUMMARY OF THE INVENTION An object of the present invention is to provide a fuel control apparatus capable of measuring the actual air charge amount flowing into the respective cylinders during transient period to thereby control the air-fuel ratio of the engine to a required value. Another object of the invention is to provide a fuel control apparatus capable of determining the fuel injection independent of fluctuation of gain, drift of output, and variation of the pressure sensor that detects the pressure in the combustion chamber. A fuel control apparatus for an internal combustion engine comprises a pressure sensor for detecting the pressure in a combustion chamber and a crank angle sensor for detecting a crank angle. During compression stroke, a microcomputer calculates the difference in pressure in the combustion chamber between two crank angles, or differentiates the pressure in the combustion PG,7 chamber with respect to the crank angle at an arbitrary crank angle. Then, the microcomputer normalizes the pressure difference between the two crank angles by the pressure difference between the two crank angles when the engine is in an arbitrary reference condition, for example, its start condition, or normalizes the differentiated pressure at the arbitrary crank angle by the differentiated pressure at the arbitrary crank angle when the engine is in the arbitrary reference condition, for example, its start condition. The microcomputer then calculates the product of an amount of charge air and the pressure difference or the pressure differenentiated which has been normalized, thereby producing a basic fuel injection. BRIEF DESCRIPTION OF THE DRAWINGS Features and other objects of the invention will be apparent from the detailed description of the preferred embodiments with reference to the accompanying drawings in which: FIG. 1 show a first and a second embodiment of a fuel control apparatus according to the present invention; FIGS. 2A-2C are diagrams for showing an example of a pressure sensor used to detect the pressure in the combustion chamber; FIG. 3 is a graph for showing the relation between the crank angle θ and the pressure P in the cylinder, which is used in the first embodiment; FIG. 4 is a graph for showing the relation between the normalized intake-air pressure and Δ21/ΔP21r according to the first embodiment; FIGS. 5A-5B are flowcharts for showing the signal processing in the first embodiment; FIGS. 6A-6B are graphs showing the relation between the pressure in the cylinder and the volume of the cylinder in logP-logV scale; FIG. 7 shows a prior art fuel control apparatus; FIG. 8 shows a characteristic of the apparatus of FIG. 7, which shows the correction factor KMR while the engine is heavily loaded; FIG. 9 illustrates the relation between various sensors and the respective corrections calculated on the basis of the outputs of the sensors; FIG. 10 is a graph showing the relation between the pressure in the cylinder and the crank angle; FIG. 11 is a graph showing the relation between the pressure in the cylinder and the air charge amount. FIG. 12 is a graph for showing the relation between the crank angle θ and the pressure P in the cylinder, which is used in a second embodiment; FIG. 13 is a graph for showing the relation between normalized intake-air pressure and (dP/dθ)/(dP/dθ)r according to the second embodiment; FIGS. 14A-14C are flowcharts for showing the signal processing in the second embodiment; FIG. 15 shows the signal flow in the first embodiment of the invention; and FIG. 16 shows the signal flow in the second embodiment of the invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Operation FIG. 15 shows the operation of a first embodiment. The cylinder pressure sensor 13 detects the pressures in combustion chamber for two arbitrary crank angles θ1 and θ2 in a crank angle range where polytropic change is valid. Calculating means calculates the difference between the pressures during compression stroke (for example, crank angles 90 deg. after bottom dead center and 40 deg. before top dead center) to output a signal indicative of the pressure difference ΔP21. This signal is normalized by normalization means with respect to a pressure difference ΔP21r when the engine is in a reference condition (for example, when the throttle valve is fully opened or the engine is idle). Then, the product of the normalized signal and the air charge amount when the engine is in the arbitrary reference condition (e.g. the product of the charging efficiency eta c and the amount of air charged into the cylinder), is taken. On the basis of this product, the basic fuel injection Tp of the engine is determined by basic injection determining means. FIG. 16 shows the operation of a second embodiment. The cylinder pressure sensor 13 detects the pressure in combustion chamber for an arbitrary crank angle θ in a crank angle range where polytropic change is valid. Calculating means calculates the derivative dP/dθ of the pressure with respect to the crank angle during compression stroke (for example, crank angles 90 deg. after bottom dead center and 40 deg. before top dead center) to output a signal indicative of the derivative. This signal is normalized by normalization means with respect to a (dP/dθ)r when the engine is in a reference condition (for example, when the throttle valve is fully opened or the engine is idle). Then, the product of the normalized signal is multiplied by the air charge amount when the engine is in the arbitrary reference condition (e.g. the product of the charging efficiency eta c and the amount of air charge into the cylinder). On the basis of this product, the basic fuel injection Tp of the engine is determined by basic injection determining means. First Embodiment A first embodiment of the invention will now be described with reference to the drawings. Referring to FIG. 1, a cylinder pressure sensor 13 detects the pressure in the combustion chamber, an intake air temperature sensor 14 detects the temperature of the intake air, and an atmospheric pressure sensor 15 detects an atmospheric pressure. FIG. 2A shows a top view of the cylinder pressure sensor 13 and FIG. 2B shows a cross-sectional view taken along the line 2B--2B. FIG. 2C is a cross-sectional view, in part, for showing the cylinder pressure sensor 13 when mounted to the engine. A piezoelectric element 13A is of a gasket type which is securely sandwiched between an ignition plug 11 and a cylinder head 16. The output of the sensor 13 is the derivative of the pressure with respect to time and is integrated by an integrator in the interface circuit. The procedure for determining the fuel injection amount will be described with reference to FIG. 3. FIG. 3 is a diagram for showing cylinder pressure P vs crank angle θ. The cylinder pressure during air intake and compression stroke is depicted in dotted line A when the engine is in the reference condition, for example, when the throttle valve is fully opened. The solid line B represents the cylinder pressure when the engine is in the arbitrary condition. θ2 denotes one of the arbitrary crank angles during compression stroke and θ1 the other angle. For reasonable crank angles during the compression stroke, the polytropic change is generally valid between the cylinder pressure P and the volume V of the cylinder. Thus the following relation exists. PV.sup.n =a constant (102) Therefore, P2 and P1 are related as follows: P2=P1(V1/V2).sup.n (103) where P1 and V1 denote the cylinder pressure and the volume of the cylinder, respectively, for the crank angle θ1. P2 and V2 denote the cylinder pressure and the volume of the cylinder, respectively, for the crank angle θ2. The pressure difference ΔP21 and between P2 and P1 is given by ΔP21=P1{(V1/V2).sup.n -1)} (104) where n is a polytropic index and is usually smaller than the ratio k of specific heats of air, V1 and V2 are known, and n can be determined in advance. Thus, Eq(104) indicates that the pressure P1 can be determined by measuring the pressure difference ΔP21. Eq. (105) can be obtained by normalizing ΔP21 with respect to ΔP21r, where ΔP21r for the dotted line A corresponds to ΔP21 for the solid line B. ##EQU1## Here, the polytropic index remains the same regardless of the operating state of the engine. We also have the following relation from equation of state. P1V1=GzRT1 Gz=Ga+Ge where R is the gas constant, T1 is the temperature at the crank angle θ1, Ga is the charged air amount, and Ge is the residual exhaust gas contained in the cylinder gas Gz. Defining the residual exhaust gas rate ηe by η=Ge/Gz thus P1=Ga(1+Ge/Ga)RT1/V1=GaRT1/{V1(1-ηe)} Furthermore, from the definition of charging efficiency, Ga=ηc Go where Go is an amount of air suctioned into the cylcinder under the standard atmosphere (Po, To, one atmosphere and 0 degree Celcius and ηc is a charging efficiency. Thus, P1 is ultimately given as follows: P1=ηc GoRT1/{V1(1-ηe)} Expressing the cylinder pressure at the angle θ, in the reference condition of the engine by P1r, Eq(105) is rewritten as follows: ##EQU2## where the quantities with a suffix r are those in the reference condition. FIG. 4 illustrates the relation between ΔP21/ΔP21r on the left hand of Eq(106) and the normalized air intake which is obtained by normalizing the air intake in the manifold with respect to the atmospheric pressure. The abscissa indicates the normalized intake air pressure and the ordinate represents ΔP21/ΔP21r. The solid line indicates the characteristic for N=1500 rpm, and the dotted line for N=3000 rpm. FIG. 4 shows a case where the fully opened throttle valve is considered to be the reference condition. It should be noted that since the intake air pressure is proportional to the charged air amount, the left hand of Eq(106) well represents the charged air amount. As will be described later, it should be noted that FIG. 4 shows the characteristics specific only to the engine involved. Eq(106) can be rewritten as follows: ##EQU3## For ηc Go, the fuel supply Gf for the required air-fuel ratio F/A is derived from Eq(107) as follows: ##EQU4## Therefore, the fuel injection Ti for the air-fuel ratio F/A is given by ##EQU5## where the basic fuel injection Tp is given by ##EQU6## In other words, correcting the basic fuel injection Tp in Eq(109) with respect to the temperature T and the residual exhaust gas rate Ge/Gz will give the fuel injection Ti. That is, it is only necessary to research the value of ηcr for the engine and to store the value thus obtained into a ROM in the microcomputer so that ΔP21 and ΔP21r are measured with cylinder pressure sensor being mounted to the vehicle, then ΔP21/ΔP21r is calculated, and then the basic fuel injection Tp can be calculated by multiplying the value of ΔP21/ΔP21r by the eta cr which is read from the ROM. Further, the basic coefficient (Tr/T)(1-ηe)/(1-ηer) for the temperature and residual exhaust gas rate can be determined in advance, and the basic coefficient is then multiplied by Tp read from the ROM, thereby determining the fuel injection Ti. For an actual vehicle, when the procedure described above is to be carried out, the initial start of the engine should be selected as the reference condition because the initial start is a state that the engine first undergoes whenever the engine is to be operated. The idle condition of the engine may alternatively be selected, after the engine has been warmed up, as the reference. As will be described later, the basic coefficient of the engine will be given by (Tr/T)(1-ηe)/(1-ηer), which is specific to the engine involved once the cooling-water temperature, intake air temperature, atmospheric pressure, rotational speed, and valve timing are determined. Thus, the basic coefficient may be calculated in advance and stored in the ROM. The variations of the basic coefficient due to the intake air temperature, atmospheric pressure, rotational speed, and cooling-water temperature can also be determined and are stored in the ROm in advance. In this manner, the fuel injection Ti can be obtained. The properties of ΔP21/ΔP21r will now be discussed below. Since the ΔP21/ΔP21r is based on the pressure difference in the cylinder, it is immune to the drift in output of the cylinder pressure sensor. The effect of the variations in gain of the sensor on the sensor output is also eliminated since division is involved. Therefore, it can be said that the characteristics in FIG. 4 are specific to the engine and are affected only by the load (given by ΔP21/ΔP21r), cooling-water temperature, intake air temperature, atmospheric pressure, rotational speed, and valve timing. For example, a change in cooling-water temperature causes a change in heat loss as well as a change in polytropic index n. A change in intake air temperature causes a change in T/Tr. Also, the value of (1-ηer)/(1-ηe) changes with the valve timing. Further, a change in atmospheric pressure also causes a change in charging efficiency ηcr when the engine is in the reference condition. However, the change in the charging efficiency ηcr may be easily corrected by providing a charging efficiency correcting means as shown in FIG. 15, which detects the atmospheric pressure Pa and then calculates Pa/Po with the engine being mounted to the vehicle. The characteristics in FIG. 4 should be of a straight line passing through the origin if the basic coefficient ##EQU7## in Eq(106) is constant. The lines in FIG. 4 are straight lines generally passing through the orgin though they deviate somewhat from the origin depending on the rotational speed. The "idle" point is also nearly on the straight line. Thus, the fuel injection Ti and the basic fuel injection Tp are given as follows: ##EQU8## where f1 is a correction coefficient for the intake air temperature Ta and the load, f2 is for cooling-water temperature Tw, f3 is for the atmospheric pressure Pa, and f4 is for the rotational speed N and the load. It should be noted that in addition to Eq(111) the actual fuel injection also requires corrections for Ft, KMR, and β because the corrections for Ft, KMR, and β are necessary regardless of how the basic injection is determined. FIG. 5 shows a program for implementing the first embodiment of the present invention. The program serves as calculating means, normalization means, and basic injection determining means. FIG. 5A shows only relevant part of the main routine involved in the first embodiment. The cooling-water temperature Tw, atmospheric pressure Pa, intake air temperature Ta, and rotational speed N are read in from the sensors at step 100. The values stored in the memory are referred to determine the correction coefficients f1(Ta), f2(load, Tw) for the cooling-water temperature, f3(Pa) for the atmospheric pressure Pa, and f4(load, N) for the rotational speed. Then, ηcr is read from the memory C at step 102 and at step 103 ηcr Pa/Po is calculated and stored again into the memory C. Then the program jumps to the fuel injection calculation interrupt routine (steps 300-308) which is called upon a crank angle interrupt generated for each of the crank angles θ1 and θ2. The ηcr Pa/Po is used to calculate Tp when the fuel injection calculation interrupt routine in FIG. 5B is executed. At step 200 in FIG. 5B, a decision is made based on whether or not the crank angle signal S3 indicates θ1. If the crank angle is θ1, then the program proceeds to step 201 to store the value P1 of the pressure signal S6 at that time into the memory A and returns to the main routine; if not θ1, the crank angle is recognized as being θ2 and therefore the difference ΔP21 between P1 and P2 at that time is calculated and stored into the memory B. At step 203, a decision is made based on whether or not the condition of engine is "start", and if "start", then the value of the difference ΔP21 in the memory B is stored into the memory D, and thereafter steps 300-308 are executed to perform the fuel injection calculation interrupt. The value of ΔP21 is used as the pressure difference ΔP21r in the reference condition when calculating the fuel injection. In the interruption for the fuel injection calculation in FIG. 5B, ΔP21 is first read out from the memory B at step 300, then ΔP21r is read out from the memory D, and then the ratio ΔP21/P21r is calculated at step 302. The basic coefficients for ΔP21/P21r are read from the memory at step 303, then ηcr Pa/Po is read as η'cr from the memory C at step 304, and the product of the values obtained in steps 302-304 is obtained to calculate the basic injection Tp at step 305. Then the values of the corrections f1, f2, f3, 3, and f4 are read out at step 306, the fuel injection Ti is calculated at step 307, and then returns to the main routine after the injector is driven at step 308. The steps 200-308 described above are repeated whenever the crank angle interrupt for each of the crank angles θ1 and θ2 is activated. The first embodiment has been described assuming that the polytropic index n is the same for both the arbitrary and reference conditions of the engine. If the two conditions differ in the index n, the following relation is obtained. ##EQU9## thus Eq(108) representing Ti is simply modified by introducing a correction factor for the polytropic index n. The value of this correction factor depends on the load and the rotational speed of the engine. This value may be included in the correction f4(load, N) as well as f4(ΔP21/ΔP21r, N). The operation in FIG. 5B is carried out when the crank interrupt is activated but the operation may be carried out by monitoring the crank angles at all times to detect a predetermined crank angle. Although ΔP21r is directly stored into the memory D after it is detected, the value of ΔP21r before the engine is mounted to the vehicle may be measured as ΔP21ro, and the ratio Kg1 of P21ro to ΔP21r may be stored in the memory D, in which case ΔP21/ΔP21r can be obtained by ##EQU10## Second Embodiment FIG. 12 is a graph for showing the relation between the crank angle θ and the pressure P in the cylinder, which relation is used in a second embodiment. The dotted line indicates the pressure in the cylinder 5 when the engine is in the reference condition as in the first embodiment, such as suction stroke or compression stroke when the throttle valve 3 is fully opened, while the solid line represents the pressure when the engine is in the arbitrary condition. For reasonable crank angles during the compression stroke, the polytropic change is generally valid between the cylinder pressure P and the volume V of the cylinder. Thus the following relation exists. PV.sup.n =a (202) where a is a constant. Differentiating Eq(202) with respect to the crank angle θ, we obtain ##EQU11## Putting Eq(202) into Eq(203), we obtain ##EQU12## where n is the polytropic index and is smaller than the ratio k of specific heats of air. V and dV/dθ are known and n can be determined by researching it in advance. Thus, the pressure P in the cylinder can be determined by measuring dP/dθ. Assuming that the polytropic index n will not change, Eq(205) is obtained by normalizing dP/dθ with respect to (dP/dθ)r as follows: ##EQU13## where (dP/dθ)r is a quantity corresponding to the dotted line in FIG. 12, and (dP/dθ) is a quantity corresponding to the solid line, and Pr is the cylinder pressure when the engine is in the reference condition. We also have the following relation from equation of state. PV=GzRT Gz=Ga+Ge where R is the gas constant, T is the temperature of a gas at the crank angle θ1, Ga is an amount of air charged, Ge is residual exhaust gas of the gas Gz contained in the cylinder. Defining residual exhaust gas rate ηe by ηe=Ge/Gz we obtain P=Ga(1+Ge/Ga)RT/V =GaRT/{V(1-ηe)} Furthermore, from the definition of charging efficiency, Ga=ηc Go where Go is an amount of air suctioned into the cylinder at the standard atmosphere (Po, To). Thus, P is ultimately given as follows: P1=ηc GoRT1/{V(1-ηe)} Thus, Eq(205) is rewritten as follows: ##EQU14## where the quantities with a suffix r are those in the reference condition. FIG. 13 illustrates (dP/dθ)/(dP/dθ)r on the left hand of Eq(206) vs the normalized air intake which is obtained by normalizing with respect to the atmospheric pressure. The abscissa indicates the normalized intake air pressure and the ordinate represents (dP/dθ)/(dP/dθ)r. The solid line indicates the characteristic for N=1500 rpm, and the dotted line for N=3000 rpm. FIG. 13 shows a case where the throttle valve 3 is fully open when the engine is in the reference condition. Since the intake air pressure is proportional to the charged air amount, the left hand of Eq(206) well represents the charged air amount. Thus, as will be described later, it can be said that FIG. 13 shows the characteristics specific only to the engine involved. Now, Eq(206) can be rewritten as follows: ##EQU15## For ηc Go, the fuel supply Gf for the required air-fuel ratio is derived from Eq(107) as follows: ##EQU16## where F/A is the air-fuel ratio. Therefore, the fuel injection Ti for the air-fuel ratio F/A is given by ##EQU17## where the basic fuel injection Tp is given by ##EQU18## Correcting the basic fuel injection Tp in Eq(209) with respect to the temperature T and the residual exhaust gas rate Ge/Gz will give the fuel injection Ti. Thus, it is only necessary to research the value of ηcr for the engine and to store the value of ηcr thus obtained into a ROM in the microcomputer so that dP/dθ and (dP/dθ)r are measured with cylinder pressure sensor being mounted to the vehicle, then (dP/dθ)/(dP/dθ)r is calculated, and the basic fuel injection Tp can be calculated by multiplying the value of (dP/dθ)/(dP/dθ)r by the ηcr which is read from the ROM. Further, the basic coefficient (Tr/T)(1-ηer) for the temperature and residual exhaust gas rate can be determined in advance, and is then multiplied by Tp read from the ROM, thereby determining the fuel injection Ti. For the actual vehicle, when the above-described procedure is to be carried out, the initial start of the engine should be selected as the reference condition because the start is a state that the engine first undergoes whenever the engine is to be operated. The idle condition of the engine may be selected as the reference once the engine has been warmed up. As will be described later, the basic coefficient (Tr/T)(1-η%)/(1-ηer) of the engine will become specific to the engine involved once the cooling-water, intake air temperature, atmospheric pressure, rotational speed, and valve timing are fixed, thus the basic coefficients may be calculated in advance and stored in the ROM. The variations of the basic coefficient can also be determined in advance with respect to the intake air temperature, atmospheric pressure, rotational speed, and cooling-water temperature and is stored in the ROM. In this manner, the fuel injection Ti can be obtained. Since the (dP/dθ)/(dP/dθ)r is based on the pressure difference in the cylinder 5, it is immune to the drift in the output of the cylinder pressure sensor 13. The effect of the variations in gain of the sensor 13 on the sensor output is also eliminated since division is involved. Therefore, it can be said that the characteristics in FIG. 13 are specific only to the engine and are affected only by the cooling-water temperature, intake air atomspheric pressure, rotational speed, and valve timing. For example, a change in cooling-water temperature causes a change in heat loss as well as a change in polytropic index n. A change in intake air temperature causes a change in T/Tr. Also, the value of (1-ηer)/(1-ηe) changes with the valve timing. Further, a change in atmospheric pressure also causes a change in charging efficiency. ηcr when the engine is in the reference condition. However, the change in the charging efficiency ηcr may be easily corrected by providing a charging efficiency correcting means as shown in FIG. 16, which detects the atmospheric pressure Pa and then calculates Pa/Po. The characteristics in FIG. 13 should be of a straight line passing through the origin if the basic coefficient (T/Tr)(1-ηer)/(1-ηe) in Eq(206) is constant. In fact, the lines in FIG. 13 are straight lines substantially passing through the origin. The "idle" point is also nearly on the straight lines. Thus, the fuel injection Ti and the basic fuel injection Tp are given as follows: ##EQU19## It should be noted that in addition to Eq(208) the actual fuel injection also requires corrections for Ft, KMR, and β because the corrections for Ft, KMR, and β are necessary corrections regardless of how the basic injection Tp is determined. FIGS. 14A-14C are the flowcharts of a program for implementing the second embodiment of the invention. The program serves as calculating means, normalization means, and injection determining means. FIG. 14A shows only part of the main routine involved in the second embodiment. At step 100, the cooling-water temperature Tw, atmospheric pressure Pa, intake air temperature Ta, and rotational speed N are read in from the sensors. The correction coefficients f1(Ta), f2(load, Tw) for the cooling-water temperature, f3(Pa) for the atmospheric pressure Pa, and f4(load, N) for the rotational speed are determined by reading values from the memory. Then, ηcr is read from the memory C at step 102 and η'cr=ηcr Pa/Po is calculated and stored again into the memory C at step 103. Then the program jumps to the fuel injection calculation interrupt routine which is called upon a crank angle interrupt generated for each of the crank angles θ1 and θ2. The η'cr is used to calculate Tp when executing a fuel injection calculation interrupt routine in FIG. 14B. At step 200 in FIG. 14B, the value of dP/dθ for the predetermined angle at which the interrupt occurs, is stored into the memory A. At step 201, a decision is made based on whether or not the engine condition is "start". If the engine condition is the "start," then the same value of dP/dθ as step 200 is stored into the memory B and is used as (dP/dθ)r to calculate the fuel injection Ti when the interrupt routine in FIG. 14C is called; if not the "start," then the program proceeds to step 300. In FIG. 14C, the value of dP/dθ is read from the memory A at step 300, and the value of (dP/dθ)r is read from the memory B at step 301, and then the ratio (dP/dθ)/(dP/dθ)r is calculated at step 302. The basic coefficient that corresponds to (dP/dθ)/(dP/dθ)r is read out at step 303, η'cr=ηcr Pa/Po is read at step 304, and the basic fuel injection Tp is calculated by taking the product of the values obtained at steps 302, 303, and 304. Then, the correction coefficients f1-f4 are read at step 306, the fuel injection Ti is calculated at step 307, and the fuel injection valve 10 is driven at step 308. Thereafter the program returns to the main routine. The interrupt routine is resumed when the crank angle interrupt for each of the crank angles θ1 and θ2 is activated again. The second embodiment has been described assuming that the polytropic index n is the same for both the arbitrary condition of the engine and the reference condition of the engine. If the two conditions differ in index n, the following relation is obtained. ##EQU20## thus Eq(208) representing Ti is simply modified by introducing a correction factor related to polytropic index n. The value of this correction factor depends on the load and the rotational speed of the engine. This value may be included in the correction f4{(dP/dθ)/(dP/dθ)r, N). The piezoelectric type pressure sensor shown in FIG. 2 inherently detects the cylinder pressure differentiated with respect to time, i.e., dP/dt=6N(dP/dθ). Thus, using dθ=6Ndt, we obtain ##EQU21## thus, the fuel injection Ti is given by ##EQU22## and the fuel injection Tp is given by ##EQU23## requiring only addition of a correction N/Nr for rotation which may be included in f4={(dP/dθ)/(dP/dθ)r, N}. The operation in FIG. 5 is carried out when the crank interrupt is activated but the operation may be carried out by monitoring the crank angles at all times to thereby detect a predetermined crank angle. Although (dP/dθ)r is directly stored into the memory B after it is detected, the value of (dP/dθ)r before the engine is mounted to the vehicle may be measured as (dP/dθ)ro, and the ratio Kg2 of (dP/dθ)ro to dP/dθ)r may be stored in the memory B, in which case (dP/dθ)/(dP/dθ)r can be obtained by ##EQU24## While in the above-described first and second embodiments the fully opened throttle valve was assumed as the reference condition, the embodiments are only exemplary and for example, the idle condition of the engine may be assumed as the reference condition. Also, the cylinder pressure sensor 13 may be of a semiconductor type. The crank angle θ1 and θ2 should be in a range in which the logP-logV graph of FIGS. 6A-6B are linear so that polytropic change is valid. FIG. 6A shows the logP -logV graph when the throttle is fully opened and FIG. 6B when the engine is partially loaded. In general, the range in which the logP-logV graph has a constant slope, considerably varies from engine to engine since the heat loss from the operating gas in the cylinder must depend only on the temperature of the operating gas. In other words, the polytropic change is valid only when the following relation is satisfied. dq=KdT where dq is a heat loss, T is a gas temperature, and dT is a change in gas temperature T. The heat loss is dependent on the heat transfer rate in the cylinder and the surface area through which heat is transferred, which varies from engine to engine, and thus the range of crank angles depends on engines. As a rule of thumb, the crank angles θ1 and θ2 can be set somewhere between compression dead center 90 deg. and an angle just before an increase in pressure due to combustion appears.
A fuel control apparatus for an internal combustion engine comprises a pressure sensor for detecting the pressure in a combination chamber and a crank angle sensor for detecting a crank angle. During compression stroke, a microcomputer calculates the difference in pressure in the combustion chamber between two crank angles, or differentiates the pressure in the combustion chamber with respect to the crank angle at an arbitrary crank angle. Then, the microcomputer normalizes the pressure difference between the two crank angles by the pressure difference between the two crank angles when the engine is in an arbitrary reference condition, for example, its start condition, or normalizes the differentiated pressure at the arbitrary crank angle by the differentiated pressure at the arbitrary crank angle when the engine is in the arbitrary reference condition, for example, its start condition. The microcomputer then calculates the product of an amount of charged air and the pressure difference or the pressure differentiated which has been normalized, thereby producing a basic fuel injection.
5
This Application is a Divisional Application of Ser. No 09/077,787, filed Sep. 29, 1998, now U.S. Pat. No. 6,184,381, which is a 371 of PCT/JP96/03523 filed Dec. 6, 1996. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing optically active compounds such as optically active alcohols and optically active amines. More specifically, the present invention relates to a novel, highly practical method for producing optically active compounds useful for various utilities such as intermediates for synthesizing pharmaceutical chemicals, liquid crystal materials and agents for optical resolution. 2. Description of the Related Art Various methods for producing optically active compounds have been known conventionally. As the method for asymmetrically synthesis of optically active alcohol compounds, for example, the following methods have been known; (1) a method by using enzymes such as baker's yeast; and (2) a method for asymmetric hydrogenation of carbonyl compounds by using metal complex catalysts. For the method (2), in particular, a great number of examples of asymmetric catalytic reactions have been reported for example as follows; (1) an asymmetric hydrogenation of carbonyl compounds with functional groups, by means of optically active ruthenium catalysts, as described in detail in Asymmetric Catalysis in organic Synthesis, Ed. R. Noyori., pp. 56-82 (1994); (2) a method through hydrogen transfer-type reduction by means of chiral complex catalysts of ruthenium, rhodium or iridium, as described in Chem. Rev., Vol. 92, pp. 1051-1069 (1992); (3) a process of asymmetric hydrogenation tartaric acid by means of a modified nickel catalyst with tartaric acid as described in Oil Chemistry, pp.882-831 (1980) and Advances in Catalysis, Vol.32, pp.215 (1983), Ed. Y. Izumi; (4) an asymmetric hydrosilylation method, as described in Asymmetric Synthesis, Vol.5, Chap.4 (1985), Ed. J. D. Morrison and J. Organomet. Chem. Vol.346, pp.413-424 (1988); and (5) a borane reduction process in the presence of chiral ligands as described J. Chem. Soc., Perkin Trans.1, pp.2039-2044 (1985) and J. Am. Chem. Soc., Vol.109, pp. 5551-5553 (1987). By the conventional method by means of enzymes, however, alcohols can be recovered at a relatively high optical purity, but the reaction substrate therefor is limited and the absolute configuration in the resulting alcohols is limited to specific one. By the asymmetric hydrogen hydrogenation method by means of transition metal complex catalysts, optically active alcohols can be produced at a high selectivity, but a pressure-resistant reactor is required therefor because hydrogen gas is used as the hydrogen source, which is disadvantageous in terms of operational difficulty and safety. Furthermore, the method through such asymmetric hydrogen transfer-type reduction by using conventional metal complex catalysts is limited in that the method requires reaction conditions under heating and the reaction selectivity is insufficient, disadvantageously in practical sense. Accordingly, it has been desired conventionally that a new, very general method for synthesizing optically active alcohols by using a highly active and highly selective catalyst with no use of hydrogen gas be achieved. But no highly efficient and highly selective method for producing such secondary alcohols through asymmetric synthetic reaction by using catalysts similar to those described above has been established yet. As to the optically active secondary alcohols, a method for synthesizing optically active secondary alcohols via optional resolution of racemic secondary alcohols has been known for some reaction substrate which can hardly be reduced, although an excellent optical purity is hardly attained. (Asymmetric Catalysis in Organic Synthesis, Ed. R. Noyori). Because hydrogen transfer-type reduction is a reversible reaction according to the method, dehydrogenation-type oxidation as its adverse reaction is used according to the method. Therefore, the method is called as kinetic optical resolution method. According to the method, however, no process of producing optically active secondary alcohols with catalysts at a high efficiency has been reported yet. As the method for synthetically producing optically active amine compounds, furthermore, a process of optically resolving once produced racemic compounds by using optically active acids and a process through asymmetric synthetic reaction have been known. By the optical resolution process, however, optically active acids should be used at an equal amount or more to amine compounds disadvantageously and complex procedures such as crystallization, separation and purification are required so as to recover optically active amine compounds. As the method through asymmetric synthesis, alternatively, the following processes have been known; (1) an enzymatic process; (2) a process by using metal hydride compounds; and (3) a process of asymmetric hydrogenation by using metal complex catalysts. As to the process by using metal hydride compounds as described above in (2), a great number of reports have been issued about a process of asymmetrically reducing carbon-nitrogen multiple bonds by using an metal hydrides with chiral modifiers. As a general process thereof, for example, it has been known a stoichiometric reduction process of imine compounds and oxime compounds by using a metal hydrides with an optically active ligand, as described in Comprehensive Organic Synthesis, EdS. B. M. Trost and I. Flemming, Vol.8, p.25 (1991), Organic Preparation and Procedures Inc. O. Zhu, R. O. Hutchins, and M. K. Huchins, Vol.26(2), pp.193-235 (1994) and Japanese Patent Laid-open No. 2-311446. The process includes a number of processes with excellent reaction selectivity, but these processes are disadvantageous because that these processes require the use of a reaction agent at an equivalent weight or more to a reaction substrate, along with neutralization treatment after the reaction and additionally in that these processes require laborious purification procedures to recover optically active substances. As the process of asymmetric hydrogenation of carbon-nitrogen multiple bonds by using metal complex catalysts as the method (3), it has been known an asymmetric hydrogenation process of imine compounds with functional groups, by means of optically active metal complex catalysts, as described in Asymmetric Catalysis inorganic Synthesis, pp.82-85 (1994), Ed. R. Noyori. But the process has a drawback in terms of reaction velocity and selectivity. By the method by using enzymes as the method (1), furthermore, amines at a relatively high optical purity can be recovered, but the reaction substrates are limited and the resulting amines have only specific absolute configurations. Furthermore, at a process of asymmetric hydrogenation by means of complex catalysts of transition metals using hydrogen gas, optically active amines have not yet been recovered at a high selectivity or pressure-resistant reactors are essentially required because hydrogen gas is used as the hydrogen source. Hence, such process is disadvantageous because of technically difficult operation and safety problems. Accordingly, it has been demanded that a novel method for synthesizing an optically active amine by using a very common, highly active and highly selective catalyst be realized. Alternatively, a great number of transition metal complexes have been used conventionally as catalysts for organic metal reactions; particularly because rare metal complexes are highly active and stable with the resultant ready handleability despite of high cost, synthetic reactions using the complexes have been developed. The progress of such synthetic reactions using chiral complex catalysts is innovative, and a great number of reports have been issued, reporting that highly efficient organic synthetic reactions have been realized. Among them, a great number of asymmetric reactions using chiral complexes catalysts with optically active phosphine ligands as the catalysts therefor have already been developed, and some of them have been applied industrially (Asymmetric Catalysis in Organic Synthesis, Ed. R. Noyori). As complexes of optically active nitrogen compounds coordinated with transition metals such as ruthenium, rhodium and iridium, a great number of such complexes additionally having excellent properties as catalysts for asymmetric synthetic action have been known. So as to enhance the properties of these catalysts, a great number of propositions concerning the use of optically active nitrogen compounds of specific structures have been done (Chem. Rev., Vol.92, pp.1051-1069 (1992)). For example, reports have been issued about (1) optically active 1,2-diphenylethylenediamines and rhodium-diamine complexes with ligands of cyclohexanediamines, as described in Tetrahedron Asymmetry, Vol.6, pp.705-718 (1995); (2) ruthenium-imide complex with ligands of optically active bisaryliminocyclohexanes, as described in Tetrahedron, Vol. 50, pp.4347-4354 (1994); (3) iridium-pyridine complex with ligands of pyridines, as described in Japanese Patent Laid-open Nos. 62-281861 and 63-119465; (4) optically active 1,2-diphenylethylenediamines or iridium-diamine complex with ligands of cyclohexanediamines, as described in Japanese Patent Laid-open No.62-273990; (5) ruthenium-diamine complex of RuCl[p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ] (arene) (chloro-(N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(arene)ruthenium) (arene represents benzene which may or may not have a substituent), which is produced by coordinating ruthenium with optically active N-p-toluenesulfonyl-1,2-diphenylethylenediamine [referred to as “p-TsNHCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ” hereinabove and below], as described in J. Am. Chem. Soc., Vol.117, pp.7562-7563(1995); J. Am. Chem. Soc., Vol.118, pp.2521-2522 (1996) and J. Am. Chem. Soc., Vol.118, pp.4916-4917 (1996). Even if these complexes are used, however, problems currently remain to be overcome for practical use, including insufficient catalyst activities, sustainability and optical purities, depending on the subjective reactions and reaction substrates. SUMMARY OF THE INVENTION So as to overcome the aforementioned problems, the present invention is to provide a method for producing optically active compounds, comprising subjecting a compound represented by the following formula (I); (wherein Ra and Rb independently represent a linear or cyclic hydrocarbon group or heterocyclic group which may or may not have a substituent; W 1 represents oxygen atom, N-H, N-Rc, N-OH or N-O-Rd; and Rc and Rd represent the same hydrocarbon group or heterocyclic group as described above) to transfer-type asymmetric reduction in the presence of a transition metal complex and an optically active nitrogen-containing compound or a transition metal complex with an optically active nitrogen-containing compound as an asymmetric ligand, along with a hydrogen-donating organic or inorganic compound, to produce an optically active compound represented by the following formula (II); (wherein W 2 represents OH, NH2, NH-Rc, NH-OH or NH-O-Rd; and Ra, Rb, Rc and Rd independently represent the same as those described above). Additionally, the present invention is to provide a method for producing an optically active alcohol according to the aforementioned method, comprising asymmetrically reducing a carbonyl compound represented by the following formula (III); (wherein R 1 represents an aromatic hydrocarbon group, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group, which may or may not have a substituent, or a heterocyclic group which may or may not have a substituent and contains hetero atoms such as nitrogen, oxygen, sulfur atoms and the like as atoms composing the ring; R 2 represents hydrogen atom, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group which may or may not have a substituent, or an aromatic hydrocarbon group, or the same heterocyclic group as described above; and R 1 and R 2 may satisfactorily be bonded together to form a ring), to produce an optically active alcohol represented by the following formula (IV); (wherein R 1 and R 2 are the same as described above). Furthermore, the present invention is to provide a method for producing an optically active amine, comprising asymmetrically reducing an imine compound represented by the following formula (V); (wherein R 3 represents an aromatic hydrocarbon group, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group, which may or may not have a substituent, or a heterocyclic group which may or may not have a substituent and contains hetero atoms such as nitrogen, oxygen, sulfur atoms and the like as atoms composing the ring; R 4 represents hydrogen atom, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group which may or may not have a substituent, or an aromatic hydrocarbon group, or the same heterocyclic group as described above; R 5 represents hydrogen atom, or a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group, which may or may not have a substituent, or an aromatic hydrocarbon group, or the same heterocyclic group as described above, or the hydrocarbon group or heterocyclic group bonded together via hydroxyl group or oxygen atom; and R 3 and R 4 , R 3 and R 5 or R 4 and R 5 , are bonded together to form a ring), to produce optically active amines represented by the following formula (VI); (wherein R 3 , R 4 and R 5 are the same as described above). Still furthermore, the present invention is to provide a method for producing optically active secondary alcohols, comprising subjecting racemic secondary alcohols or meso-type diols to hydrogen transfer reaction by using a catalyst of an optically active ruthenium-diamine complex represented by the following general formula (VII); (wherein * represents an asymmetric carbon atom; R 01 and R 02 are the same or different, independently representing alkyl group, or phenyl group or cycloalkyl group which may or may not have an alkyl group; or R 01 and R 02 together form an alicyclic ring unsubstituted or substituted with an alkyl group; R 03 represents methanesulfonyl group, trifluoromethanesulfonyl group, naphthylsulfonyl group, camphor sulfonyl group, or benzenesulfonyl group which may or may not be substituted with an alkyl group, an alkoxyl group or halogen atom, alkoxycarbonyl group, or benzoyl group which may or may not be substituted with an alkyl group; R 04 represents hydrogen atom or alkyl group; X represents an aromatic compound which may or may not be substituted with an alkyl group; and m and n together represent 0 or 1). DESCRIPTION OF THE PREFERRED EMBODIMENTS In accordance with the present invention, the characteristic methods for producing optically active compounds and catalysts therefor as described above are provided. The detail is described below. Firstly, the method for producing an optically active alcohol of the general formula (I) wherein W 1 is oxygen atom and of the general formula (II) wherein R 2 is OH (hydroxyl group) is described. In the formulas (I) and (II), Ra and Rb independently represent a linear or cyclic hydrocarbon or heterocyclic group which may or may not have a substituent, and the carbonyl compound represented by Ra, Rb and W 1 (oxygen atom) are represented by the following formula (III) as described above, and the optically active alcohol compound produced by the hydrogen transfer-type asymmetric reduction of the carbonyl compound represented by the formula (III) may satisfactorily be represented by the formula (IV). Herein, R 1 represents a monocyclic or polycyclic aromatic hydrocarbon group, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group, which may or may not have a substituent, or a heterocyclic group which may or may not have a substituent and contains hetero atoms such as nitrogen, oxygen, sulfur atoms and the like as atoms composing the ring. The cyclic aliphatic hydrocarbon group and heterocyclic group may satisfactorily be monocyclic or polycyclic like the aromatic hydrocarbon group. The cyclic hydrocarbon (aromatic or alicyclic) and the heterocyclic groups are of condensed series or non-condensed series if they are polycyclic. For example, R 1 specifically includes aromatic monocyclic or polycyclic groups such as phenyl group, 2-methylphenyl, 2-ethylphenyl, 2-isopropylphenyl, 2-tert-butylphenyl, 2-methoxyphenyl, 2-chlorophenyl, 2-vinylphenyl, 3-methylphenyl, 3-ethylphenyl, 3-isopropylphenyl, 3-methoxyphenyl, 3-chlorophenyl, 3-vinylphenyl, 4-methylphenyl, 4-ethylphenyl, 4-isopropylphenyl, 4-tert-butylphenyl, 4-vinylphenyl, cumenyl (cumyl), mesityl, xylyl, 1-naphthyl, 2-naphthyl, anthryl, phenanthryl, and indenyl; hetero monocyclic or polycyclic groups such as thienyl, furyl, pyranyl, xanthenyl, pyridyl, pyrrolyl, imidazolynyl, indolyl, carbazoyl, and phenanthronylyl; and ferrocenyl group. Like these examples, the compound may satisfactorily have various substituents as the substituent, which may be hydrocarbon groups such as alkyl, alkenyl, cycloalkyl and cycloalkenyl; halogen atoms; oxygen-containing groups such as alkoxy group, carboxyl group and ester group; nitro group; amino group and the like. Alternatively, R 2 represents hydrogen atom, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group which may or may not have a substituent or an aromatic hydrocarbon group, or the same heterocyclic group containing hetero atoms, as described above. These are for example alkyl groups such as methyl, ethyl, propyl, butyl, pentyl, hexyl and heptyl; cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl; unsaturated hydrocarbon such as vinyl and allyl; and the same as those for R 1 . Furthermore, R 2 may satisfactorily include derivatives of β-keto acid with a functional group at position β. When R 1 and R 2 are bonded together to form a ring, R 2 is for example a saturated or unsaturated alicyclic group to form cyclic ketones, such as cyclopentanone, cyclohexanone, cycloheptane, cyclopentenone, cyclohexenone, and cycloheptenone; and saturated and unsaturated alicyclic groups with a linear or cyclic hydrocarbon substituent group containing alkyl group, aryl group, unsaturated alkyl group and hetero atom on individual carbons. According to the method for producing optically active alcohol compounds through asymmetric reduction of carbonyl compounds, an asymmetric reduction catalyst system of a transition metal complex and an optically active nitrogen-containing compound is used for the asymmetric reduction. As the metal catalyst, then, use is made of various transition metals because they have ligands; particularly preferably; use is made of a transition metal complex represented by the following general formula (a); MXmLn  (a) (wherein M represents transition metals of group VIII, such as iron, cobalt, nickel, ruthenium, rhodium, iridium, osmium, palladium and platinum; X represents hydrogen, halogen atom, carboxyl group, hydroxy group and alkoxy group and the like; L represents neutral ligands such as aromatic compounds and olefin compounds; and m and n represent an integer). As the transition metals in these transition metal catalysts, ruthenium is one of preferable examples. When the neutral ligands are aromatic compounds, a monocyclic aromatic compound represented by the following general formula (b) can be illustrated. Herein, R 0 's are all the same or different substituent groups, including hydrogen atom, a saturated or unsaturated hydrocarbon group, allyl group or a functional group containing hetero atoms. For example, R 0 includes alkyl groups such as methyl, ethyl, propyl, isopropyl, butyl, t-butyl, pentyl, hexyl, and heptyl; cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl; groups of unsaturated hydrocarbons such as benzyl, vinyl, and allyl; functional groups containing hetero atoms, such as hydroxyl group, alkoxy group, and alkoxycarbonyl group. The number of the substituents R 0 's is an appropriate number of 1 to 6, and the substituents can occupy any position. The transition metal catalysts of the group VIII and the like are used to an amount variable, depending on the size, mode and economy of the reactor, but the catalysts may satisfactorily be used within a molar ratio range of approximately 1/100 to 1/100,000, preferably 1/500 to 1/5,000 to the reaction substrate carbonyl compound. In accordance with the present invention, use is made of optically active nitrogen-containing compounds in the asymmetric catalyst system, and it is possibly assumed that the compounds are present as asymmetric ligands to the transition metal complexes or serve as such. For more easily understandable expression, such optically active nitrogen-containing compounds may also be illustrated as “optically active amine compounds”. The optically active amine compounds are optically active diamine compounds represented by the following general formula (c); (wherein R 9 , R 10 , R 15 and R 16 are independently hydrogen, a saturated or unsaturated hydrocarbon group, urethane group or sulfonyl group; R 11 , R 12 , R 13 and RL 14 are the same or different so that the carbon bonded with these substituent groups might occupy the asymmetric center, including hydrogen atom, an aromatic group, a saturated or unsaturated aliphatic hydrocarbon group or cyclic aliphatic hydrocarbon group; even in this case, the aromatic or cyclic aliphatic group may be monocyclic or polycyclic; the polycyclic aromatic group is any of condensed series or non-condensed series; and furthermore, any one of R 11 and R 12 and any one of R 13 and R 14 are bonded together to form a ring. For example, such compounds include optically active diamine compounds such as optically active 1,2-diphenylethylenediamine, 1,2-cyclohexanediamine, 1,2-cycloheptanediamine, 2,3-dimethylbutanediamine, 1-methyl-2,2-diphenylethylenediamine, 1-isobutyl-2,2-diphenylethylenediamine, 1-isopropyl-2,2-diphenylethylenediamine, 1-methyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-isobutyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-isopropyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-benzyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-methyl-2,2-dinaphthyldiamine, 1-isobutyl-2,2-dinaphthylethylenediamine, 1-isopropyl-2,2-dinaphthylethylenediamine and the like. Additionally, optically active diamine compounds wherein any one or two of substituents R 9 through R 15 are sulfonyl group, acyl group or urethane group are illustrated. Preferably, furthermore, use may be made of optically active diamine compounds with one sulfonyl group. Furthermore, the optically active diamine (compounds) for potential use are not limited to the illustrated optically active ethylenediamine derivatives, and use may be made of optically active propanediamine, butanediamine, and phenylenediamine derivatives. As the optically active amine compounds, use is made of optically active amino alcohol compounds represented by the following general formula (d). Herein, at least one of R 17 and R 18 is hydrogen atom, and the remaining one is hydrogen atom, a saturated or unsaturated hydrocarbon group, urethane group or sulfonyl group; R 19 , R 20 , R 21 and R 22 are the same or different so that the carbon bonded with these substituent groups might occupy the asymmetric center, including hydrogen atom, a monocyclic or polycyclic aromatic group, a saturated or unsaturated aliphatic hydrocarbon group, and a cyclic aliphatic hydrocarbon group; R 23 represents hydrogen atom, a monocyclic or polycyclic aromatic group, a saturated or unsaturated aliphatic hydrocarbon group and cyclic aliphatic hydrocarbon group. Furthermore, any one of R 19 and R 20 and any one of R 21 and R 22 may satisfactorily be bonded together to form a ring. Additionally, any one of R 17 and R 18 and any one of R 20 and R 21 may satisfactorily be bonded together to form a ring. More specifically, use may satisfactorily be made of optically active amino-alcohols shown in the examples described below. As the optically active amine compounds, furthermore, use may be made of aminophosphine compounds represented by the following general formula (e); Herein, R 24 and R 25 are hydrogen atom, a saturated or unsaturated hydrocarbon group, urethane group, sulfonyl group and acyl group; (CR 2 26 ) n are the same or different so that the carbon bonded with these substituent groups might occupy the asymmetric center, including hydrogen atom, a monocyclic or polycyclic aromatic group, a saturated or unsaturated hydrocarbon group, and a cyclic hydrocarbon group; R 27 and R 28 represent hydrogen atom, and a saturated or unsaturated hydrocarbon group. More specifically, use may be made of the optically active aminophosphines shown in the examples. The optically active amine compounds as illustrated above are generally used for example at an amount at approximately 0.5 to 20 equivalents, and preferably used for example within a range of 1 to 4 equivalents, to the transition metal complex. In the aforementioned catalyst system to be used for the method for producing optically active alcohols through asymmetric reduction of carbonyl compounds, advantageously, an additional basic substance is advantageously present currently. Such basic substance includes for example metal salts or quaternary ammonium compounds represented by the following formula (f); M 1 Y  (f) (wherein M 1 represents an alkali metal or alkali earth metal; and Y represents hydroxy group, alkoxy group, mercapto group and naphthyl group). More specifically, M 1 includes KOH, KOCH 3 , KOCH(CH 3 ) 2 , KOC(CH 3 ) 3 , KC 10 H 8 , LiOH, LiOCH 3 , LiOCH(CH 3 ) 2 , LiOC(CH 3 ) 3 , NaOH, NaOCH 3 , NaOCH(CH 3 ) 2 , NaC 10 H 8 , NaOC(CH 3 ) 3 , and the like. Furthermore, quaternary ammonium salts may be used satisfactorily. The amount of the base to be used is generally about 0.5 to 50 equivalents, preferably 2 to 10 equivalents to the transition metal complex. As has been described above, the basic substance is used for smoothly progressing the asymmetric reduction. Therefore, the base is an important component so as to give optically active alcohol compounds with a high a optical purity. For the method for producing optically active alcohol compounds through hydrogen transfer-type asymmetric reduction in accordance with the present invention, it is inevitable to use hydrogen-donating organic or inorganic compounds. By these are meant compounds capable of donating hydrogen via thermal action or catalytic action, and the types of such hydrogen-donating compounds are not specifically limited, but preferably include alcohol compounds such as methanol, ethanol, 1-propanol, 2-propanol, butanol, and benzyl alcohol; formic acid and salts thereof, for example those in combination with amines; an unsaturated hydrocarbon and heterocyclic compounds having in part a saturated carbon bond, such as tetralin and decalin; hydroquinone or phosphorous acid or the like. Among them, alcohol compounds are preferable, and 2-propanol and formic acid are more preferable. The amount of an organic compound to be used and function as a hydrogen source is determined on the basis of the solubility and economy of the reaction substrate. Generally, the substrate concentration may be about 0.1 to 30% by weight for some type of substrates, but preferably, the concentration is 0.1 to 10% by weight. When using formic acid and a combination of formic acid with amine as a hydrogen source, no solvent is necessarily used. If any solvent is intentionally used, use is made of aromatic compounds such as toluene and xylene; halogen compounds such as dichloromethane, organic compounds such as DMSO, DMF or acetonitrile. According to the method for producing optically active alcohol compounds in accordance with the present invention, hydrogen pressure is essentially not required, but depending on the reaction conditions, hydrogen pressure may satisfactorily be loaded. Even if hydrogen pressure is loaded, the pressure may satisfactorily be about 1 atom. to several atm. because the catalyst system is extremely highly active. The reaction temperature is about −20° C. to 100° C. from the economical standpoint. More practically, the reaction can be carried out around room temperature of 25 to 40° C. The reaction time varies, depending on the reaction conditions such as the concentration of a reaction substrate, temperature and pressure, but the reaction is on completion from several minutes to 100 hours. For use, the metal complex is preliminarily mixed with an optically active amine compound as an optically active nitrogen-containing compound, but an a chiral metal complex may be synthesized preliminarily by the following method, and the resulting complex may be used. More specifically, the method comprises adding an optically active amine compound, a transition metal complex and a complex into for example alcohol, and subsequently heating the resulting mixture in an inactive gas under agitation. Then, the resulting solution is cooled and treated under reduced pressure, prior to recrystallization, to prepare an asymmetric complex catalyst. Together with the method for producing optically active alcohol compounds as described above, the present invention is to provide a method for producing optically active amine compounds represented by the general formula (II) as described above, wherein W 1 is OH, NH 2 , NH-Rc, NH-OH or NH-O-Rd, comprising asymmetric reduction by using an imine compound represented by the general formula (I) wherein W 1 is NH, N-Rc, N-OH or N-O-Rd (Rc and Rd independently represent a linear or cyclic hydrocarbon group which may or may not have a substituent, or a heterocyclic group). More specifically, for example, the present invention is to provide a method for producing an optically active amine compound of the following formula (VI), comprising asymmetric reduction of an imine compound of the following formula (V). Herein, R 3 and R 4 are almost the same as those in the case of the carbonyl compounds and the optically active alcohol compounds of the formulas (III) and (IV), respectively. For example, R 3 is an aromatic monocyclic or polycyclic hydrocarbon group, unsubstituted or substituted, a saturated or unsaturated aliphatic hydrocarbon group or cyclic hydrocarbon group, unsubstituted or substituted, or a hetero monocyclic or polycyclic group containing hetero atoms such as nitrogen, oxygen, sulfur atoms and the like; more specifically, R 3 includes aromatic monocyclic or polycyclic hydrocarbon groups such as phenyl group, 2-methyphenyl, 2-ethylphenyl, 2-isopropylphenyl, 2-tert-butylphenyl, 2-methoxyphenyl, 2-chlorophenyl, 2-vinylphenyl, 3-methylphenyl, 3-ethylphenyl, 3-isopropylphenyl, 3-methoxyphenyl, 3-chlorophenyl, 3-vinylphenyl, 4-methyphenyl, 4-ethylphenyl, 4-isopropylphenyl, 4-tert-butylphenyl, 4-vinylphenyl, cumenyl, mesityl, xylyl, 1-naphthyl, 2-naphthyl, anthryl, phenanthryl, and indenyl groups; hetero monocyclic or polycyclic groups such as thienyl, furyl, pyranyl, xanthenyl, pyridyl, pyrrolyl, imidazolyl, indolyl, carbazoyl, and phenanthronylyl; and ferrocenyl group. Like these examples, R 3 may contain any of various substituents, which may satisfactorily be hydrocarbon groups such as alkyl, alkenyl, cycloalkyl, and cycloalkenyl; halogen atom; oxygen-containing groups such as alkoxy group, carboxyl group and ester group; nitro group; cyano group and the like. Furthermore, R 4 represents hydrogen atom, a saturated or unsaturated hydrocarbon group, aryl group, hetero atom-containing functional groups, including for example alkyl groups such as methyl, ethyl, propyl, butyl, pentyl, hexyl, and heptyl; cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl; unsaturated hydrocarbons such as vinyl and allyl; and the same as those for R1. Additionally, R 5 represents hydrogen atom, a saturated and unsaturated hydrocarbon group, aryl group, a hetero atom-containing heterocyclic group, or the hydrocarbon group or heterocyclic group bonded together via hydroxyl group or oxygen atom, including for example alkyl groups such as methyl, ethyl, propyl, butyl, pentyl, hexyl and heptyl; cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl; unsaturated hydrocarbon groups such as benzyl, vinyl and allyl; hydroxyl group; alkyl ether groups; aryl ether groups; and the like. Furthermore, a saturated or unsaturated cyclic imine compound formed by bonding together R 3 and R 4 , R 3 and R 5 or R 4 and R 5 , is illustrated. Non-cyclic imine compounds can be synthesized readily from the corresponding ketone and amines. In this case, the syn-form and anti-form or a mixture enriched with either one of these syn- and anti-forms may be used satisfactorily, but a purified product of the mixture may be used singly or a mixture thereof with another imine compound may also be used. Even by the method for producing optically active amine compounds, like the method for producing optically active alcohol compounds, use is made of an asymmetric reduction catalyst composed of a transition metal complex and an optically active nitrogen-containing compound. In the transition metal complex among them, various transition metals with ligands are used, and particularly preferably, use is made of those similar to a transition metal complex represented by the general formula (a); MXmLn  (a) (wherein M is a transition metal of group VIII, such as iron, cobalt, nickel, ruthenium, rhodium, iridium, osmium, palladium and platinum; X represents hydrogen, halogen atom, carboxyl group, hydroxy group and alkoxy group and the like; L represents neutral ligands such as aromatic compounds and olefin compounds; m and n represent an integer). The transition metal in the transition metal complex is preferably rare metal, and specifically, ruthenium is one of preferable examples. Like the method for producing optically active alcohols, a monocyclic aromatic compound represented by the general formula (b) is illustrated for the aromatic compound as the neutral ligand. Herein, R 0 's are the same or different substituent-groups, representing hydrogen atom, a saturated or unsaturated hydrocarbon group, aryl group, and functional groups containing hetero atoms, for example alkyl groups such as methyl, ethyl, propyl, isopropyl, butyl, t-butyl, pentyl, hexyl, and heptyl; cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl; unsaturated hydrocarbon groups such as benzyl, vinyl, and allyl; hetero atom-containing functional groups such as hydroxyl group, alkoxy group and alkoxycarbonyl group. The number of the substituents R 0 's is an optional number of 1 to 6, and the substituents each can occupy any position. The transition metal catalysts are used at an amount variable, depending on the size, mode and economy of the reactor, but the catalysts may satisfactorily be used within a molar ratio range of approximately 1/100 to 1/100,000, preferably 1/200 to 1/5,000 to the reaction substrate imine compound. According to the method for producing optically active amine compounds in accordance with the present invention, additionally, use is made of optically active nitrogen-containing compounds in the asymmetric catalyst system, and it is possibly assumed that the compounds may be present as asymmetric ligands in the transition metal complexes or may serve as such. For more easily understandable expression, such optically active nitrogen-containing compounds are illustrated as “optically active amine compounds”. As described above, the optically active amine compounds are optically active diamine compounds represented for example by the following general formula (c); (wherein R 9 , R 10 , R 15 , and R 16 are independently hydrogen, a saturated or unsaturated hydrocarbon group, urethane group or sulfonyl group; R 11 , R 12 , R 13 and R 14 are the same or different so that the carbon bonded with these substituent groups might occupy the asymmetric center, including hydrogen atom, aromatic monocyclic and polycyclic groups, a saturated or unsaturated hydrocarbon group or cyclic hydrocarbon group; even in this case, the aromatic, or cyclic, or cyclic aliphatic group may be monocyclic or polycyclic; the polycyclic aromatic group is any of condensed series or non-condensed series; and furthermore, any one of R 11 and R 12 may satisfactorily form a ring. For example, such compounds include optically active diamine compounds such as optically active 1,2-diphenylethylenediamine, 1,2-cyclohexanediamine, 1,2-cycloheptanediamine, 2,3-dimethylbutanediamine, 1-methyl-2,2-diphenylethylenediamine, 1-isobutyl-2,2-diphenylethylenediamine, 1-isopropyl-2,2-diphenylethylenediamine, 1-methyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-isobutyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-isopropyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-benzyl-2,2-di(p-methoxyphenyl)ethylenediamine, 1-methyl-2,2-dinaphthylethylenediamine, 1-isobutyl-2,2-dinaphthylethylenediamine, 1-isopropyl-2,2-dinaphthylethylenediamine and the like. Additionally, optically active diamine compounds wherein any one or two of substituents R 9 through R 15 are sulfonyl group, acyl group or urethane group may also be used. Preferably, furthermore, use may be made of optically active diamine compounds with one sulfonyl group. Furthermore, optically active diamine (compounds) to be possibly used are not limited to the illustrated optically active ethylenediamine derivatives, and use may be made of optically active propanediamine, butanediamine, and phenylenediamine derivatives. As the optically active amine compound, use is made of an optically active amino alcohol compound represented by the following general formula (d); Herein, at least one of R 17 and R 19 is hydrogen atom, and the remaining one is hydrogen atom, a saturated or unsaturated hydrocarbon group, urethane group or sulfonyl group; R 19 , R 20 , R 21 and R 22 are the same or different so that the carbon bonded with these substituent groups might occupy the asymmetric center, including hydrogen atom, an aromatic monocyclic or polycyclic group, a saturated or unsaturated hydrocarbon group, or a cyclic hydrocarbon group; R 23 represents hydrogen atom, an aromatic monocyclic or polycyclic group, a saturated or unsaturated hydrocarbon group and a cyclic hydrocarbon group. Furthermore, any one of R 19 and R 20 and any one of R 21 and R 22 may satisfactorily be bonded together to form a ring, or any one of R 17 and R 18 and any one of R 20 and R 21 may satisfactorily be bonded together to form a ring. More specifically, use is made of optically active amino alcohols shown in the examples described below. As the optically active amine compound, furthermore, use is made of aminophosphine compound represented by the following general formula (e). Herein, R 24 and R 25 are hydrogen atom, a saturated or unsaturated hydrocarbon group, urethane group, sulfonyl group and acyl group; (CR 2 16 ) n are the same or different so that the carbon bonded with these substituent groups might occupy the asymmetric center, including hydrogen atom, an aromatic monocyclic or polycyclic group, a saturated or unsaturated hydrocarbon group, and a cyclic hydrocarbon group; R 27 and R 28 represent hydrogen atom, a saturated or unsaturated hydrocarbon group, and allyl group. More specifically, use is made of the optically active aminophosphines shown in the examples. The optically active amine compounds as illustrated above are used at an amount for example of approximately 0.5 to 20 equivalents, and preferably within a range of 1 to 2 equivalents, to the transition metal complex. The transition metal catalyst to be used as the catalyst as described above and the optically active amine compound are essential components to progress the asymmetric reduction in a smooth manner thereby attaining a higher asymmetric yield, and amine compounds at a higher optical purity cannot be recovered at a sufficiently high reaction activity, if either one of the two is eliminated. For the method for producing optically active amines through hydrogen transfer-type asymmetric reduction in accordance with the present invention, the presence of a hydrogen-donating organic or inorganic compound is indispensable. These compounds mean compounds capable of donating hydrogen through thermal action or catalytic action, and the types of these hydrogen-donating compounds are not limited, but preferably include alcohol compounds such as methanol, ethanol, 1-propanol, 2-propanol, butanol, and benzyl alcohol; formic acid and salts thereof, such as those in combination with amines; unsaturated hydrocarbons and heterocyclic compounds having saturated carbon bonds in part, such as tetralin and decalin; hydroquinone or phosphorous acid or the like. Among them, alcohol compounds are preferable, and 2-propanol is more preferable. The amount of an organic acid to be used as a hydrogen source is determined, depending on the solubility and economy of the reaction substrate. Generally, the substrate is used at a concentration of approximately 0.1 to 30% by weight, depending on the type of the substrate to be used, and is preferably at a concentration of 0.1 to 10% by weight. When using formic acid and a combination of formic acid with amine as a hydrogen source, no solvent is necessarily used, but use may satisfactorily be made of aromatic compounds such as toluene and xylene; halogen compounds such as dichloromethane, or organic compounds such as DMSO, DMF or acetonitrile, if it intended to use any solvent. Hydrogen pressure is essentially not required, but depending on the reaction conditions, hydrogen pressure may satisfactorily be loaded. Even if hydrogen pressure is loaded, the pressure may satisfactorily be about 1 atm to 50 atm. The reaction temperature is about −20° C. to 100° C. from the economical standpoint. More practically, the reaction can be carried out around room temperature of 25 to 40° C. The reaction time varies, depending on the reaction conditions such as the concentration of a reaction substrate, temperature and pressure, but the reaction is on completion from several minutes to 100 hours. The metal complex to be used in accordance with the present invention is preliminarily mixed with an optically active amine compound, but an asymmetric metal complex may be preliminarily synthesized by the following method, and the resulting complex may be used. More specifically, for example, a method is illustrated, comprising suspending a ruthenium-arene complex, an optically active amine compound and triethylamine in 2-propanol, heating the resulting mixture in argon or nitrogen gas stream under agitation, and cooling then the resulting reaction mixture, from which the solvent is then removed, and re-crystallizing the resulting mixture in an alcohol solvent to prepare an asymmetric complex. The catalyst system to be used for the hydrogen transfer-type asymmetric reduction in accordance with the present invention is very characteristic and has never been known up to now. The optically active ruthenium-diamine complex represented by the following formula (VII) as described above as one metal complex composed of a transition metal and an optically active nitrogen-containing compound ligand is useful as a catalyst for producing optically active secondary alcohol compounds, comprising subjecting racemic secondary alcohol or meso-type diols to hydrogen transfer reaction, and therefore, the complex draws higher attention. In the formula, * represents an asymmetric carbon atom; R 01 and R 02 are the same or different, independently representing alkyl group, or phenyl group or cycloalkyl group which may or may not have an alkyl group; or R 01 and R 02 together form an alicyclic ring unsubstituted or substituted with an alkyl group; R 03 represents methanesulfonyl group, trifluoromethanesulfonyl group, naphthylsulfonyl group, camphor sulfonyl group, or benzenesulfonyl group which may or may not be substituted with an alkyl group, an alkoxyl group or halogen atom, alkoxycarbonyl group, or benzoyl group which may or may not be substituted with an alkyl group; R 04 represents hydrogen atom or alkyl group; X represents an aromatic compound which may or may not be substituted with an alkyl group; and m and n simultaneously represent 0 or 1. For more description of the optically active ruthenium-diamine complex of the formula (VII), the aromatic compound which may or may not have an alkyl group represented by X, for example alkyl groups with C1 to C4, means for example benzene, toluene, xylene, mesitylene, hexamethylbenzene, ethylbenzene, tert-butylbenzene, p-cymene, and cumene and preferably includes benzene, mesitylene and p-cymene. R 01 and R 02 represent a linear or branched alkyl group, if they represent an alkyl group, for example alkyl groups with C1 to C4. More specifically, the alkyl group includes methyl, ethyl, n-propyl, isopropyl, n-, iso-, sec- and tert-butyl. More preferably, the group includes methyl, ethyl, n-propyl or iso-propyl. If R 01 and R 02 are bonded together to form an alicyclic group, the group may satisfactorily be a C5 to C7-membered ring. The alkyl group which may or may not be a substituent therefor, for example alkyl substituent group with C1 to C4, includes methyl group, ethyl group, n-propyl group, isopropyl group, and n-, iso-, sec- and tert-butyl groups. Preferably, the alkyl group is methyl. R 1 and R 2 as phenyl group wherein R 01 and R 02 may have an alkyl group, for example methyl group, specifically include phenyl, o-, m- and p-tolyl groups. R 01 and R 02 representing cycloalkyl group contain carbon atoms in 5 to 6-membered rings, preferably including cyclopentyl or cyclohexyl. In more preferable examples, R 01 and R 02 are independently phenyl or R 01 and R 02 together mean tetramethylene (-(CH 2 ) 4 -). R 03 represents methanesulfonyl group, trifluoromethanesulfonyl group, naphthylsulfonyl group, camphor sulfonyl group, or benzenesulfonyl group which may or may not be substituted with alkyl group, for example alkyl group with C1 to C3, alkoxy group for example alkoxy group with C1 to C3, or halogen atom, or benzoyl group which may or may not be substituted with alkyl group, for example C1 to C4 alkoxycarbonyl groups, or alkyl group, for example C1 to C4 alkyl group. More specifically, R 03 representing benzenesulfonyl group which may or may not be substituted with C1 to C3 alkyl group, C1 to C3 alkoxyl group or halogen atom, includes benzenesulfonyl, o-, m- and p-toluenesulfonyl, o-, m-, and p-ethylbenzenesulfonyl, o-, m-, and p-methoxybenzenesulfonyl, o-, m-, and p-ethoxybenzenesulfonyl, o-, m-, and p-chlorobenzenesulfonyl, 2, 4, 6-trimethylbenzenesulfonyl, 2,4,6-triisopropylbenzenesulfonyl, p-fluorobenzenesulfonyl, and pentafluorobenzenesulfonyl, and more preferably includes benzenesulfonyl or p-toluenesulfonyl. Specifically, R 03 representing C1 to C4 alkoxycarbonyl groups includes methoxycarbonyl, ethoxycarbonyl, isopropyloxycarbonyl, and tert-butoxycarbonyl, preferably including methoxycarbonyl or tert-butoxycarbonyl. R 03 representing benzoyl group which may or may not be substituted with C1 to C4 alkyl groups specifically includes benzoyl, o-, m-, and p-methylbenzoyl, o-, m-, and p-ethylbenzoyl, o-, m-, and p-isopropylbenzoyl, and o-, m-, and p-tert-butylbenzoyl, preferably including benzoyl or p-methylbenzoyl. In the most preferable example, R 03 is methanesulfonyl, trifluoromethanesulfonyl, benzenesulfonyl or p-toluenesulfonyl. R 04 representing hydrogen atom or alkyl group, for example C1 to C4 alkyl groups, specifically includes for example hydrogen, methyl, ethyl, n-propyl, isopropyl, n-, iso-, sec- and tert-butyl, and more preferably includes hydrogen atom or methyl group. The optically active ruthenium-diamine complex is used for the method for producing optically active secondary alcohols from ketones as descried above in accordance with the present invention, and in this case, the racemic secondary alcohols as the raw material compounds in accordance with the present invention are illustrated by the following formula (VIII). It is needless to say that the racemic alcohols are not limited to those represented by the formula. R 4 represents an aromatic monocyclic or polycyclic hydrocarbon group, unsubstituted or substituted or a hetero monocyclic or polycyclic group containing hetero atoms including nitrogen, oxygen, sulfur atoms and the like, specifically representing aromatic monocyclic or polycyclic groups such as phenyl group, 2-methylphenyl, 2-ethylphenyl, 2-isopropylphenyl, 2-tert-butylphenyl, 2-methoxyphenyl, 2-chlorophenyl; 2-vinylphenyl, 3-methylphenyl, 3-ethylphenyl, 3-isopropylphenyl, 3-methoxyphenyl, 3-chlorophenyl, 3-vinylphenyl, 4-methylphenyl, 4-ethylphenyl, 4-isopropylphenyl, 4-tert-butylphenyl, 4-vinylphenyl, cumenyl, mesityl, xylyl, 1-naphthyl, 2-naphthyl, anthryl, phenanthryl, and indenyl; hetero monocyclic or polycyclic groups such as thienyl, furyl, pyranyl, xanthenyl, pyridyl, pyrrolyl, imidazolyl, indolyl, carbazoyl, and phenthronylyl; and ferrocenyl group. Furthermore, R 7 represents hydrogen atom, a saturated or unsaturated hydrocarbon group, or a functional group containing hetero atoms, including for example alkyl groups such as methyl, ethyl, propyl, isopropyl, butyl, pentyl, hexyl, and heptyl; cycloalkyl groups such as cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl; and unsaturated hydrocarbons such as benzyl, vinyl, and allyl. R 6 and R 7 may be bonded together to form a ring, and in this case, R 7 includes for example a saturated or unsaturated alicyclic group giving a cyclic ketone such as cyclopentanone, cyclohexanone, cycloheptane, cyclopentenone, cyclohexenone, and cycloheptenone; or a saturated and unsaturated alicyclic group with a substituent group having an alkyl group, an aryl group, a unsaturated alkyl group or a linear or cyclic hydrocarbon group on each of the individual carbons. Additionally, the meso-type diols are represented for example by the following formula (IX). It is needless to say that the meso-diols are not limited to them. In this case, R 8 and R 9 are the same and represent a saturated or unsaturated hydrocarbon group which may or may not have a substituent group, or R 8 and R 9 may be bonded together to form a saturated or unsaturated alicyclic group which may or may not have a substituent group. More specifically, the ruthenium-diamine complex of the present invention is for example such that m and n are simultaneously zero in the formula (VII). Herein, η is used to represent the number of carbon atoms bonded to a metal in unsaturated ligands, and therefore, hexahapto (six carbon atoms bonded to metal) is represented by η 6 ; p-Ts represents p-toluenesulfonyl group; Ms represents methanesulfonyl group; and Tf represents trifluoromethanesulfonyl group. Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) Ru[(R, R)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene) (((R, R)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -benzene) ruthenium) Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium) Ru[(R, R)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((R, R)-N-p-toluenesulfonyl-1, 2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium) Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -mesitylene)ruthenium) Ru[(R, R)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((R, R)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene)(((S, S)-N-methanesulfonyl-1,2-diphenylethylenediamine) (η 6 -benzene)ruthenium) Ru[(R, R)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene)(((R, R)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) Ru[(S, S)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((S, S)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) Ru[(R, R)-MSNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((R, R)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) Ru[(S, S)-MSNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((S, S)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(R, R)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((R, R)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene)(((S S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) Ru[(R, R)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene) ((R, R)-N-trifluoromethanesulfonyl-1, 2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RU[(S, S)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((S, S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) Ru[(R, R)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((R, R)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) Ru[(S, S)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((S, S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(R, R)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((R, R)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene)(((S, S)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene) ruthenium) Ru[(R, R)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -benzene)(((R, R)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene) ruthenium) Ru[(S, S)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((S, S)-N-benzenssulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) Ru[(R, R)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((R, R)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) Ru[(S, S)-C 6 H 5 SO 3 NCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((S, S)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(R, R)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((R, R)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -benzene) (((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(R, R)-N-p-Ts-1,2-cyclohexanediamine](η 6 -benzene) (((R, R)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -p-cymene) (((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine) (η 6 -p-cymene)ruthenium) Ru[(R, R)-N-p-Ts-1,2-cyclohexanediamine](η 6 -p-cymene) (((R, R)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -mesitylene) (((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) Ru[(R, R)-N-p-Ts-1,2-cyclohexanediamine](η 6 -mesitylene) (((R, R)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-N-Ms-1,2-cyclohexanediamine](η 6 -benzene) (((S, S)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(R, R)-N-Ms-1,2-cyclohexanediamine](η 6 -benzene) ((R, R)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene) ruthenium) Ru[(S, S)-N-Ms-1,2-cyclohexanediamine](η 6 -p-cymene) (((S, S)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) Ru[(R, R)-N-Ms-1,2-cyclohexanediamine](η 6 -p-cymene) (((R, R)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -p- cymene)ruthenium) Ru[(S, S)-N-Ms-1,2-cyclohexanediamine](η 6 -mesitylene) ((S, S)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) Ru[(R, R)-N-Ms-1,2-cyclohexanediamine](η 6 -mesitylene)(((R, R)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-N-Tf-1,2-cyclohexanediamine](η 6 -benzene)(((S, S)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(R, R)-N-Tf-1,2-cyclohexanediamine](η 6 -benzene)(((R, R)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(S, S)-N-Tf-1,2-cyclohexanediamine] (η 6 -p-cymene) (((S, S)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) Ru[(R, R)-N-Tf-1,2-cyclohexanediamine] (η 6 -p-cymene) (((R, R)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) Ru[(S, S)-N-Tf-1,2-cyclohexanediamine](η 6 -mesitylene) (((S, S)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) Ru[(R, R)-N-Tf-1,2-cyclohexanediamine](η 6 -mesitylene)(((R, R)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) Ru[(S, S)-N-C 4 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -benzene)(((S, S)-N-benzenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(R, R)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 2 -benzene) (((R, R)-N-benzenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) Ru[(S, S)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -p-cymene) (((S, S)-N-benzenesulfonyl-1,2-cyclohexanediamine) (η 6 -p-cymene)ruthenium) Ru[(R, R)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -p-cymene) (((R, R)-N-benzeneesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) Ru[(S, S)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -mesitylene)(((S, S)-N-benzenesulfonyl-1,2-cyclohexanediamine) (η 6 -mesitylene)ruthenium) Ru[(R, R)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -mesitylene)(((R, R)-N-benzenesulfonyl-1,2-cyclohexanediamine) (η 6 -mesitylene)ruthenium) Those of the formula (VII) wherein m and n are simultaneously 1 are illustrated as follows. Herein, η is used to represent the number of carbon atoms bonded to a metal in unsaturated ligands, and therefore, hexahapto (six carbon atoms bonded to metal) is represented by η 6 ; p-Ts represents p-toluenesulfonyl group; Ms represents methanesulfonyl group; and Tf represents trifluoromethanesulfonyl group. RuH[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene) (hydride-((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RuH[(R, R)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene) (hydride-((R, R)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RuH[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) RuH[(R, R)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((R, R)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) RuH[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene) (hydride-((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) RuH[(R, R)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene) (hydride-((R, R)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) RuH[(S, S)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene)(hydride-((S, S)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RuH[(R, R)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene)(hydride-((R, R)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RuH[(S, S)-MSNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((S, S)-N-methanesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium) RuH[(R, R)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((R, R)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) RuH[(S, S)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene)(hydride-((S, S)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) RUH[(R, R)-MsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(hydride-((R, R)-N-methanesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) RuH[(S, S)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine) (η 6 -benzene)ruthenium) RuH[(R, R)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene) (hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine) (η 6 -benzene) ruthenium) RuH[(S, S)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium) RuH[(R, R)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium) RuH[(S, S)-TfNCH(C 6 HS)CH(C 6 H 5 )NH 2 ](η 6 -mesitylene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine) (η 6 -mesitylene) ruthenium) RuH[(R, R)-TfNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene)(hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-diphehylethylenediamine) (η 6 -mesitylene)ruthenium) RuH[(S, S)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -benzene)(hydride-((S, S)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RuH[(R, R)-C 6 H 5 SO 2 NCH(C 6 H 5 ) CH(C 6 H 5 )NH 2 ](η 6 -benzene) (hydride-((R, R)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -benzene)ruthenium) RuH[(S, S)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) RuH[(R, R)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium) RuH[(S, S)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene)(hydride-((S, S)-N-benzenesulfonyl-1,2-diphenylethylenediamine) (η 6 -mesitylene)ruthenium) RuH[(R, R)-C 6 H 5 SO 2 NCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene)(hydride-((R, R)-N-benzenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) RuH[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -benzene)(hydride-((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) RuH[(R, R)-N-p-Ts-1,2-cyclohexanediamine](η 6 -benzene)(hydride-((R, R)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) RuH[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) RuH[(R, R)-N-p-Ts-1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((R, R)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) RuH[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -mesitylene)(hydride-((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) RuH[(R, R)-N-p-Ts-1,2-cyclohexanediamine](η 6 -mesitylene) (hydride-((R, R)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) RuH[(S, S)-N-Ms-1,2-cyclohexanediamine](η 6 -benzene)(hydride-((S, S)-N-methanesulfonyl-1,2-cyclohexanediamine) (η 6 -benzene)ruthenium) RuH[(R, R)-N-Ms-1,2-cyclohexanediamine](η 6 -benzene)(hydride-((R, R)-N-methanesulfonyl-1,2-cyclohexanediamine) (η 6 -benzene)ruthenium) RuH[(S, S)-N-Ms-1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((S, S)-N-methanesulfonyl-1,2cyclohexanediamine) (η 6 -p-cymene)ruthenium) RuH[(R, R)-N-Ms-1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((R, R)-N-methanesulfonyl-1,2-cyclohexanediamine) (η 6 -p-cymene)ruthenium) RuH[(S, S)-N-Ms-1,2-cyclohexanediamine](η 6 -mesitylene)(hydride-((S, S)-N-methanesulfonyl-1,2-cyclohexanediamine) (η 6 -mesitylene) ruthenium) RuH[(R, R)-N-MS-1,2-cyclohexanediamine](η 6 -mesitylene) (hydride-((R, R)-N-methanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) RuH[(S, S)-N-Tf-1,2-cyclohexanediamine](η 6 -benzene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) RuH[(R, R)-N-Tf-1,2-cyclohexanediamine](η 6 -benzene)(hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine) (η 6 -benzene)ruthenium) RuH[(S, S)-N-Tf-1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) RuH[(R, R)-N-Tf-1,2-cyclohexanediamine](η 6 -p-cymene) (hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene) ruthenium) RuH[(S, S)-N-Tf-1,2-cyclohexanediamine](η 6 -mesitylene)(hydride-((S, S)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) RuH[(R, R)-N-Tf-1,2-cyclohexanediamine](η 6 -mesitylene) (hydride-((R, R)-N-trifluoromethanesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) RuH[(S, S)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -benzene)(hydride-((S, S)-N-benzenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene) ruthenium) RuH[(R, R)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -benzene) (hydride-((R, R)-N-benzenesulfonyl-1,2-cyclohexanediamine)(η 6 -benzene)ruthenium) RuH[(S, S)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((S, S)-N-benzenesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene) ruthenium) RuH[(R, R)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -p-cymene)(hydride-((R, R)-N-benzeneesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) RuH[(S, S)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -mesitylene)(hydride-((S, S)-N-benzenesulfonyl-1,2-cyclohexanediamine) (η 6 -mesitylene)ruthenium) RuH[(R, R)-N-C 6 H 5 SO 2 -1,2-cyclohexanediamine](η 6 -mesitylene)(hydride-((R, R)-N-benzenesulfonyl-1,2-cyclohexanediamine) (η 6 -mesitylene)ruthenium) Among the compounds represented by the general formula (VII) in accordance with the present invention, the complex of the formula (VII) wherein m and n are simultaneously 0 can be produced as follows. More specifically, Ru[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 ) NH[(η 6 -p-cymene)(((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine)(η 6 -p-cymene)ruthenium (wherein R 01 and R 02 are the same as described above and Ts is p-toluenesulfonyl group), is readily synthesized by reacting a raw material [RuCl 2 (η 6 -p-cymene) 2 (tetrachlorobis(η 6 -p-cymene)diruthenium) prepared by the method described in a reference J. Chem. Soc., Dalton Trans., pp.233-241(1974) with (S, S)-, (R, R)-TSNHCH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-N-p-toluenesulfonyl-1,2-disubstituted ethylenediamine) in the presence of alkali metal hydroxide or alkali metal alcolate in a solvent. The reaction is generally carried out quantitatively, by reacting a raw material [RuCl 2 (η 6 -p-cymene)] 2 (tetrachlorobis(η 6 -p-cymene)diruthenium (1 mole) and (S, S)-, (R, R)-TsNHCH(R 01 )CH(R 02 )NH,(((S, S) and (R, R)-N-p-toluenesulfonyl-1,2-disubstituted ethylenediamine)(2 moles) with alkali metal hydroxide or alkali metal alcolate in the stream of inactive gases such nitrogen, helium or argon in an inactive solvent at a temperature of −10 to 50° C. for 30 minutes to 3 hours, and leaving the reaction product to stand alone, prior to liquid separation procedure to remove the aqueous phase, and subsequently removing the solvent under reduced pressure. The alkali metal hydroxide or alkali metal alcolate specifically includes NaOH, NaOCH 3 , NaOC 2 H 5 , KOH, KOCH 3 , KOC 2 H 5 , LiOH, LiOCH 3 , and LiOC 2 H 5 , preferably including NaOH or KOH. The amount of the alkali metal hydroxide or alkali metal alcolate is 5 to 10 fold the amount of ruthenium. The inactive solvent appropriately includes for example hydrocarbons such as benzene, toluene, xylene, cyclohexane, and methylcyclohexane; ethers such as dimethyl ether, diethyl ether, diisopropyl ether, methyl-tert-butyl ether, tetrahydrofuran, 1,3-dioxolanee, and 1,4-dioxane; halogenated hydrocarbons such as chloroform, methylene chloride and chlorobenzene. The complex can be produced by another method. Specifically, Ru[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 )NH](η 6 -p-cymene)(((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine)(η 6 -p-cymene)ruthenium (wherein R 01 and R 02 are the same as described above and Ts is p-toluenesulfonyl group), is readily synthesized by reacting a raw material RuCl[(S, S)-, (R, R)- TsNCH(R 01 )CH(R 02 )NH 2 ](η 6 -p-cymene)(chloro-((S, S) and (R, R)-N-p-toluenesulfonyl-1,2-disubstituted ethylenediamine)(η 6 -p-cymene)ruthenium prepared through the reaction of [RUCl 2 (η 6 -p-cymene) 2 (tetrachlorobis(η 6 -p-cymene)diruthenium, (S, S)-, (R, R)-TsNHCH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-N-p-toluenesulfonyl-1,2-disubstituted ethylenediamine) with a tertiary amine (for example, triethylamine) for example by the method described in J. Am. Chem. Soc., Vol.117, pp.7562-7563 (1995), J. Am. Chem. Soc., Vol.118, pp.2521-2522 (1996) and J. Am. Chem. Soc., Vol.118, pp.4916-4917 (1996), in the presence of alkali metal hydroxide or alkali metal alcolate in a solvent. The reaction is generally carried out quantitatively, by reacting a raw material RUCl[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 )NH 2 ](η 6 -p-cymene)(chloro-((S, S) and (R, R)-N-p-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene)ruthenium) (1 mole) with alkali metal hydroxide or alkali metal alcolate in the stream of inactive gases such nitrogen, helium or argon in an inactive solvent at a temperature of −10 to 50° C. for 30 minutes to 3 hours, and leaving the reaction product to stand alone, prior to liquid separation procedure to remove the aqueous phase, and subsequently removing the solvent under reduced pressure. The alkali metal hydroxide or alkali metal alcolate specifically includes NaOH, NaOCH 3 , NAOC 2 H 5 , KOH, KOCH 3 , KOC 2 H 5 , LiOH, LiOCH 3 , and LiOC 2 H 5 , preferably including NaOH or KOH. The amount of the alkali metal hydroxide or alkali metal alcolate is 1 to 2-fold in mole the amount of ruthenium. The inactive solvent appropriately includes for example hydrocarbons such as benzene, toluene, xylene, cyclohexane, and methylcyclohexane; ethers such as dimethyl ether, diethyl ether, diisopropyl ether, methyltert-butyl ether, tetrahydrofuran, 1,3-dioxolane, and 1,4,-dioxane; and halogenated hydrocarbons such as chloroform, methylene chloride and chlorobenzene. In accordance with the present invention, the complex represented by the general formula (V) wherein m and n are simultaneously 1 can be produced as follows. More specifically, RuH[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 )NH 2 ](η 6 -p-cymene)(hydride-((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene)ruthenium) (wherein R 01 and R 02 are the same as described above and Ts is p-toluenesulfonyl group), is readily synthesized, by reacting a raw material Ru[(S, S)-, (R, R)-TSNCH(R 01 )CH(R 02 )NH] (η 6 -p-cymene)(((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene) ruthenium)(wherein R 01 and R 02 are the same as defined above; and Ts represents p-toluenesulfonyl group) in an alcohol solvent. The reaction is generally carried out quantitatively, by reacting a raw material Ru[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 )NH] (η 6 -p-cymene)(((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene)ruthenium) (wherein R 01 and R 02 are the same as defined above; and Ts represents p-toluenesulfonyl group) in an inactive gas stream in an alcohol solvent at a temperature of 0 to 100° C. for 3 minutes to 1 hour for hydrogen transfer reaction, and subsequently removing the solvent under reduced pressure. Appropriate alcohol solvents include for example methanol, ethanol, n-propanol, isopropanol, n-butanol, iso-butanol, and sec-butanol. The complex can be produced by another method. Specifically, RuH[(S, S)-, (R, R)-TSNCH(R 01 )CH(R 02 )NH 2 ](η 6 -p-cymene)(hydride-((S, S) and (R, R)-N-p-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene)ruthenium) (wherein R 01 and R 02 are the same as described above and Ts is p-toluenesulfonyl group), is readily synthesized, by reacting for example a raw material Ru[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 )NH] (η 6 -p-cymene)(((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene) ruthenium) (wherein R 01 and R 02 are the same as defined above; and Ts represents p-toluenesulfonyl group), in a solvent in pressurized hydrogen. The reaction is generally carried out quantitatively, by hydrogenating a raw material RuH[(S, S)-, (R, R)-TsNCH(R 01 )CH(R 02 )NH 2 (η 6 -p-cymene)(hydride-((S, S) and (R, R)-N-toluenesulfonyl-1,2-disubstituted ethylenediamine) (η 6 -p-cymene)ruthenium)(wherein R 01 and R 02 are the same as defined above; and Ts represents p-toluenesulfonyl group), in an inactive solvent at a temperature of 0 to 50° C. for 30 minutes to 24 hours (preferably 1 to 10 hours) in pressurized hydrogen and subsequently removing the solvent under reduced pressure. The hydrogen pressure is within a range of 1 to 150 atm, preferably 20 to 100 atm. Appropriate inactive solvents include for example hydrocarbons such as benzene, toluene, xylene, hexane, heptane, cyclohexane, and methylcyclohexane; and ethers such as dimethyl ether, diethyl ether, diisopropyl ether, methyl-tert-butyl ether, tetrahydrofuran, 1,3-dioxolane and 1,4-dioxane. An optically active diamine of the formula (S, S)-, (R, R)-R 03 NHCH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-N-substituted-1,2-disubstituted ethylenediamines) (wherein R 01 R 02 and R 03 are the same as described above) is synthesized, by using raw materials (S, S)-, (R, R)-NH 2 CH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-1,2-disubstituted ethylenediamines in a conventional manner [Protective Groups in Organic Synthesis, Vol.2, pp.309-405(1991)]. More specifically, (S, S)-, (R, R)-TsNHCH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-N-P-toluenesulfonyl-1,2-disubstituted ethylenediamines) (wherein R 01 and R 02 are the same as defined above; and Ts represents p-toluenesulfonyl group) are readily synthesized, by reacting for example (S, S)-, (R, R)-NH 2 CH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-1,2-disubstituted ethylenediamines) as raw materials with TsCl (p-toluenesulfonyl chloride) in the presence of an alkali (for example, tertiary amine, alkali metal salts and the like) in a solvent. The reaction is generally carried out quantitatively, by reacting together (S, S)-, (R, R)-NH 2 CH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-1,2-disubstituted ethylenediamines) (1 mole) and TsCl (p-toluenesulfonyl chloride) (1 mole) with an alkali (for example, triethylamine) in an inactive solvent (for example, toluene, tetrahydrofuran, and methylene chloride) in an inactive gas stream such as nitrogen, helium or argon or the like at a temperature of 0 to 50° C. for 30 minutes to 3 hours, subsequently adding water to the resulting mixture to gently leave the reaction product to stand, prior to liquid separation procedure, to remove the aqueous phase, and evaporating the solvent under reduced pressure. The optically active diamine (S, S)-, (R, R)—NH 2 CH(R 01 )CH(R 02 )NH 2 ((S, S) and (R, R)-1,2-disubstituted ethylenediamines)(wherein R 01 and R 02 are the same as defined above), is known and is sometimes commercially available or can be produced in a conventional manner or by conventional resolution process of racemates (Tetrahedron Lett., Vol.32, pp.999-1002) (1991), Tetrahedron Lett., Vol.34, pp.1905-1908 (1993)]. (S, S) and (R, R)-1,2-diphenylethylenediamines and (S, S) and (R, R)-1,2-cyclohexanediamines are commercially available. For example, the optically active diamine of the general formula (e) can be produced by the following method (Tetrahedron Lett., Vol.32, pp.999-1002 (1991)]. The optically active diamine of the general formula (e) ((S, S) and (R, R)-1,2-disubstituted ethylenediamines) can be produced readily at a high yield, by preparing cyclophosphate from raw materials optically active 1,2-disubstituted ethylene diols, which is then reacted with amidine to recover imidazoline, and ring opening the imidazoline by using an acid catalyst. The ruthenium-diamine complex of the present invention may be isolated and used, but while generating the complex in a reaction solution, the resulting complex is used as a catalyst for asymmetric synthesis and the like. The method for producing optically active secondary alcohols by utilizing the complex of the present invention as a hydrogen transfer-type oxidation catalyst will now be described below. The racemic secondary alcohols or meso-type diols to be used as the reaction substrates for producing optically active secondary alcohols are represented by the aforementioned formulas (VIII) and (IXI). In the formula (VIII), the racemic secondary alcohols in this case specifically include 1-phenylethanol, 1-(2-methylphenyl)ethanol, 1-(2-ethylphenyl)ethanol, 1-(2-isopropylphenyl)ethanol, 1-(2-tert-butylphenyl)ethanol, 1-(2-methoxyphenyl)ethanol, 1-(2-ethoxyphenyl)ethanol, 1-(2-isopropoxyphenyl)ethanol, 1-(2-tert-butoxyphenyl)ethanol, 1-(2-dimethylaminophenyl)ethanol, 1-(3-methylphenyl)ethanol, 1-(3-ethylphenyl)ethanol, 1-(3-isopropylphenyl)ethanol, 1-(3-tert-butylphenyl)ethanol, 1-(3-methoxyphenyl)ethanol, 1-(3-ethoxyphenyl)ethanol, 1-(3-isopropoxyphenyl)ethanol, 1-(3-tert-butoxyphenyl)ethanol, 1-(3-dimethylaminophenyl)ethanol, 1-(4-methylphenyl)ethanol, 1-(4-ethylphenyl)ethanol, 1-(4-isopropylphenyl)ethanol, 1-(4-tert-butylphenyl)ethanol, 1-(4-methoxyphenyl)ethanol, 1-(4-ethoxyphenyl)ethanol, 1-(4-isopropoxyphenyl)ethanol, 1-(4-tert-butoxyphenyl)ethanol, 1-(4-dimethylaminophenyl)ethanol, 1-cumenylethanol, 1-mesitylethanol, 1-xylylethanol, 1-(1-naphthyl)ethanol, 1-(2-naphthyl)ethanol, 1-phenanthrylethanol, 1-indenylethanol, 1-(3,4-dimethoxyphenyl)ethanol, 1-(3,4-diethoxyphenyl)ethanol, 1-(3,4-methylenedioxyphenyl)ethanol, 1-ferrocenylethanol, 1-phenylpropanol, 1-(2-methylphenyl)propanol, 1-(2-ethylphenyl)propanol, 1-(2-isopropylphenyl)propanol, 1-(2-tert-butylphenyl)propanol, 1-(2-methoxyphenyl)propanol, 1-(2-ethoxyphenyl)propanol, 1-(2-isopropoxyphenyl)propanol, 1-(2-tert-butoxyphenyl)propanol, 1-(2-dimethylaminophenyl)propanol, 1-(3-methylphenyl)propanol, 1-(3-ethylphenyl)propanol, 1-(3-isopropylphenyl)propanol, 1-(3-tert-butylphenyl)propanol, 1-(3-methoxyphenyl)propanol, 1-(3-ethoxyphenyl)propanol, 1-(3-isopropoxyphenyl)propanol, 1-(3-tert-butoxyphenyl)propanol, 1-(3-dimethylaminophenyl)propanol, 1-(4-methylphenyl)propanol, 1-(4-ethylphenyl)propanol, 1-(4-isopropylphenyl)propanol, 1-(4-tert-butylphenyl)propanol, 1-(4-methoxyphenyl)propanol, 1-(4-ethoxyphenyl)propanol, 1-(4-isopropoxyphenyl)propanol, 1-(4-tert-butoxyphenyl)propanol, 1-(4-dimethylaminophenyl)propanol, 1-cumenylpropanol, 1-mesitylpropanol, 1-xylylpropanol, 1-(1-naphthyl) propanol, 1-(2-naphthyl)propanol, 1-phenanthrylpropanol, 1-indenylpropanol, 1-(3,4-dimethoxyphenyl) propanol, 1-(3,4-diethoxyphenyl) propanol, 1-(3,4-methylenedioxyphenyl) propanol, 1-ferrocenylpropanol, 1-phenylbutanol, 1-(2-methylphenyl)butanol, 1-(2-ethylphenyl)butanol, 1-(2-isopropylphenyl)butanol, 1-(2-tert-butylphenyl)butanol, 1-(2-methoxyphenyl)butanol, 1-(2-ethoxyphenyl)butanol, 1-(2-isopropoxyphenyl)butanol, 1-(2-tert-butoxyphenyl)butanol, 1-(2-dimethylaminophenyl)butanol, 1-(3-methylphenyl)butanol, 1-(3-ethylphenyl)butanol, 1-(3-isopropylphenyl)butanol, 1-(3-tert-butylphenyl)butanol, 1-(3-methoxyphenyl)butanol, 1-(3-ethoxyphenyl)butanol, 1-(3-isopropoxyphenyl)butanol, 1-(3-tert-butoxyphenyl)butanol, 1-(3-dimethylaminophenyl)butanol, 1-(4-methylphenyl)butanol, 1-(4-ethylphenyl)butanol, 1-(4-isopropylphenyl)butanol, 1-(4-tert-butylphenyl)butanol, 1-(4-methoxyphenyl)butanol, 1-(4-ethoxyphenyl)butanol, 1-(4-isopropoxyphenyl)butanol, 1-(4-tert-butoxyphenyl)butanol, 1-(4-dimethylaminophenyl)butanol, 1-cumenylbutanol, 1-mesitylbutanol, 1-xylylbutanol, 1-(1-naphthyl)butanol, 1-(2-naphthyl)butanol, 1-phenanthrylbutanol, 1-indenylbutanol, 1-(3,4-dimethoxyphenyl)butanol, 1-(3,4-diethoxyphenyl)butanol, 1-(3,4-methylenedioxyphenyl)butanol, 1-ferrocenylbutanol, 1-phenylisobutanol, 1-(2-methylphenyl)isobutanol, 1-(2-ethylphenyl)isobutanol, 1-(2-isopropylphenyl)isobutanol, 1-(2-tert-butylphenyl)isobutanol, 1-(2-methoxyphenyl)isobutanol, 1-(2-ethoxyphenyl)isobutanol, 1-(2-isopropoxyphenyl)isobutanol, 1-(2-tert-butoxyphenyl)isobutanol, 1-(2-dimethylaminophenyl)isobutanol, 1-(3-methylphenyl)isobutanol, 1-(3-ethylphenyl)isobutanol, 1-(3-isopropylphenyl)isobutanol, 1-(3-tert-butylphenyl)isobutanol, 1-(3-methoxyphenyl)isobutanol, 1-(3-ethoxyphenyl)isobutanol, 1-(3-isopropoxyphenyl)isobutanol, 1-(3-tert-butoxyphenyl)isobutanol, 1-(3-dimethylaminophenyl)isobutanol, 1-(4-methylphenyl)isobutanol, 1-(4-ethylphenyl)isobutanol, 1-(4-isopropylphenyl)isobutanol, 1-(4-tert-butylphenyl)isobutanol, 1-(4-methoxyphenyl)isobutanol, 1-(4-ethoxyphenyl)isobutanol, 1-(4-isopropoxyphenyl)isobutanol, 1-(4-tert-butoxyphenyl)isobutanol, 1-(4-dimethylaminophenyl)isobutanol, 1-cumenylisobutanol, 1-mesitylisobutanol, 1-xylylisobutanol, 1-(1-naphthyl)isobutanol, 1-(2-naphthyl)isobutanol, 1-phenanthrylisobutanol, 1-indenylisobutanol, 1-(3,4-dimethoxyphenyl)isobutanol, 1-(3,4-diethoxyphenyl)isobutanol, 1-(3,4-methylenedioxyphenyl)isobutanol, 1-ferrocenylisobutanol, 1-phenylpentanol, 1-(2-methylphenyl)pentanol, 1-(2-ethylphenyl)pentanol, 1-(2-isopropylphenyl)pentanol, 1-(2-tert-butylphenyl)pentanol, 1-(2-methoxyphenyl)pentanol, 1-(2-ethoxyphenyl)pentanol, 1-(2-isopropoxyphenyl)pentanol, 1-(2-tert-butoxyphenyl)pentanol, 1-(2-dimethylaminophenyl)pentanol, 1-(3-methylphenyl)pentanol, 1-(3-ethylphenyl)pentanol, 1-(3-isopropylphenyl)pentanol, 1-(3-tert-butylphenyl)pentanol, 1-(3-methoxyphenyl)pentanol, 1-(3-ethoxyphenyl)pentanol, 1-(3-isopropoxyphenyl)pentanol, 1-(3-tert-butoxyphenyl)pentanol, 1-(3-dimethylaminophenyl)pentanol, 1-(4-methylphenyl)pentanol, 1-(4-ethylphenyl)pentanol, 1-(4-isopropylphenyl)pentanol, 1-(4-tert-butylphenyl)pentanol, 1-(4-methoxyphenyl)pentanol, 1-(4-ethoxyphenyl)pentanol, 1-(4-isopropoxyphenyl)pentanol, 1-(4-tert-butoxyphenyl)pentanol, 1-(4-dimethylaminophenyl)pentanol, 1-cumenylpentanol, 1-mesitylpentanol, 1-xylylpentanol, 1-(1-naphthyl)pentanol, 1-(2-naphthyl)pentanol, 1-phenanthrylpentanol, 1-indenylpentanol, 1-(3,4-dimethoxyphenyl)pentanol, 1-(3,4-diethoxyphenyl)pentanol, 1-(3,4-methylenedioxyphenyl)pentanol, 1-ferrocenylpentanol, 1-indanol, 1, 2, 3, 4-tetrahydro-1-naphthol, 2-cyclopenten-1-ol, 3-methyl-2-cyclopenten-1-ol, 2-cyclohexen-1-ol, 3-methyl-2-cyclohexen-1-ol, 2-cycloheptan-1-ol, 3-methyl-2-cycloheptan-1-ol, 2-cyclooctan-1-ol, 3-methyl-2-cyclooctan-1-ol, and 4-hydroxy-2-cyclopenten-1-one. Additionally, the meso-type diol represented by the formula (IX) specifically represents meso-2-cyclopenten-1,4-diol, meso-2-cyclohexane-1,4-diol, meso-2-cycloheptane-1,4-diol, meso-2-cyclooctan-1,4-diol, 5,8-dihyroxy-1,4,4a, 5, 8, 8a-hexahydro-endo-1,4-methanonaphtharene and the like. As the ruthenium-diamine complex to be used for the hydrogen transfer-type oxidation of the present invention, the optically active ligand diamine of the general formula (VII), namely (R, R) form or (S, S) form, may satisfactorily be used. Depending on the selection, an objective compound of the desired absolute configuration can be produced. Such ruthenium-diamine complex can be used at 1/10,000 to 1/10 fold in mole, preferably 1/2,000 to 1/200 fold in mole to the substrate compound. For carrying out the reaction, the substrate compound and the ruthenium-diamine complex are added to ketone alone or an appropriate mixture of ketone with an inactive solvent, to prepare a homogenous solution, for reaction at a reaction temperature of 0 to 100° C., preferably 10 to 50° C., for 1 to 100 hours, preferably 3 to 50 hours. Ketones including for example acetone, ketone, diethyl ketone, diisopropyl ketone, methyltert-butyl ketone, cyclopentanone, and cyclohexanone are used. More preferably, acetone is better. These ketones may satisfactorily be used singly or in a mixture with an inactive solvent. Ketones can be used at an amount of 0.1 to 30 fold (volume/weight), depending on the type of the substrate, but preferably at an amount of 2,to 5 fold (volume/weight). Appropriate inactive solvents include for example hydrocarbons such as benzene, toluene, xylene, hexane, heptane, cyclohexane, and methylcyclohexane; and ethers such as dimethyl ether, diethyl ether, diisopropyl ether, methyltert-butyl ether, tetrahydrofuran, 1,3-dioxolane, and 1,4-dioxane. In accordance with the present invention, the reaction may be carried out in a batchwise manner or a continuous manner. The resulting product can be purified by known processes such as silica gel column chromatography. EXAMPLES Example A Production of Optically Active Alcohols Production examples of optically active alcohols are shown below, and the inventive method will further be described in detail. Tables 1, 2 and 3 collectively show reaction substrates, transition metal complexes and optically active amine compounds as chiral ligands, which are to be used as typical examples. The instrumental analysis was done by using the following individual systems. NMR: JEOL GSX-400/Varian Gemini-200 ( 1 H-NMR sample: TMS, 31 P-NMR standard sample phosphoric acid) GLC: SHIMADZU GC-17A(column: chiral CP-Cyclodextrin-b-236-M19) HPLC: JASCO GULLIVER (column: CHIRALCEL OJ, OB-H, OB, OD) TABLE 1 Carbonyl compounds TABLE 2 Asymmetric metal complexes TABLE 3 Examples 1 through 19 To dry 2-propanol (5.0 ml) were added various amino alcohol compounds (0.05 mmol) as chiral ligands of optically active amine compounds as shown in Table 3 and the ruthenium arene complex (0.0125 mmol) shown in Table 2, for agitation in argon or nitrogen gas atmosphere at 80° C. for 20 minutes, and the resulting mixture was cooled to room temperature, to which were then added frozen and degassed dry 2-propanol (45.0 ml), various carbonyl compounds (5 mmol) deaerated and distilled as shown in Table 1, and a solution of 0.05M KOH in 2-propanol (2.5 ml; 0.125 mmol) in this order, for subsequent agitation at room temperature. After completion of the reaction, dilute hydrochloric acid was added to adjust the resulting mixture to acidity, from which most of 2-propanol was evaporated off under reduced pressure, followed by addition of saturated sodium chloride solution. The resulting product was extracted into ethyl acetate, rinsed with saturated sodium chloride solution several times and dried over anhydrous sodium sulfate. The solvent was distilled off from the product. The final product was analyzed by 1 H-NMR (CDC 3 ), to calculate the conversion. Then, the product was purified by thin-layer silica gel chromatography, and the isolated alcohol fraction was used to determine the optical purity and absolute configuration by HPLC or GLC. The results are collectively shown in Table 4. Furthermore, the conversion and optical purity of the sampled reaction solution can be calculated simultaneously by GLC. Examples 20 to 23 Using the same method as in Example 1, aminophosphine compound was used as an optically active amine compound for the reaction. The results are collectively shown in Table 4. TABLE 4 Exam- [RuCl 2 Li- Carbonyl % ples (arene)] 2 gands compounds Time conv % ee config. 1 13 19 1a 1 64 52 S 2 13 20 1a 1 91 17 S 3 14 20 1a 1 97 59 S 4 14 21 1a 1 97 56 S 5 15 20 1a 1 97 56 S 6 15 21 1a 1 62 52 S 7 16 17 1a 1 95 91 S 8 16 20 1a 1 94 92 S 9 16 21 1a 1 59 55 S 10 16 22 1a 1 96 75 S 11 16 20 1b 2 95 82 S 12 16 20 1c 15 93 5 S 13 16 20 1d 20 22 40 R 14 16 20 o-1e 6 96 83 S 15 16 18 o-1f 1 99 89 S 16 16 20 p-1g 4 73 79 S 17 16 20 3 2 99 93 S 18 16 18 4 3 93 75 S 19 16 16 7 4 62 94 S 20 13 23 1a 1 65 0.4 S 21 13 24 1a 1 61 61 R 22 13 25 1a 1 70 23 13 26 1a 1 73 4 S Examples 24 to 41 By using the same method as described in Example 1 and using optically active amine compounds, the chiral Ru complexes shown in Table 2 were synthesized. The complex catalysts and carbonyl compounds were added to a mixture of formic acid and triethylamine (5:2), for reaction at room temperature for a given period. After completion of the reaction, the reaction mixture was diluted with water, to extract the product in ethyl acetate. After drying the organic phase over anhydrous sodium sulfate and evaporating the solvent off, 1 H-NMR (CDCl 3 ) was analyzed to calculate the conversion. The optical purity and absolute configuration were determined by HPLC or GLC. The results are collectively shown in Table 5. The conversion and optical purity of each sampled reaction solution can be calculated simultaneously by GLC. In accordance with the present invention, optically active alcohols can be produced at a high optical purity and a high synthetic yield. TABLE 5 Carbonyl Examples Ru complex compounds Time % conv % ee config. 24 27(S, S) 1a 24 >99 98 S 25 27(S, S) 1b 60 >99 97 S 26 27(S, S) m-1f 21 >99 97 S 27 27(S, S) p-1f 24 >99 95 S 28 27(S, S) m-1g 20 >99 98 S 29 27(S, S) p-1g 50 >99 97 S 30 27(S, S) p-1h 14 >99 90 S 31 27(S, S) 1i 60 >99 95 S 32 27(S, S) 2 60 93 83 S 33 27(S, S) 3 22 >99 96 S 34 27(S, S) 5 60 >54 66 S 35 27(S, S) 6 48 >99 99 S 36 27(S, S) 7 48 >99 99 S 37 27(S, S) 8 60 70 82 S 38 27(S, S) 9 40 47 97 S 39 28(R, R) 10 40 95 99 R 40 28(R, R) 11 65 95 98 R 41 28(R, R) 12 72 68 92 R Example B Production of Optically Active Amines Production examples of optically active amines are shown below and the present inventive method will be described in detail. Tables 6 and 7 show reaction substrates and asymmetric metal catalysts to be possibly used as typical examples. The instrumental analysis was done by using the following individual systems. NMR: JEOL GSX-400/Varian Gemini-200 ( 1 H-NMR sample: TMS, 31 P-NMR standard sample: phosphoric acid) GLC: SHIMADZU GC-17A(column: chiral CP-Cyclodextrin-b-236-M19) HPLC: JASCO GULLIVER (column: CHIRALCEL OJ, OB-H, OB, OD) The absolute configurations of the resulting optically active amine compounds were determined on the basis of optical rotation and by HPLC and X-ray structural analysis. Blanks are not definitely shown. TABLE 6 Imine compounds Enamine compounds TABLE 7 Asymmetric metal complexes Example 42 6,7-Dimethoxy-1-methyl-3,4-dihydroxyisoquinoline (Table 6-2a) (1.03 g, 5 mmol) and a ruthenium catalyst (Table 7) (R, R)-1a (16 mg, 0.025 mmol) were dissolved in acetonitrile (10 ml), followed by addition of a mixture of formic acid-triethylamine (5:2), for agitation at 28° C. for 3 hours. To the reaction mixture was added an aqueous sodium carbonate solution to extract the product in ethyl acetate. After evaporation of the solvent, 1 H-NMR(CDCl 3 ) of the resulting product was measured to calculate the conversion. Then, the product was purified by silica gel chromatography, to determine the optical purity and absolute configuration of the resulting optically active amine by HPLC or GLC. As collectively shown in Table 8, (S)-6,7-dimethoxy-1-methyl-1,2,3,4-tetrahydroisoquinoline (1.02 g, yield of 99%, 96% ee) was obtained. Examples 43 to 69 By using the same reactor as in Example 42 but using different reaction substrates, catalysts, reaction solvents and ratios of reaction substrates/catalysts, the same experimental procedures as in Example 42 were carried out. The results are collectively shown in Table 8. Example 70 Using the same reactor as in Example 42, the enamine compound was used for the same experimental procedures as in Example 42, so that the reaction progressed in a smooth manner, to recover the corresponding optically active amine compound. The results are collectively shown in Table 8. Comparative Example 1 Under the same conditions as in Example 42, ruthenium-arene catalysts with no optically active amine ligands were used as catalysts, so that the reaction was facilitated, to recover a racemic amine compound quantitatively. Comparative Example 2 Under the same conditions as in Example 51, ruthenium-arene catalysts with no optically active amine ligands were used as catalysts, so that no reaction was never facilitated. As has been described above in detail, in accordance with the present invention, optically active amines can be produced at a high yield and an excellent optical purity. TABLE 8 Amines yield ee absolute Examples Imines Catalysts S/C Solvents Time, h % % configuration 42 2a (R,R)-1a 200 CH 2 CN 3 99 96 S 43 2a (R,R)-1a 200 CH 2 Cl 2 3 99 94 S 44 2a (S,S)-1a 200 CH 2 Cl 2 3 99 93 R 45 2a (R,R)-1a 200 acetone 3 99 95 S 46 2a (R,R)-1a 200 DMF 3 99 95 S 47 2a (R,R)-1a 200 DMSO 3 99 95 S 48 2a (R,R)-1a 1000 CH 2 Cl 2 98 99 90 S 49 2b (S,S)-1a 200 CH 2 Cl 2 8 81 87 R 50 2c (S,S)-1b 200 CH 2 Cl 2 16 99 92 R 51 2d (S,S)-1c 200 CH 2 Cl 2 8 99 84 R 52 2e (S,S)-1c 100 CH 2 Cl 2 12 96 84 R 53 2f (R,R)-1e 200 CH 2 Cl 2 18 68 82 54 2g (R,R)-1e 200 CH 2 Cl 2 14 94 98 55 3 (S,S)-1a 200 CH 2 Cl 2 16 99 84 56 4a (S,S)-1a 200 DMF 5 86 97 R 57 4b (S,S)-1a 200 DMF 5 83 96 R 58 5 (R,R)-1e 200 CH 2 Cl 2 48 59 78 59 6 (S,S)-1c 200 CH 2 Cl 2 39 22 47 S 60 7 (S,S)-1c 200 CH 2 Cl 2 40 100  34 61 8 (S,S)-1c 100 CH 2 Cl 2 6 90 89 S 62 9 (S,S)-1c 100 CH 2 Cl 2 12 64 88 S 63 10  (S,S)-1d 200 CH 2 Cl 2 36 72 77 S 64 11  (R,R)-1e 200 CH 2 Cl 2 15 13 36 65 12a (R,R)-1e 200 CH 2 Cl 2 37 43 46 66 12b (R,R)-1e 200 CH 2 Cl 2 109 35 36 67 12c (R,R)-1e 200 CH 2 Cl 2 65 67 25 68 13  (S,S)-1c 200 CH 2 Cl 2 16 82 64 69 14  (S,S)-1e 200 CH 2 Cl 2 67 71 12 R 70 15  (S,S)-1e 200 CH 2 Cl 2 12 69 43 [In the table, s/c means the molar ratio of substrate/ruthenium-optically active diamine complex.] Example C Production of Optically Active Secondary Alcohols by Kinetic Resolution Method of Alcohols Production examples of optically active secondary alcohols are shown below, and the inventive method will further be described in detail. However, the invention is not limited to these examples. Collectively, Table 9 shows racemic secondary alcohols or meso-type diols to be used as typical examples and Table 10 shows ruthenium-diamine complexes. Abbreviations used in the present Example are as follows. η:representing the number of carbon atoms bonded to the metal of unsaturated ligand; and hexahapto (6 carbon atoms bonded to metal) is expressed as η 6 . The instrumental analysis was done by using the following individual systems. NMR: JEOL GSX-400/Varian Gemini-200 ( 1 H-NMR internal standard: TMS) GLC: SHIMADZU GC-17A(column: chiral CP-cyclodextrin-b-236-M19) HPLC: JASCO GULLIVER (column: CHIRALCEL OJ, OB-H, OB, OD-H, OD) 81 TABLE 9 TABLE 10 Reference Example 1 Synthesis of RuCl[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(chloro((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium [-RuCl 2 (η 6 -p-cymene)] 2 (tetrachlorobis (η 6 -p-cymene)diruthenium) (1.53 g; 2.5 mmol) and (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (1.83 g; 5.0 mmol) and triethylamine (1.4 ml; 10 mmol) are dissolved in 2-propanol (50 ml) in a Schlenk's reactor which is preliminarily dried in vacuum and of which the inside is then substituted with argon. The reaction solution was agitated at 80° C. for 1 hour and is then condensed, to recover crystal, which was then filtered and rinsed with a small amount of water, followed by drying under reduced pressure to recover orange crystal (2.99 g). The yield is 94%. m.p.>100° C. (decomposed) IR(KBr) [cm −1 ]:3272, 3219, 3142, 3063 3030, 2963, 2874 1 H-NMR (400 MHz, 2 H-chloroform, δ): ppm 1.32 (d, 3H), 1.34 (d, 3H), 2.19 (s, 3H), 2.28 (s, 3H), 3.07 (m, 1H), 3.26 (m, 1H), 3.54 (m, 1H), 3.66 (d, 1H), 5.68 (d, 1H), 5.70 (d, 1H), 5.72 (d, 1H), 5.86 (d, 1H), 6.61 (m, 1H), 6.29-7.20 (m, 14H) Elemental Analysis (C 35 H 35 ClN 2 O 2 Rus) C H N Cl Ru Theoretical values (%) 58.53 5.54 4.40 5.57 15.89 Elemental values (%) 58.37 5.44 4.36 5.75 18.83 The present catalyst was tested by X-ray crystallography. It was indicated that the complex was of a structure satisfying the analysis results. Reference Example 2 Synthesis of RuCl[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -Mesitylene)(Chloro((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine) (η 6 -Mesitylene)Ruthenium Instead of [RuCl 2 (η 6 -p-cymene)] 2 (tetrachlorobis(η 6 -p-cymene)diruthenium), [RuCl 2 (η 6 -mesitylene)] 2 (tetrachlorobis(η 6 -mesitylene)diruthenium) was used, and by the same procedures as in the Reference Example 1, the aforementioned catalyst was recovered as orange crystal. The yield was 64%. m.p. 218.6-222.5 (decomposed) 1 H-NMR (400 MHz, 2 H-chloroform, δ): ppm 2.24 (3H), 2.38 (s, 9H), 3.69 (dd, 1H), 3.79 (d, 1H), 3.99 (dd, 1H), 4.19 (brd, 1H), 5.30 (s, 3H), 6.65-6.93 (m, 9H), 7.06-7.15 (m, 3H), 7.35 (d, 2H) Reference Example 3 Synthesis of RuCl[(S, S)-N-p-TS-Cyclohexane-1,2-Diamine](η 6 -p-Cymene)(Chloro-((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -p-Cymene)Ruthenium) Instead of (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine), (S, S)-N-p-Ts-cyclohexane-1,2-diamine)((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine) was used, and by the same procedures as in the Reference Example 1, the aforementioned catalyst was recovered as orange crystal. The yield is 60%. Reference Example 4 Synthesis of RuCl[(S, S)-N-p-Ts-Cyclohexane-1,2-Diamine](η 6 -Mesitylene)(Chloro-((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -Mesitylene)Ruthenium Instead of (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine), (s, S)-N-p-Ts-cyclohexane-1,2-diamine)((1S, 2S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine) was used, and by the same procedures as in the Reference Example 2, the aforementioned catalyst was recovered as orange crystal. The yield is 58%. Example 71-a Synthesis of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-Cymene)((S, S)-N-p-Toluenesulfonyl-1,2-Diamine)(η 6 -p- Cymene)Ruthenium) [RuCl 1 (η 6 -p-cymene)] 2 (tetrachlorobis(η 6 -p-cymene)diruthenium) (306.2 mg; 0.5 mmol) and (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (366.4 mg; 1.0 mmol) and potassium hydroxide (400 mg; 7.1 mmol) are dissolved in methylenechloride (7 ml) in a Schlenk's reactor which is preliminarily dried in vacuum and of which the inside is then substituted with argon. The reaction solution was agitated at room temperature for 5 minutes, and by adding water (7 ml) to the reaction solution, the color of the reaction solution turned from orange to deep purple. The organic phase was separated and rinsed in water (7 ml). The organic phase was dried over calcium hydroxide, from which the solvent was distilled off. Then, the resulting product was dried under reduced pressure, to recover catalyst No.10 of deep purple crystal (522 mg) in Table 10. The yield is 87%. m.p.>80° C. (decomposed) IR(KBr)[cm −1 ]:3289, 3070, 3017, 2968 2920, 2859 1 H-NMR (400 MHz, 2 H-toluene, δ): ppm 1.20 (d, 3H), 1.25 (d, 3H), 2.05 (s, 3H), 2.22 (s, 3H), 2.53 (m, 1H), 4.08 (d, 1H), 4.89 (s, 1H), 5.11 (d, 1H), 5.27 (d, 1H), 5.28 (d, 1H), 5.39 (d, 1H), 5.64 (brd, 1H), 6.87(d, 2H), 7.67 (d, 2H), 7.2-7.7 (m, 10H) Elemental Analysis (C 31 H 34 N 2 O 2 ,RuS) C H N Ru Theoretical values (%) 62.09 5.71 4.67 16.85 Elemental values (%) 62.06 5.77 4.66 16.47 The present catalyst was tested by X-ray crystallography. It was indicated that the complex was of a structure satisfying the analysis results. Example 71-b Alternative Synthesis of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-Cymene)((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine)(η 6 -p-Cymene)Ruthenium) RuCl[(1S, 2S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ] (η 6 -p-cymene)(chloro-(1S, 2S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) (318.6 mg; 0.5 mmol) and potassium hydroxide (200 mg; 3.5 mmol) are dissolved in methylene chloride (7 ml) in a Shlenk's reactor which is preliminarily vacuum dried and of which the inside is substituted with argon. The reaction solution was agitated at room temperature for 5 minutes, and by adding water (7 ml) to the reaction solution, the color of the reaction solution turned from orange to deep purple. The organic phase was separated and rinsed in water (7 ml). The organic phase was dried over calcium hydroxide, from which the solvent was distilled off. Then, the resulting product was dried under reduced pressure, to recover crystal in deep purple crystal (522 mg). The yield is 87%. Example 72-a Synthesis of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -Mesitylene)(((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine) (η 6 -Mesitylene)Ruthenium) Instead of (RuCl 2 (η 6 -p-cymene)] 2 (tetrachlorobis(η 6 -p-cymene)diruthenium), [RuCl 2 (η 6 -mesitylene)] 2 (tetrachlorobis(η 6 -mesitylene)diruthenium) was used, and by the same procedures as in the Example 71-a, the catalyst in purple crystal as No.11 in Table 10 was recovered. The yield is 80%. 1 H-NMR (400 MHz, 2 H-chloroform, δ) ppm 1.91 (s. 9H). 1.99 (s. 3H). 3.83 (d. 1H). 4.51 (s. 1H). 4.95 (s. 3H). 5.92 (brd. 1H). 6.38-7.71 (m. 14H) Example 72-b Alternative Synthesis of Ru((S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -Mesitylene)(((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine)(η 6 -Mesitylene)Ruthenium) Instead of RuCl[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(chloro-((S, S)-N-p-toluenesulfonyl-1,2- diphenylethylenediamine)(η 6 -p-cymene)ruthenium), RuCl[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -mesitylene)(chloro-((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -mesitylene)ruthenium) synthesized as in the Reference Example 2 was used, and by the same procedures as in the Example 71-b, the catalyst in purple crystal was recovered. The yield is 90%. Example 73-a Synthesis of Ru[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -p-Cymene)(((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine) (η 6 -p-Cymene)Ruthenium) Instead of (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ]((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine), (S, S)-N-p-Ts-1,2-cyclohexanediamine((1S, 2S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine) was used, and by the same procedures as in the Example 71-a, the catalyst in purple crystal as No.14 in Table 10 was recovered. The yield is 58%. Example 73-b Alternative Synthesis of Ru[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -p-Cymene) (((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -p-Cymene)Ruthenium) Instead of RuCl[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ])(η 6 -p-cymene)(chloro-((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium), RuCl[(S, S)-N-p-Ts-cyclohexane-1,2-diamine synthesized in the Reference Example 3 was used, and by the same procedures as in the Example 71-b, the catalyst in purple crystal was recovered. The yield is 62%. Example 74-a Synthesis of Ru[(S, S)-N-p-TS-1,2-Cyclohexanediamine](η 6 -Mesitylene)((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -Mesitylene)Ruthenium) Instead of (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine), (S, S)-N-p-Ts-cyclohexane-1,2-diamine ((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine) was used, and by the same procedures as in the Example 71-a, the catalyst as No.15 shown in Table 10 was recovered as purple crystal. The yield is 60%. Example 74-b Alternative Synthesis of Ru[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -Mesitylene) ((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -Mesitylene)Ruthenium) Instead of RuCl[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(chloro-(S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium), RuCl[(S, S)-N-p-TS-1,2-cyclohexanediamine](η 6 -mesitylene)(chloro-(1S, 2S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) synthesized in the Reference Example 4 was used, and by the same procedures as in the Example 71-b, the aforementioned catalyst was recovered as purple crystal. The yield is 62%. Example 75-a Synthesis of RuH[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-Cymene)(Hydride-(S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine)(η 6 -p-Cymene)Ruthenium) Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) (600 mg; 1.0 mmol) is dissolved in 2-propanol (10 ml) in a Shlenk's reactor which is preliminarily vacuum dried and of which the inside is substituted with argon. The reaction solution was agitated at room temperature for 15 minutes. The solvent was recovered under reduced pressure at room temperature, to recover a compound in brown yellow. After rinsing the compound in cool pentane and recrystallizing the compound in methanol, the catalyst No.12 in Table 10 was recovered as orange crystal. The yield is 85%. m.p. >60° C. (decomposed) IR(KBr)[cm −1 ]:3335, 3317, 3228, 3153, 3060, 3025, 2960, 2917, 2867 1 H-NMR (400 MHz, 2 H-chloroform, δ):ppm −5.47 (s, 1H), 1.53 (d, 3H), 1.59 (d, 3H), 2.29 (d, 3H), 2.45 (s, 3H), 2.79 (m, 1H), 2.93 (m, 1H), 3.80 (d, 1H), 4.02 (m, 1H), 5.15 (d, 1H), 5.19 (d, 1H), 5.29 (m, 1H), 5.43 (d, 1H), 5.58 (d, 1H), 6.49 (d, 2H), 6.9-7.3 (m, 10H), 7.59 (d, 2H) Elemental Analysis (C 31 H 36 N 2 O 2 RuS) C H N Ru Theoretical values (%) 61.88 6.02 4.66 16.80 Experimental values (%) 61.79 5.94 4.70 16.56 The X-ray crystallography shows that the complex was of a structure satisfying the analytical results. Example 75-b Alternative synthesis of RuH[(S, S)-p-TsNCH(C 6 H 5 )CH(C 4 H 5 )NH 2 (η 6 -p-Cymene) (Hydride-((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine) (η 6 -p-Cymene)Ruthenium) Toluene (7 ml) was added into the Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -p-cymene)ruthenium) (306.2 mg; 0.5 mmol) synthesized in the Example 72 in an autoclave which was preliminarily vacuum dried and of which the inside was substituted with argon, for reaction at room temperature and a hydrogen pressure of 80 atm. After elimination of the solvent and rinsing in cool pentane and subsequent recrystallization in methanol, crystal in orange (420 mg) was recovered. The yield is 70%. Example 76-a Synthesis of RuH (S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -Mesitylene) (Hydride-((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine) (η 6 -Mesitylene)Ruthenium) Instead of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -p-cymene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium), Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) synthesized in the Example 72 was used, and by the same procedures as in the Example 75-a, the aforementioned catalyst No.13 in Table 10 was recovered. The yield was 60%. Example 76-b Alternative Synthesis of RuH[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH 2 ](η 6 -Mesitylene)(Hydride-((S, S)-N-p-Toluenesulfonyl-1,2-Diphenylethylenediamine)(η 6 -Mesitylene)Ruthenium) Instead of Ru((S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium), Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -mesitylene)(((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 6 -mesitylene)ruthenium) synthesized in the Example 72 was used, and by the same procedures as in the Example 75-b, the aforementioned catalyst was recovered. The yield is 60%. Example 77-a Synthesis of RuH[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -p-Cymene)(Hydride-(S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -p-Cymene)Ruthenium) Instead of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium), Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -p-cymene) ((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) synthesized in the Example 73 was used, and by the same procedures as in the Example 75-a, the catalyst No.16 in Table 10 was recovered. The yield is 54%. Example 77-b Alternative Synthesis of RUH[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -p-Cymene)(Hydride-(S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -p-Cymene)Ruthenium) Instead of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)(chloro-(S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium), Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -p-cymene)ruthenium) synthesized in the Example 73 was used, and by the same procedures as in the Example 75-b, the catalyst was recovered. The yield is 55%. Example 78-a Synthesis of RuH[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -Mesitylene)(Hydride(S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -Mesitylene)Ruthenium) Instead of Ru[(S, S)-p-TsNcH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine)(η 60 -p-cymene)ruthenium), Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -mesitylene) ((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) synthesized in the Example 74 was used, and by the same procedures as in the Example 75-a, the catalyst No.17 in Table 10 was recovered. The yield is 52%. Example 78-b Alternative Synthesis of RuH[(S, S)-N-p-Ts-1,2-Cyclohexanediamine](η 6 -Mesitylene)(Hydride((S, S)-N-p-Toluenesulfonyl-1,2-Cyclohexanediamine)(η 6 -Mesitylene)Ruthenium) Instead of Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (η 6 -p-cymene)ruthenium), Ru[(S, S)-N-p-Ts-1,2-cyclohexanediamine](η 6 -mesitylene) ((S, S)-N-p-toluenesulfonyl-1,2-cyclohexanediamine)(η 6 -mesitylene)ruthenium) synthesized in the Example 74 was used, and by the same procedures as in the Example 75-b, the aforementioned catalyst was recovered. The yield is 48%. Example 79 Synthesis of (R)-1-Indanol Ru[(S, S)-p-TsNCH(C 6 H 5 )CH(C 6 H 5 )NH](η 6 -p-cymene)((S, S)-N-p-toluenesulfonyl-1,2-diphenylethylenediamine) (ruthenium-η 6 -p-cymene mesitylene (6.0 mg; 10 μmmol) synthesized in the Example 71 and 1-indanol (671 mg; 5 mmol) were weighed in a Shlenk's reactor which was preliminarily vacuum dried and of which the inside was substituted with argon, and acetone (2.5 ml) was then added to the resulting mixture for agitation at 28° C. for 6 hours. The solvent was distilled off under reduced pressure, prior to separation by silica gel chromatography (eluent; ethyl acetate:hexane=1:3), to recover (R)-indanol (286 mg) in colorless crystal. The yield is 84%. m.p. 71-72° C. [α] 24 D =−30.1° (c=1.96, chloroform) The resulting (R)-1-indanol was analyzed by HPLC (high-performance liquid chromatography), and the objective (R)-1-indanol was at an optical purity of 97% ee. <HPLC Analytical Conditions> Column: Chiralcel OB (manufactured by Daicell Chemical Industry, Co.) Developing solution: isopropanol: hexane=10:90 Flow rate: 0.5 ml/min Retention time: (S)-1-indanol 18.6 minutes (R)-1-indanol 12.9 minutes. Examples 80 to 93 According to the method described in Example 79, the optically active ruthenium-diamine complexes for racemic secondary alcohols and meso-type diols as reaction substrates as shown in Table 9 were used for reaction under reaction conditions of reaction time, to recover the individually corresponding optically active secondary alcohols at high yields. The results are collectively shown in Table 11. TABLE 11 Reaction Exam- Sub- time % % Prod- ples strates Catalysts s/c (hr) (yield) ee ucts 80 1a (S,S)-10 500 36 50 92 1a(R) 81 1a (S,S)-11 500 30 51 94 1a(R) 82 1a (S,S)-10 500 22 47 92 1b(R) 83 1b (S,S)-11 500 30 44 98 1c(R) 84 1c (S,S)-11 500 36 47 97 2a(R) 85 2a (S,S)-11 500 24 47 97 2b(R) 79 2b (S,S)-10 500 6 46 97 3a(R) 86 3a (S,S)-10 500 6 49 99 3b(R) 87 3b (S,S)-11 500 36 51 98 4(R) 88 4 (S,S)-10 500 4.5 43 93 5a(R) 89 5a (S,S)-10 500 5 46 95 5b(R) 90 5b (S,S)-11 200 3 70 96 7 91 5 (S,S)-10 200 3 56 87 9 92 1a (S,S)-14 500 36 48 82 1a(R) 93 1a (S,S)-15 500 36 48 86 1a(R) (In the table, s/c means the molar ratio of substrate/ruthenium-optically active diamine complex.) INDUSTRIAL APPLICABILITY In accordance with the present invention, optically active alcohols and optically active amines are provided, which are useful in various fields of pharmaceutical products, synthetic intermediates thereof, food, flavor, cosmetics, liquid crystal materials and the like. The ruthenium-diamine complex of the present invention is industrially useful as a chiral catalyst providing higher selectivity and activity in that the complex can be used for organic synthesis such as asymmetric synthetic reactions. If the complex is used as a hydrogen transfer-type asymmetric reduction catalyst of racemic secondary alcohols or meso-type diols, optically active secondary alcohols useful as production intermediates of drugs can be produced highly efficiently.
A method for producing optically active compounds is disclosed. The method is highly practical for producing optically active compounds useful for various utilities such as intermediates for synthesizing pharmaceutical agents, liquid crystal materials and agents for optical resolution.
2
BACKGROUND OF THE INVENTION The present invention relates generally to protection of remote sensing devices from interrogating radiation source and more specifically to optical devices which provide false reply signals to the interrogating source. Remote sensing devices such as missile seekers are often interrogated by radiation sources such as laser beams to determine the operating band of the sensor, its modulation rate, timing signal, chop frequency, or similar data which might be used to deteriorate the performance of the sensor. In addition the nature of these sensors is such that they have a high probability of being damaged from high amplitude incoming radiation. Thus a need arose for a device that would shield the remote sensing devices from interrogating radiation which could either damage its sensor or detect parameters of its operation or both. OBJECT OF THE INVENTION It is therefore the object of the present invention to provide an inexpensive and reliable device for shielding the sensors of a remote sensing device from interrogating radiation. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings wherein: SUMMARY OF THE INVENTION The present invention achieves these results through the use of beam splitting devices and false detection apparatus. In general, a beam splitter is used to divide part of the incoming light away from the detector to protect the detector from high power incoming radiation. The light which is divided away is operated on by a series of optical elements including chop wheels, filters, and false detectors to give false indications to the interrogating source. The beam splitter can also be coated with an optical filter so that only light of the operating frequency of the detector is transmitted to the detector. BRIFE DESCRIPTION OF THE DRAWINGS FIG. 1 shows a remote sensing device without optical protection. FIG. 2 shows a detecting surface of one embodiment of the invention. FIG. 3A shows a second embodiment of the invention. FIGS. 3B and 3C show modifications of the second embodiment of the invention. DETAILED DESCRIPTION FIG. 1 shows a typical remote sensing device having an optical element 10 to focus the incoming radiation and a detector 12 with a filter mounted on its surface. Incoming beams such as beams 13 and 15 will be reflected back along their axis and return to their point of origin. Similarly incoming beans such as bemas 14 which are at an angle to the axis of the optical system as shown in FIG. 1 will reflect a certain portion of radiation back to its origin since the filter and detector are usually not prefectly flat. The system in effect acts like a low grade retro-reflector. A laser or similar source can thus be used to interrogate the receiver by studying the radiation which returns from the sensor. In this manner the collimated source can determine the chop frequency, spectral response, general method of scan and similar parameters which might be used to counter the sensor. In addition, the same source might be used to damage the optical elements, filter and detectors of the sensor. If is thus desirable to provide means for protecting the sensors from both interrogating and damaging radiation. FIG. 2 shows a detecting device for use with the structure of FIG. 1 which provides protection against interrogating radiation through the use of a series of false detectors. It consists of a conventional true detector 18 which is overcoated or covered with an interference filter 16 which provides spectral selectively for the true detector 18. Small partially absorbing semiopaque materials 20 are placed on top of the interference filter to act as false detectors so that either a symmetric or random array of various size flase and real detectors are seen by the interrogating radiation. The false detectors 20 are of approximately the same absorptivity as the real detector but with absorptivity peaks occurring at different wavelengths. The interrogating device will thus interpret the return as a variety of detectors operating at different spectral regions. The detecting device of FIG. 2 however, used in conjunction with the apparatus of FIG. 1, provides no protection against damaging radiation. The apparatus of FIG. 3A shows another embodiment of the invention which protects its detector 24 from both interrogating and damaging radiation by addition of a beam splitter to the sensor optical system. Mounted on the beam splitter 22 is a reflective filter such as an interference filter which could be either bandpass or band limiting. The bandpass filter provides the greatest protection but is the most expensive to install and fabricate. In any event, the reflective filter allows radiation of a certain frequency to pass to the detector 24 while the remainder of the incoming radiation is reflected to reflective surface 26. The reflective surface can be made to have a broad band of absorptivity or selected bands of absorptivity. Additionally reflective surface 26 can be divided into a series of subareas similar to the false detectors of FIG. 2 having arbitrary sizes and reflectivities. Since both the detector 24 and the reflective surface 26 are primarily reflective, the preponderence of the radiation will be reflected back outside the receiver. Thus the false detectors of reflective surface 26 will make the receiver appear to the interrogating system as if it were operating in a different spectral region. In those instances where the incoming power is expected to be exceptionally large a totally reflecting surface such as collecting and return mirror 28 as shown in FIG. 3B can be used to offer the maximum degree of protection. In addition, radiation shields or baffles 32 can be used to block any scattered light from the detector 24. This modification also permits radiation to leave the optical system with the least amount of scatter. Of course, any motion imparted to reflective surface 26 will be interpreted by the interrogating system as another type of scanning and will imply different scanning frequencies. FIG. 3C depicts a further modification of the second embodiment of the invention which allows power handling capabilities greater than the device shown in FIG. 3A. In operation, collimating lens 33 focuses the light reflected by the beam splitter on a large reflecting surface 34 similar to reflecting surface 26 in FIG. 3A. The collimated radiation from collimating lens 33 is reflected back from reflecting surface 34 whereupon the radiation continues to reverse its path until it exits the optical system. In effect a magnified image is formed on reflecting surface 34 of the image that would normally appear on reflecting surface 26 of FIG. 3A. Since the image is expanded on reflecting surface 34 it can handle incoming radiation which under other circumstances could not be handled by the reflective surface 26 in FIG. 3A. Thus the invention will not allow the exact operating frequency or band of operation of the true sensor to be determined, but instead will only allow the reduction of possibilities to a few selected bands or frequencies. In addition, the beam splitter 22 of the second embodiment is flat and has a relatively small surface, and is thereby easily coated with an interference filter at a reasonable cost while accurately maintaining the frequency of its bandpass. Also, the present invention is compatible with presently existing systems and could be installed in them with out considerable modification. Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
The invention presents means for protecting a remote sensing device such as missile seeker unit from damaging radiation outside of the sensing band of the detector and interrogating radiation attempting to determine the operating band of the sensor, its modulation rate, timing signal, or similar data which might be used to deteriorate the performance of the sensor.
5
BACKGROUND OF THE INVENTION 1. Field of the Invention The invention concerns a steplessly variable pulling means transmission in which the variation in the transmission ratio is effected by varying the operative diameter of at least one of the pulling means pulleys over which the pulling means runs. 2. Description of the Related Art The pulling means used can be a belt. For example a V-belt or a round belt. As well as a chain or another link-type belt or band member. The pulling means pulleys are adapted to the respective pulling means used. In which respect. Particularly when employing round belts and V-belts. Pulleys are used whose substantially axially oriented pulling means running surfaces are slightly inclined with respect to the plane in which the endless pulling means circulates. Those pulling means pulleys whose operative diameter is variable for the purposes of varying the transmission ratio are referred to as adjusting pulleys. In that respect it is known in the case of the described conical pulling means running surfaces for the adjusting pulley to be composed of two pulley halves which are arranged on respective sides of the plane of the pulling means and the axial spacing of which is variable whereby the operative diameter of that adjusting pulley can also be altered, by virtue of the conical configuration of the running surfaces. It is likewise also possible for the operative diameter to be varied without axial movement, just by radial movements of the adjusting pulley, for example by virtue of the adjusting pulley being formed by segments which are possibly in mutually overlapping relationship and which are pivotable in the plane of the pulling means or which are displaceable radially relative to the axis of the adjusting pulley. The simplest form of a pulling means transmission comprises two pulleys, over which the endless pulling means is guided, at least one of the pulleys being in the form of an adjusting pulley. To increase the transmission ratio range, the pulling means transmission may comprise a plurality of, for example, two, pulling means which are then passed over a total of at least four pulleys. In such a situation, one belt pulley of the one pulling means is frequently carried on the same axis as a pulling means pulley of the other pulling means and is non-rotatably connected thereto, being for example of an integral construction in the form of a double pulley, as can be seen for example from DE 38 25 091. However, it is precisely those adjusting pulleys which are varied in terms of their operative diameter by axial displacement of the pulley halves of the adjusting pulley that suffer from the problem that the plane of the pulling means is axially displaced when one pulley half is fixed and one pulley half is axially displaceable. If in that case the other pulley results in the pulling means extending in an inclined position, with the consequence of defective traction and in particular increasing wear on the pulling means. Therefore, the attempt has already been made in DE 38 25 091 to eliminate that axial displacement by simultaneous axial movement of the carrier on which the adjusting pulleys are disposed. That however entails additional structural expenditure and also means that the adjusting pulleys are mounted in a movable member, that is to say in this case in the variator or variable speed unit, although for other reasons, for example to minimize structural size, it would be desirable if possible for the pulleys of the variator unit to be in the form of fixed pulleys which are not variable in respect of their diameter. BRIEF SUMMARY OF THE INVENTION The object in accordance with the present invention is to provide a pulling means transmission which is simple and inexpensive to produce and in terms of its structure and to afford a minimum possible structural space with the largest possible band width in respect of the transmission ratio. The fact that, within the pulling means transmission, the one or more adjusting pulleys are symmetrically pre-stressed with respect to the plane of the pulling means which runs thereon, means that, upon a variation in the operative diameter of that adjusting pulley, there is no axial displacement of the pulling means and thus no undesirable increase in wear on the pulling means, nor is there any need to compensate for the axial displacement of the pulling means by way of the belt pulleys. In accordance with the invention, when the transmission involves axial pre-stressing of axial pulley halves which make up an adjusting pulley, both pulley halves are pre-stressed in the same manner, that is to say by the same amount and with mutually opposite pre-stressing directions. In the case of such an adjusting pulley which is composed of pulley halves, the pre-stressing direction is always directed in the direction of the largest operative diameter as otherwise there is no traction effect as between the pulling means and the adjusting pulley. The same applies in regard to an adjusting pulley which is to be varied by radial displacement. The pre-stressing is effected for example by means of spring force, but it can also be achieved by the pressure of a fluid, that is to say a hydraulic oil or a gas or by magnetic force. If the pulling means transmission includes two pulling means, wherein two of the pulleys, of which there are then at least four, run on a common axis or shaft, in particular in the form of a double pulley, a preferred embodiment of the invention provides that, of the pulling means pulleys of which there are then a total of at least four, the two outer pulleys which are associated with different pulling means are in the form of adjusting pulleys and the two pulleys which run on an axis or shaft and which are disposed therebetween and which run on a common axis or shaft and which can be moved to and fro jointly in respect of their position between the two outer pulleys are in the form of fixed pulleys, preferably in the form of a double pulley. That has the advantage that this so-called variator or variable speed unit which includes the two central pulleys, apart from its pivotability, does not have to embrace any further functions such as for example displaceability of the pulleys, and therefore does not become unnecessarily complicated and large. Instead, there is in any case more structural space available in the case of the outer pulleys as the axis of rotation thereof does not have to be displaceable with respect to the surrounding housing so that, at those outer pulleys, it is also easier to provide them in the form of an adjusting pulley. An embodiment in accordance with the invention is described in greater detail by way of example hereinafter with reference to the drawings in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a detail view of an adjusting pulley; FIG. 2 shows a structural form of the transmission, and FIG. 3 shows another variant of the transmission. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 2 shows a structural form of the transmission according to the invention in partial vertical section (FIG. 2 a ) and in plan view (FIG. 2 b ). FIG. 1 additionally shows in detail on a larger scale the drive adjusting pulley 9 illustrated in FIG. 2 . In the transmission the two outer pulling means pulleys, the drive adjusting pulley 9 and the driven adjusting pulley 10 , are in the form of adjusting pulleys insofar as their respective axis of rotation admittedly remains unchanged relative to the housing 17 of the transmission, but their operative diameter is variable, as can best be seen with reference to the view in FIG. 1 . FIG. 1 is a view in longitudinal section of the drive adjusting pulley 9 which is fixed with its shaft non-rotatably on the motor shaft 7 of the driving motor 25 . Otherwise however the driven adjusting pulley 9 is of a similar design configuration. Except for the fact that its shaft represents the drive output shaft 18 which can be non-rotatably connected to the unit to be driven, for example the drilling chuck of a drilling machine etc. Adjustment of the operative diameter is effected by virtue of the face that—reference is best directed to FIG. 1 —the adjusting pulley comprises two pulley halves 2 a , 2 d which engage the pulling means, in this case the drive V-belt 14 , in particular a flat V-belt, on opposite sides. The flanks of the belt are arranged in conical relationship with each other and likewise the oppositely directed pulling means running surfaces 22 a , 22 b of the two pulley halves 2 a , 2 a are disposed at an angle relative to the pulling means plane 20 in which the V-belt 14 circulates. Relative movement of the two pulley halves 2 a , 2 b relative to each other along the axis of rotation of the adjusting pulley causes the axial spacing of the two pulling means running surfaces 22 a , 22 b relative to each other to be varied, and, because of the fixed width of the V-belt 14 in the axial direction, that if to say in the direction of the axis of rotation 21 a of the adjusting pulley, the V-belt 14 which bears against those running surfaces 22 a 22 b moves radially inwardly or outwardly respectively. The spacing between the running surfaces 22 a and 22 b is passively set insofar as the two pulley halves 2 a and 2 b are respectively pre-stressed or biased from their rear side in the direction of the axis of rotation 21 a by means of a spring 3 a towards the pulling means plane 20 . The springs 3 a , 3 b are supported by way of a spring plate 4 a , 4 b and a securing ring 5 a , 5 b on the end which is respectively remote from the pulley half 2 a , 2 b , with respect to the shaft 7 of the adjusting pulley. As the springs 3 a , 3 b which are arranged coaxially with respect to the shaft 7 are of equal dimensions and in addition vibrations also occur upon rotation of the transmission, the pulling means plane 20 , that is to say the middle of the circulating V-belt 14 , will always set itself to the middle between the two securing rings 5 a and 5 b and thus always remain in the same position, irrespective of the spacing of the two running surfaces 22 a , 22 b relative to each other. There will therefore be no displacement in the direction of the axis of rotation 21 a at the V-belt 14 . The non-rotatable but axially displaceable connection of the pulley halves 2 a , 2 b with respect to the shaft 27 carrying them is effected in conventional fashion by means of fitting keys 8 a , 8 b extending in the axial direction, and corresponding but longer groves in the inside periphery of the pulley halves on the one hand and in the outer periphery of the shaft 27 ; approximately half of each of the keys 8 a , 8 b engages into the respective groves to afford the non-rotatable connection. The spacing of the running surfaces 22 a , 22 b relative to each other is passively adjusted in accordance with the forces which are operative in the plane 20 of the pulling means and which act on the V-belt 14 on the other side of the adjusting pulley. As FIG. 2 shows, the pulling means transmission comprises two V-belts, the drive V-belt 14 and the drive V-belt 15 , of which the former passes around the drive adjusting pulley 9 and the variator unit double pulley 13 while the latter circulates in a plane which is parallel thereto and which is at a somewhat lower position, as shown in FIG. 2 a , around the variator double pulley 13 and a driven adjusting pulley 10 . In that arrangement—according to the desired overall step-up or step-down ratio—the two V-belts 14 and 15 run of the variator double pulley 13 on operative diameters which are of different magnitudes but which are fixed and not adjustable. The variator double pulley 13 is mounted by ball bearing assemblies on a variator shaft 12 which is parallel to the axes of rotation 21 a and 21 b of the outer adjusting pulleys 9 and 10 . The variator shaft 12 in turn is fixed in approximately perpendicular relationship on the variator lever 16 pivotable about a pivot axis 24 which is arranged parallel to the variator axis and which is not disposed on the connecting line between the axes of rotation 21 a and 21 b of the outer adjusting pulleys. Pivotal movement of the variator lever 16 causes the spacing of the variator double pulley 13 relative to the axis of rotation 21 a of the left-hand adjusting pulley 9 to be for example reduced and at the same time the spacing relative to the axis of rotation 21 b of the right-hand adjusting pulley 10 is increased. As a result an increased pull is applied to the right-hand V-belt 14 , whereby the -pulley halves 2 a , 2 b of the right-hand adjusting pulley 10 are urged apart symmetrically in upward and downward directions and thus their operative diameter is reduced. Conversely the tension at the left-hand V-belt 114 is reduced whereby the springs 3 a , 3 b of the left-hand adjusting pulley 9 urge the pulley halves 2 a , 2 b axially towards each other and the operative diameter at the left-hand adjusting pulley 9 is increased. As a result, in both V-belt 14 , 15 , the step-up or step-down ratio is altered in the same direction and therefore, with the above-described movement, the speed of rotation of the drive output shaft is increased, with the speed of rotation of the motor 25 remaining the same. The reversed procedure also operates in a similar fashion. By virtue of the fact that, irrespective of the adjustment of the adjusting pulleys, the V-belt 14 , 15 always remain in the same pulling means plane 20 a , 20 b , adjustment of the variator unit, that is to say the pivotal movement of the variator lever 16 with the variator double pulley 13 , can also occur parallel to or in that plane 20 , without any need for a compensating movement transversely with respect to that plane. That permits the steplessly operative transmission to be of a very simple and compact structure, as shown in FIG. 2 . A further important advantage of the transmission as shown in FIG. 2 is that the double pulley 13 with its two operative diameters determines the overall transmission ration of the transmission. By virtue of the fact that for example the double pulley 13 can be removed from the variator shaft 12 and re-fitted in an inverted position, that is to say with the small operative diameter at the top side, with the two V-belts being interchanged at the same time, the transmission ration can already be drastically altered. It will be appreciated likewise that, instead of the double pulley 13 , it is also possible to fit another double pulley with different operative diameters, that then giving a different transmission ratio range for the transmission. It is possible to compensate for the resulting variations in the lengths of the belts passing around the pulleys, for example by displacing the variator shaft 12 along the lever 16 . FIG. 3 shows another structural form of the transmission which differs from the structure shown in FIG. 2 in that the central double pulley 13 ′ is no longer mounted on the variator but is mounted stationarily with its shaft 12 ′, with respect to the housing (not shown). On the contrary, the variator unit 11 comprises two tensioning rollers 23 a , 23 b which are connected together by way of a tensioning lever 28 and on the ends of which they are rotatably mounted. The one roller 23 a is disposed in the pulling means plane 20 a and within the V-belt 15 . For the tensioning roller 23 b , this applies in a similar manner to the V-belt 14 . The tensioning lever 28 is pivotable by means of a variator lever 16 about an axis which is perpendicular to the pulling means plane, in the central region of the lever 28 , with the consequence that either the tensioning roller 23 b urges the V-belt 14 outwardly or the tensioning roller 23 a urges the V-belt 15 outwardly, and thus seeks to increase the length of the path of movement thereof, with the consequence that the V-belt in question urges the two pulley halves 2 a , 2 b of the corresponding adjusting pulley away from each other, and reduces the operative diameter thereof.
A pulling device transmission includes an stepless V-belt connection two pulleys wherein at least one of the pulleys is an adjusting pulley which is composed by two halves between which the belt runs through. The operative diameter of the adjusting pulley is adjustable relative to the belt plane where the belt runs thereon and the adjusting pulley halves are symmetrically pre-stressed with respect to the belt plane. A variator unit is designed for displacing the travel path of the belt in the respective to the adjusting pulley.
5
This application is a divisional of Serial No. 09/166,722 filed Oct. 5, 1998, now U.S. Pat. No. 5,962,693 and claims the benefit of Provisional Application No. 60/061,707 filed Oct. 6, 1997. FIELD OF THE INVENTION The present invention relates generally to processes for the conversion of cyano groups into amidines for the purpose of producing compounds which are useful as antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex. These compounds may be used for the inhibition of platelet aggregation, as thrombolytics, and/or for the treatment of thromboembolic disorders. BACKGROUND There are several methods to convert cyano groups into amidine groups (S. Patai, Z. Rappoport, The Chemistry of Amidines and Imidates, 1991, John Wiley & Sons Ltd.). One of the most widely used methods for the preparation of amidines is the Pinner synthesis (R. Roger, D. G. Neilson, Chem. Rev . 1961, 61, 179-211), which proceeds in two steps through an imidate intermediate. Abood et al, in U.S. Pat. No. 5,484,946, discusses formation of the amidine moiety from a nitrile group through an amidoxime intermediate. Jendrall et al, in Tetrahedron 1995, 51, 12047-12068, used a similar process to convert a cyano group into the amidinium functionality. Eloy and Leners, in Chem. Rev ., 1962, 62, 155-183, review the preparation of amidoximes from nitrites. Chio and Shine, in J. Heterocyclic Chem ., 1989, 26, 125-128, reported that these amidoximes can be transformed into 1,2,4-oxadiazole derivatives. Judkins et al, in Synthetic Commun . 1996, 26, 4351, describe formation of amidine moiety from nitrile through an amidoxime intermediate under acetylation or acylation conditions. This literature however, does not disclose any regioselectivity between an amidoxime and an isoxazoline. In fact, Mueller et al, Angew. Chem ., 1994, 106, 1305-1308, report that hydrogenation with 10% Pd/C will reduce a isoxazoline ring system. There is also no precedent for the transformation of a cyano group into an amidine functionality through a 1,2,4-oxadiazole moiety, and therefore the conversion of a 1,2,4-oxadiazole into amidine directly through catalytic hydrogenation is not taught. Compounds of generic form (I) are antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex which are currently being evaluated for the inhibition of platelet aggregation, as thrombolytics, and for the treatment of thromboembolic disorders. Consequently, large quantities of these compounds are needed to support drug development studies. The preparation of compounds of generic form (I) have been disclosed in U.S. Pat. No. 5,446,056, PCT international publication WO 95/14683, PCT international publication Wo 96/38426, pending and commonly owned U.S. application Ser. No. 08/700,906, and in J. Med. Chem ., Xue et al, 1997, 40, 2064-2084. The preparation of (X) has been disclosed by Zhang et al in Tetrahedron Lett . 1996, 37, 4455-4458 and J. Org. Chem . 1997, 62, 2466-2470, which describe amidine formation from a nitrile using the Pinner reaction. Although this process has been able to produce compounds of formula (X) on a multikilogram scale, employing the Pinner reaction on a commercial scale poses several disadvantages. The Pinner approach involves the use of an excess of hydrogen chloride gas which is environmentally unfriendly, and removal of the inorganic salts generated during the Pinner process requires extensive purification protocols. It was therefore necessary to develop an efficient, safer process to produce compounds of formula (I) on large scale. SUMMARY OF THE INVENTION The present invention relates generally to processes for the conversion of cyano groups into amidines for the purpose of producing compounds, and intermediates therefore, which are useful as antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex. These compounds may be used for the inhibition of platelet aggregation, as thrombolytics, and/or for the treatment of thromboembolic disorders. There is provided by this invention a process for the preparation of compounds of formula (I), (III), (IV), (V) and (VI): wherein: R 1 is selected from H or NHR 1a ; R 1a is selected from the group consisting of: —C(═O)—O—R 1b , —C(═O)—R 1b , —C(═O)N(R 1b ) 2 , —C(═O)NHSO 2 R 1b , —C(═O)NHC(═O)R 1b , —C(═O)NHC(═O)OR 1b , —C(═O)NHSO 2 NHR 1b , —C(═S)—NH—R 1b , —NH—C(═O)—O—R 1b , —NH—C(═O)R 1b , —NH—C(═)—NH—R 1b , —SO 2 —O—R 1b , —S 2 —R 1b , —SO 2 —N(R 1b ) 2 , —SO 2 —NHC(═O)OR 1b , —P(═S)(OR 1b ) 2 , —P(═O)(OR 1b ) 2 , —P(═S)(R 1b ) 2 , —P(═O)(R 1b )2, and R 1b is selected from the group consisting of: C 1 -C 8 alkyl substituted with 0-2 R 1c , C 2 -C 8 alkenyl substituted with 0-2 R 1c , C 2 -C 8 alkynyl substituted with 0-2 R 1c , C 3 -C 8 cycloalkyl substituted with 0-2 R 1c , aryl substituted with 0-4 R 1c , aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c , a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ; R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 2 is selected from H or C 1 -C 10 alkyl; R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ; R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ; R 3b and R 3c are each independently selected from the group consisting of H, C 1 —C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 —C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ; R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; R 5 is selected from the group consisting of: hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy, C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy, C 3 -C 10 alkylcarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonylalkyloxy, C 5 -C 10 cycloalkylcarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonylalkyloxy, C 8 -C 11 aryloxycarbonylalkyloxy, C 8 -C 12 aryloxycarbonyloxyalkyloxy, C 8 -C 12 arylcarbonyloxyalkyloxy, C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy, 5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, (5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-; 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl; R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl (C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, aryloxy and aryl substituted with 0-5 R 6c ; R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; n is 0-4; and a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ; said process comprising one or more of: (1): contacting a compound of formula (II) with a salt of hydroxyl amine in the presence of a suitable base to form a compound of formula (III); (2): contacting a compound of formula (III) with an acylating agent of formula R 6 CO—O—COR 6 or R 6 COX, wherein X is fluorine, bromine, chlorine or imidazole, in a suitable solvent to form a compound of formula (IV) or a salt thereof; and (3): contacting a compound of formula (IV) with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof. DETAILED DESCRIPTION OF THE INVENTION In a first embodiment, the present invention provides a process for the preparation of compounds of formula (I): or a pharmaceutically acceptable salt form thereof; wherein: R 1 is selected from H or NHR 1a ; R 1a is selected from the group consisting of: —C(═O)—O—R 1b , —C(═O)—R 1b , —C(═O)N(R 1b ) 2 , —C(═O) NHSO 2 R 1b , —C(═O)NHC(═O)R 1b , —C(═O)NHC(═O)OR 1b , —C(═O)NHSO 2 NHR 1b , —C(═S)—NH—R 1b , —NH—C(═O)—O—R 1b , —NH—C(═O)R 1b , —NH—C(═)—NH—R 1b , —SO 2—O—R 1b , —SO 2 —R 1b , —SO 2 —N(R 1b )2, —SO 2 —NHC(═O)OR 1b , —P(═S)(OR 1b ) 2 , —P(═O)(OR 1b ) 2 , —P(═S)(R 1b ) 2 , —P(═O)(R 1b ) 2 , and R 1b is selected from the group consisting of: C 1 -C 8 alkyl substituted with 0-2 R 1c , C 2 -C 8 alkenyl substituted with 0-2 R 1c , C 2 -C 8 alkynyl substituted with 0-2 R 1c , C 3 -C 8 cycloalkyl substituted with 0-2 R 1c , aryl substituted with 0-4 R 1c , aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c , a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ; R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 2 is selected from H or C 1 -C 10 alkyl; R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ; R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ; R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ; R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; R 5 is selected from the group consisting of: hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy, C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy, C 3 -C 10 alkylcarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonylalkyloxy, C 5 -C 10 cycloalkylcarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonylalkyloxy, C 8 -C 11 aryloxycarbonylalkyloxy, C 8 -C 12 aryloxycarbonyloxyalkyloxy, C 8 -C 12 arylcarbonyloxyalkyloxy, C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy, 5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, (5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-; R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl; n is 0-4; a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ; said process comprising: contacting a compound of formula (IV): wherein: R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, C 1 -C 6 alkyloxy, aryloxy and aryl substituted with 0-5 R 6c ; R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof. In a preferred embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein: said suitable pressure is up to 100 psi, and said hydrogenation catalyst is selected from the group consisting of palladium on carbon, palladium hydroxide on carbon, palladium on calcium carbonate and platinum on carbon. In a more preferred embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein: R 1 is selected from H or NHR 1a ; R 1a is —C(═O)—O—R 1b or —SO 2 —R 1b ; R 1b is selected from the group consisting of: C 1 -C 8 alkyl substituted with 0-1 R 1c , C 2 -C 8 alkenyl substituted with 0-1 R 1c , C 2 -C 8 alkynyl substituted with 0-1 R 1c , C 3 -C 8 cycloalkyl substituted with 0-1 R 1c , aryl substituted with 0-3 R 1c , aryl(C 1 -C 6 alkyl)-substituted with 0-3 R 1c , a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O,S, and N, said heterocyclic ring being substituted with 0-4 R 1c ; R 1c is selected from the group consisting of H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy and C 2 -C 5 alkoxycarbonyl; R 2 is H or C 1 -C 10 alkyl; R 3 and R 4 are H or C 1 -C 6 alkyl; R 5 is selected from the group consisting of hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy, C 6 -C 10 aryloxy and C 7 -C 11 arylalkyloxy; R 6 is selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, C 1 -C 8 perfluoroalkyl, C 7 -C 10 arylalkyloxy, C 1 -C 6 alkyloxy, aryloxy, aryl substituted with 0-2 R 6c ; R 6c is H, halogen, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; and R 6d and R 6e are independently selected from H or C 1 -C 10 alkyl; n is 1; a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 . In an even more preferred embodiment, the present invention provides a process for the preparation of a compound of formula (I-a): or a pharmaceutically acceptable salt form thereof, wherein: R 1a is —C(═O)OCH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4-yl-sulfonyl; comprising contacting a compound of formula (IV-a):  wherein R 6 is H, methyl, ethyl, propyl, butyl, pentyl, hexyl C 7 -C 8 arylalkyloxy, C 1 - 5 alkyloxy, aryloxy or aryl; with hydrogen under a suitable pressure from about 20 to about 50 psi in the presence of palladium on carbon, in the range of about 1% to about 10% by weight of compound (IV), to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof. In a second embodiment, the present invention provides a process for the preparation of compounds of formula (IV) or a salt thereof comprising: contacting a compound of formula (III):  with an acylating agent of formula R 6 CO—O—COR 6 or R 6 COX, wherein X is fluorine, bromine, chlorine or imidazole, in a suitable solvent to form a compound of formula (IV) or a salt thereof. In a preferred second embodiment, the present invention provides a process for the preparation of a compound of formula (IV), wherein: X is chlorine; R 1 is NHR 1a ; R 1a is —C(═O)OCH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4-yl-sulfonyl; R 2 is H; R 3 and R 4 are H; R 5 is methyl; R 6 is CH 3 ; n is 1; a is a single bond; and said suitable solvent is acetic acid. In a third embodiment, the present invention provides a process for the preparation of compounds of formula (III), comprising: contacting a compound of formula (II):  with a salt of hydroxyl amine in the presence of a suitable base to form a compound of formula (III). In a preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (III), wherein said salts of hydroxyl amine are hydroxylamine hydrochloride and hydroxlyamine sulfate. In a more preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (III), wherein: X is chlorine; R 1 is NHR 1a ; R 1a is —C(═O)—O—CH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4yl-sulfonyl; R 2 is H; R 3 and R 4 are H; R 5 is methyl; R 6 is selected from the group consisting of: H, C 1 -C 6 alkyl, C 7 -C 8 arylalkyloxy, C 1 -C 5 alkyloxy, aryloxy and aryl; n is 1; a is a single bond; said suitable salt of hydroxylamine is hydroxlyamine hydrochloride; and the suitable base is selected from the group consisting of: triethylamine, diisopropylethylamine and 4-methyl morpholine. In a fourth embodiment, the present invention provides a process for the preparation of compounds of formula (I): or a pharmaceutically acceptable salt form thereof, said process comprising: (a) heating a compound of the formula (IV):  wherein: R 1 is selected from H or NHR 1a ; R 1a is selected from the group consisting of: —C(═O)—O—R 1b , —C(═O)—R 1b , —C(═O)N(R 1b ) 2 , —C(═O)NHSO 2 R 1b , —C(═O)NHC(═O)R 1b , —C(═O)NHC(═O)OR 1b , —C(═O)NHSO 2 NHR 1b , —C(═S)—NH—R 1b , —NH—C(═O)—O—R 1b , —NH—C(═O)R 1b , —NH—C(═)—NH—R 1b , —SO 2 —O—R 1b , —SO 2 —R 1b , —SO 2 —N(R 1b ) 2 , —SO2—NHC(═O)OR 1b , —P(═S)(OR 1b ) 2 , —P(═O)(OR 1b ) 2 , —P(═S)(R 1b ) 2 , —P(═O)(R 1b ) 2 , and R 1b is selected from the group consisting of: C 1 -C 8 alkyl substituted with 0-2 R 1c , C 2 -C 8 alkenyl substituted with 0-2 R 1c , C 2 -C 8 alkynyl substituted with 0-2 R 1c , C 3 -C 8 cycloalkyl substituted with 0-2 R 1c , aryl substituted with 0-4 R 1c , aryl (C 1 -C 6 alkyl)-substituted with 0-4 R 1c , a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ; R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 2 is selected from H or C 1 -C 10 alkyl; R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ; R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ; R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ; R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; R 5 is selected from the group consisting of: hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy, C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy, C 3 -C 10 alkylcarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonylalkyloxy, C 5 -C 10 cycloalkylcarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonylalkyloxy, C 8 -C 11 aryloxycarbonylalkyloxy, C 8 -C 12 aryloxycarbonyloxyalkyloxy, C 8 -C 12 arylcarbonyloxyalkyloxy, C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy, 5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, (5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-; R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl; R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, aryloxy and aryl substituted with 0-5 R 6c ; R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; n is 0-4; a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ; for a time sufficient, and to a temperature sufficient to form a compound of formula (V): and (b) contacting said compound of formula (V) with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a salt thereof. In a preferred fourth embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein: said suitable pressure is up to 100 psi; said hydrogenation catalyst is selected from the group consisting of palladium on carbon, palladium hydroxide on carbon, palladium on calcium carbonate and platinum on carbon; said sufficient temperature is from about 30° C. to about 120° C.; said sufficient time is from about 10 minutes to about 24 hours; wherein an amount of catalyst loaded on carbon is from about 1% to about 10% by weight; and wherein an amount of a hydrogenation catalyst is from about 1% to about 30% by weight of compound (IV). In a more preferred fourth embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein: R 1 is NHR 1a ; R 1a is —C(═O)—O—CH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4yl-sulfonyl; R 2 is H; R 3 and R 4 are H; R 5 is methyl; R 6 is selected from the group consisting of: H, methyl, ethyl, propyl, butyl, pentyl, hexyl, C 7 -C 8 arylalkyloxy, aryloxy, C 1 -C 5 alkoxy and aryl; n is 1, and a is a single bond; said suitable pressure is from about 20 to about 50 psi; said sufficient temperature is from about 50° C. to about 120° C.; said sufficient time is from about 10 minutes to about 3 hours; said hydrogenation catalyst is palladium on carbon; wherein an amount of catalyst loaded on carbon is from about 3% to about 5% by weight; and wherein an amount of palladium on carbon is from about 3% to about 7% by weight of compound (IV). In a fifth embodiment, the present invention provides a process for the preparation of compounds of the formula (I): or a pharmaceutically acceptable salt form thereof; wherein: R 1 is selected from H or NHR 1a ; R 1a is selected from the group consisting of: —C(═O)—O—R 1b , —C(═O)—R 1b , —C(═O)N(R 1b ) 2 , —C(═O)NHSO 2 R 1b , —C(═O)NHC(═O)R 1b , —C(═O)NHC(═O)OR 1b , —C(═O)NHSO 2 NHR 1b , —C(═S)—NH—R 1b , —NH—C(═O)—O—R 1b , —NH—C(═O)R 1b , —NH—C(═)—NH—R 1b , —SO 2 —O—R 1b , —SO 2 —R 1b , —SO 2 —N(R 1b ) 2 , —SO 2 —NHC(═O)OR 1b , —P(═S)(OR 1b ) 2 , —P(═O)(OR 1b ) 2 , —P(═S)(R 1b ) 2 , —P(═O)(R 1b ) 2 , and R 1b is selected from the group consisting of: C 1 -C 8 alkyl substituted with 0-2 R 1c , C 2 -C 8 alkenyl substituted with 0-2 R 1c , C 2 -C 8 alkynyl substituted with 0-2 R 1c , C 3 -C 8 cycloalkyl substituted with 0-2 R 1c , aryl substituted with 0-4 R 1c , aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c , a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ; R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 2 is selected from H or C 1 -C 10 alkyl; R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ; R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ; R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ; R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; R 5 is selected from the group consisting of: hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy, C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy, C 3 -C 10 alkylcarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonyloxyalkyloxy, C 3 -C 10 alkoxycarbonylalkyloxy, C 5 -C 10 cycloalkylcarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy, C 5 -C 10 cycloalkoxycarbonylalkyloxy, C 8 -C 11 aryloxycarbonylalkyloxy, C 8 -C 12 aryloxycarbonyloxyalkyloxy, C 8 -C 12 arylcarbonyloxyalkyloxy, C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy, 5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, (5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-; R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl; n is 0-4; a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ; said process comprising: contacting a compound of formula (VI):  wherein: Z is selected from R 6 SO 2 — or (R 7 ) 3 Si—; R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, aryloxy and aryl substituted with 0-5 R 6c ; R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ; R 7 is selected independently from C 1 -C 10 alkyl or aryl substituted 0-3 R 7a ; and R 7a is C 1 -C 10 alkyl; with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof. In a sixth embodiment, the present invention provides a process for the preparation of compounds of formula (VI): comprising: contacting a compound of formula (III): with an agent of formula Z-X, wherein: X is fluorine, bromine or chlorine; Z is R 6 SO 2 — or (R 7 ) 3 Si—; R 7 is selected independently from C 1 -C 10 alkyl or aryl substituted 0-3 R 7a ; and R 7a is C 1 -C 10 alkyl; in the presence of a suitable acid scavenger in a suitable solvent to form a compound of formula (IV) or a salt thereof. In a seventh embodiment, the present invention provides a compound of formula (III-i): and salt forms thereof. In a eighth embodiment, the present invention provides a compound of formula (IV-i): and salt forms thereof. In a ninth embodiment, the present invention provides a compound of formula (V-i): and salt forms thereof. DEFINITIONS The reactions of the synthetic methods claimed herein are carried out in suitable solvents which may be readily selected by one of skill in the art of organic synthesis, said suitable solvents generally being any solvent which is substantially nonreactive with the starting materials (reactants), the intermediates, or products at the temperatures at which the reactions are carried out, i.e., temperatures which may range from the solvent's freezing temperature to the solvent's boiling temperature. A given reaction may be carried out in one solvent or a mixture of more than one solvent. Depending on the particular reaction step, suitable solvents for a particular reaction step may be selected. Suitable halogenated solvents include: carbon tetrachloride, bromodichloromethane, dibromochloromethane, bromoform, chloroform, bromochloromethane, dibromomethane, butyl chloride, dichloromethane, tetrachloroethylene, trichloroethylene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, 1,1-dichloroethane, 2-chloropropane, hexafluorobenzene, 1,2,4-trichlorobenzene, o-dichlorobenzene, chlorobenzene, fluorobenzene, fluorotrichloromethane, chlorotrifluoromethane, bromotrifluoromethane, carbon tetrafluoride, dichlorofluoromethane, chlorodifluoromethane, trifluoromethane, 1,2-dichlorotetrafluorethane and hexafluoroethane. Suitable ether solvents include: dimethoxymethane, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, furan, diethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, anisole, or t-butyl methyl ether. Suitable protic solvents may include, by way of example and without limitation, water, methanol, ethanol, 2-nitroethanol, 2-fluoroethanol, 2,2,2-trifluoroethanol, ethylene glycol, 1-propanol, 2-propanol, 2-methoxyethanol, 1-butanol, 2-butanol, i-butyl alcohol, t-butyl alcohol, 2-ethoxyethanol, diethylene glycol, 1-, 2-, or 3- pentanol, neo-pentyl alcohol, t-pentyl alcohol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, cyclohexanol, benzyl alcohol, phenol, or glycerol. Suitable aprotic solvents may include, by way of example and without limitation, tetrahydrofuran (THF), dimethylformamide (DMF), dimethylacetamide (DMAC), 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU), 1,3-dimethyl-2-imidazolidinone (DMI), N-methylpyrrolidinone (NMP), formamide, N-methylacetamide, N-methylformamide, acetonitrile, dimethyl sulfoxide, propionitrile, ethyl formate, methyl acetate, hexachloroacetone, acetone, ethyl methyl ketone, ethyl acetate, sulfolane, N,N-dimethylpropionamide, tetramethylurea, nitromethane, nitrobenzene, or hexamethylphosphoramide. Suitable hydrocarbon solvents include: benzene, cyclohexane, pentane, hexane, toluene, cycloheptane, methylcyclohexane, heptane, ethylbenzene, m-, o-, or p-xylene, octane, indane, nonane, or naphthalene. Suitable carboxylic acid solvents include acetic acid, trifluoroacetic acid, ethanoic acid, propionic acid, propiolic acid, butyric acid, 2-butynoic acid, vinyl acetic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid and decanoic acid. Suitable pressures range from atmospheric to any pressure obtainable in a laboratory or industrial plant. Suitable hydrogenation catalysts are those which facilitate the delivery of hydrogen to the N—O bond of an N-acylated hydroxylamine. Such hydrogenation catalysts by way of example and without limitation are palladium on carbon, palladium hydroxide on carbon, palladium on calcium carbonate poisoned with lead and platinum on carbon. As used herein, suitable acid scavengers include those compounds capable of accepting a proton from a hydroxyamidine during either an acylation, sulfonation or silation reaction without reacting with the agent reacting with the oxygen of the hydroxyamidine. Examples include, but are not limited to tertiary bases such as N,N-diisopropylethylamine, 2,3-, 2,4-, 2,5-, 2,6-, 3,4-, 3,5-lutidine, triethylamine, 2-, 3-, or 4-picoline, pyrrole, pyrrolidine, N-methyl morpholine, pyridine and pyrimidine. As used herein, suitable bases include those soluble in the reaction solvent and capable of free-basing hydroxylamine. Examples include, but are not limited to: lithium hydroxide, sodium hydroxide, potassium hydroxide, lithium carbonate, sodium carbonate, potassium carbonate, imidazole, ethylene diamine, N,N-diisopropylethylamine, 2,3-, 2,4-, 2,5-, 2,6-, 3,4-, 3,5-lutidine, triethylamine, 2-, 3-, or 4-picoline, pyrrole, pyrrolidine, N-methyl morpholine, pyridine, pyrimidine or piperidine. As used herein, acylating agent refers to an acid halide or anhydride, which, when reacted with a hydroxyamidine results in O-acylation of the hydroxyl amidine. Such acylating agents by way of example and without limitation are of the general structure R 6c COX or R 6 CO—O—COR 6 , as defined above in the specification. By way of further example, and without limitation, where X is fluorine, chlorine, bromine or imidazole, R 6 is H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , methyl, ethyl, propyl, butyl, ethenyl, allyl, ethynyl, cyclopropyl, phenyl, benzyl, C 7 -C 10 arylalkyloxy, C 1 -C 10 alkyloxy or aryloxy. As used herein, agent refers to a compound of the formula Z-X, which, when reacted with a hydroxyamidine results in placement of the Z group on the oxygen of the hydroxyamidine. By way of further example, and without limitation, where X is fluorine, chlorine, bromine or imidazole, Z is either R 6 SO 2 — or (R 7 ) 3 Si—, R 6 is H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , methyl, ethyl, propyl, butyl, ethenyl, allyl, ethynyl, cyclopropyl, phenyl, benzyl, C 7 -C 10 arylalkyloxy, or aryloxy, and R 7 is independently selected from C 1 -C 10 alkyl or aryl substituted with 0-3 R 7a , and R 7a is C 1 -C 10 alkyl. The compounds described herein may have asymmetric centers. Unless otherwise indicated, all chiral, diastereomeric and racemic forms are included in the present invention. Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention. It will be appreciated that compounds of the present invention that contain asymmetrically substituted carbon atoms may be isolated in optically active or racemic forms. Methods on how to prepare optically active forms from optically active starting materials are known in the art, such as by resolution of racemic forms or by synthesis. All chiral, diastereomeric, racemic forms and all geometric isomeric forms of a structure are intended. When any variable (for example but not limited to R 1b , R 1c , R 3a , R 3b , R 3c , R 6c , etc.) occurs more than one time in any constituent or in any formula, its definition on each occurrence is independent of its definition at every other occurrence. Thus, for example, if a group is shown to be substituted with 0-2 R 3a , then said group may optionally be substituted with up to two R 3a and R 3a at each occurrence is selected independently from the defined list of possible R 3a . Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. By stable compound or stable structure it is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent. The term “substituted”, as used herein, means that any one or more hydrogen on the designated atom is replaced with a selection from the indicated group, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound. As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms; for example, C 1 -C 4 alkyl includes methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, s-butyl, and t-butyl; for example C 1 -C 10 alkyl includes C 1 -C 4 alkyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomer thereof. As used herein, any carbon range such as “Cx-Cy” is intended to mean a minimum of “x” carbons and a maximum of “y” carbons representing the total number of carbons in the substituent to which it refers. For example, “C 3 -C 10 alkylcarbonyloxyalkyloxy” could contain one carbon for “alkyl”, one carbon for “carbonyloxy” and one carbon for “alkyloxy” giving a total of three carbons, or a larger number of carbons for each alkyl group not to exceed a total of ten carbons. “Alkenyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur in any stable point along the chain, such as ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1,3-butadienyl and the like. “Alkynyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur in any stable point along the chain, such as ethynyl, propynyl, butynyl and the like. “Aryl” is intended to mean phenyl or naphthyl. The term “arylalkyl” represents an aryl group attached through an alkyl bridge; for example aryl(C 1 -C 2 )alkyl is intended to mean benzyl, phenylethyl and the like. As used herin, “cycloalkyl” is intended to include saturated ring groups, including mono-, bi-, or poly-cyclic ring systems, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and adamantyl. As used herein, “alkyloxy” or “alkoxy” represents an alkyl group of indicated number of carbon atoms attached through an oxygen bridge, for example methoxy, ethoxy, propoxy, i-propoxy, butoxy, i-butoxy, s-butoxy and t-butoxy. The term “aryloxy” is intended to mean phenyl or naphthyl attached through an oxygen bridge; As used herein, “carbonyl” means a carbon double bonded to oxygen and additionally substituted with two groups through single bonds; “carbonyloxy” means a carbon double bonded to oxygen and additionally bonded through a single bonds to two groups, one of which is an oxygen. As used herein, “sulfonyl” is intended to mean a sulfur bonded through double bonds to two oxygens and bonded to two additional groups through single bonds. As used herein, “hydroxy” means a group consisting of an oxygen and a hydrogen bonded to another group through the oxygen. “Halo” or “halogen” as used herein refers to fluoro, chloro, bromo and iodo. As used herein, the term “heterocycle” or “heterocyclic” is intended to mean a stable 5- to 10-membered monocyclic or bicyclic or 5- to 10-membered bicyclic heterocyclic ring which may be saturated, partially unsaturated, or aromatic, and which consists of carbon atoms and from 1 to 3 heteroatoms independently selected from the group consisting of N, O and S and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. Examples of such heterocycles include, but are not limited to, pyridyl (pyridinyl), pyrimidinyl, furanyl (furyl), thiazolyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothiophenyl, indolyl, indolenyl, isoxazolinyl, quinolinyl, isoquinolinyl, benzimidazolyl, piperidinyl, 4-piperidonyl, pyrrolidinyl, 2-pyrrolidonyl, pyrrolinyl, tetrahydrofuranyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl or octahydroisoquinolinyl, azocinyl, triazinyl, 6H-1,2,5-thiadiazinyl, 2H, 6H-1,5,2-dithiazinyl, thianthrenyl, pyranyl, isobenzofuranyl, chromenyl, xanthenyl, phenoxathiinyl, 2H-pyrrolyl, pyrrolyl, imidazolyl, pyrazolyl, isothiazolyl, isoxazolyl, oxazolyl, pyrazinyl, pyridazinyl, indolizinyl, isoindolyl, 3H-indolyl, 1H-indazolyl, purinyl, 4H-quinolizinyl, phthalazinyl, naphthyridinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, 4aH-carbazole, carbazole, β-carbolinyl, phenanthridinyl, acridinyl, perimidinyl, phenanthrolinyl, phenazinyl, phenarsazinyl, phenothiazinyl, furazanyl, phenoxazinyl, isochromanyl, chromanyl, imidazolidinyl, imidazolinyl, pyrazolidinyl, pyrazolinyl, piperazinyl, indolinyl, isoindolinyl, quinuclidinyl, morpholinyl or oxazolidinyl. Also included are fused ring and spiro compounds containing, for example, the above heterocycles. As used herein, the term “heteroaryl” refers to aromatic heterocyclic groups. Such heteroaryl groups are preferably 5-6 membered monocylic groups or 8-10 membered fused bicyclic groups. Examples of such heteroaryl groups include, but are not limited to pyridyl (pyridinyl), pyrimidinyl, furanyl (furyl), thiazolyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, indolyl, isoxazolyl, oxazolyl, pyrazinyl, pyridazinyl, benzofuranyl, benzothienyl, benzimidazolyl, quinolinyl, or isoquinolinyl. As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the intermediates or final compound are modified by making acid or base salts of the intermediates or final compounds. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like. The pharmaceutically acceptable salts of the intermediates or final compounds include the conventional non-toxic salts or the quaternary ammonium salts from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric and the like; and the salts prepared from organic acids such as acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, and the like. The pharmaceutically acceptable salts are generally prepared by reacting the free base or acid with stoichiometric amounts or with an excess of the desired salt-forming inorganic or organic acid or base in a suitable solvent or various combinations of solvents. The pharmaceutically acceptable salts of the acids of the intermediates or final compounds are prepared by combination with an appropriate amount of a base, such as an alkali or alkaline earth metal hydroxide e.g. sodium, potassium, lithium, calcium, or magnesium, or an organic base such as an amine, e.g., dibenzylethylenediamine, trimethylamine, piperidine, pyrrolidine, benzylamine and the like, or a quaternary ammonium hydroxide such as tetramethylammoinum hydroxide and the like. As discussed above, pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid, respectively, in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences , 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418, the disclosure of which is hereby incorporated by reference. The present invention is contemplated to be practiced on at least a multigram scale, kilogram scale, multikilogram scale, or industrial scale. Multigram scale, as used herein, is preferably the scale wherein at least one starting material is present in 10 grams or more, more preferably at least 50 grams or more, even more preferably at least 100 grams or more. Multikilogram scale, as used herein, is intended to mean the scale wherein more than one kilogram of at least one starting material is used. Industrial scale as used herein is intended to mean a scale which is other than a laboratory scale and which is sufficient to supply product sufficient for either clinical tests or distribution to consumers. The methods of the present invention, by way of example and without limitation, may be further understood by reference to Scheme 1. Scheme 1 details the general synthetic method for synthesis of compounds of formula (I). Compound (II) can be prepared by methods described in J. Org. Chem . 1997, 62, 2466-2470, and Tetrahedron Lett . 1996, 37, 4455-4458. It is understood to one skilled in the art that the anhydride or acid chlorides used in the acylation step can be prepared by conversion of carboxylic acid derivatives as described in Advanced Organic Chemistry , March, 4th edition, John Wiley and Sons, Inc., 1992, p. 401-402 and p. 437-438. In reaction 1, a compound of formula (II) is dissolved in about 10 liters of suitable solvent per kilogram of compound (II). A suitable salt of hydroxyl amine is added. While a wide range of solvents such as halogenated, protic, aprotic, hydrocarbon, or ethers can be used, protic solvents such as methanol, ethanol and isopropanol are preferred, of which methanol is most preferred. Suitable salts of hydroxyl amine include phosphate, sulfate, nitrate and hydrochloride salts; a most preferred salt is hydroxyl amine hydrochloride. The hydroxyl amine salt is free-based with about 1.0 to about 2.0 equivalents of an appropriate base. Preferrable bases are tertiary amines; most preferred is triethyl amine. The reaction mixture can then be heated for a time sufficent to form a compound of form (III). By way of general guidance, compound (II) may be contacted with free-based hydroxyl amine at about 40° C. to about 65° C. for about 1 to about 5 hours to produce compound (III). Preferred temperatures are from about 55° C. to about 65° C. Preferred reaction times are from about 2 to about 4 hours. The product precipitates as a white solid during the course of the reaction. The solids can then be filtered and the cake washed with a solvent, the choice of which is readily understood by one skilled in the art. The product is dried to afford pure compound (III). In reaction 2, a vessel is charged with compound (III). The solids are dissolved in a suitable solvent followed by the slow charging of the vessel with a second solution made by dissolving a suitable acylating agent in the solvent being used for the reaction. Preferably, the addition of the acylating agent solution should be done over a period of about 15 minutes to about one hour. While a wide range of reaction solvents such as halogenated, aprotic, hydrocarbon, ether, or organic acids are possible, preferred solvents are acetic acid, trifluoroacetic acid, pyridine, chloroform, dichloromethane, dichlorobenzene, acetonitrile, and tetrahydrofuran. Most preferred are carboxylic acids which are structural derivatives of the acylating agent being used. By way of general example, acetic acid would preferably be used as the solvent when acetic anhydride is the acylating agent, whereas triflouroacetic acid would be preferably used when trifluoroacetic anhydride is the acylating agent. Certain solvents such as aprotic, ether, halogenated and hydrocarbon solvents may require the addition of an acid scavenger. Preferred acid scavengers include tertiary bases such as triethyl amine, diisopropyl ethylamine, N-methyl morpholine and pyridine. Most preferred is triethyl amine. Solvents capable of reacting with the acylating agent, such as alcohols, water and the like are not preferred as is readily understood by one skilled in the art. Preferred acylating agents are anhydrides. Most preferred is acetic anhydride. Further, the acylating agent (and preferable solvent) can be strategically chosen to form the desired salt of the reaction product. By way of general example, acetic anhydride would be selected as the acylating agent if the acetate salt of the product is desired. The choice of acylating agent and solvent in this regard is readily understood by one skilled in the art. After the addition of the acylating agent, the reaction progression can be monitored by HPLC analysis performed on an aliquot of the reaction solution. The acylation reaction is considered finished when compound (III) is completely consumed. Typical reaction times are in the range of about 5 minutes to about 24 hours. Preferred reaction times are about 5 minutes to about 3 hours. The product can be isolated by the removal of the solvent via distillation and precipitation of the product through the addition of a suitable aprotic solvent. Preferred aprotic solvents are ethers. The choice of precipition solvent and the methods of isolation are readily understood by one skilled in the art. Preferably, the product is carried forward without isolation. Reaction 3, comprises the hydrogenation of the O-substituted hydroxyamidine. This reaction can be carried out without isolation of compound (IV), by the addition of a slurry of a suitable hydrogention catalyst in the solvent used in the preceding reaction. If compound (IV) is isolated, the hydrogenation can be carried out in protic, aprotic, hydrocarbon, ether, or organic acid solvents. The preferred solvents are methanol, ethanol, 2-propanol, dimethylformamide, ethyl acetate, anisole, acetic acid and trifluoroacetic acid. Most preferred is a mixture of methanol and acetic acid. While numerous hydrogenation catalysts are possible, palladium on carbon is most preferred. The amount of catalyst loaded on the carbon ranges from about 0.5% to about 30%. The preferred amount of catalyst on carbon is about 1% to about 10%. Most preferred is about 3% to 5%. The total weight of the catalyst and carbon per gram of starting material is preferably about 1% to about 10%. Most preferred is about 3% to 7%. The total weight of catalyst and carbon is based on the weight of the O-alkylated hydroxyamidine. The reaction solution is then subjected to a hydrogen atmosphere under a suitable pressure. Preferred pressures range from about 1 psi to 100 psi. Most preferred is 20 psi to 50 psi. The reaction time of the hydrogenation is dependent on cumulative factors, including the amount of catalyst present, the reaction temperature and the hydrogen pressure. By way of general example, an acetylation reaction containing 10.0 kilograms of compound (III) required the use of 0.5 kilograms of 3% palladium on carbon, under 5 psi of hydrogen at room temperature to reach completion in about 5 hours. Varying any one of these conditions will effect reaction time which is readily understood by one skilled in the art. Reaction completion can be monitored by HPLC analysis performed on aliquots of the reaction mixture. The reaction is considered complete when compound (IV) has been completely consumed. After the reaction is judged complete, the catalyst is filtered off and washed with reaction solvent. The filtrate is concentrated, and the product precipitated by the addition of a suitable aprotic solvent. The most preferred solvent for precipitation is acetone. The choice of precipition solvent and the methods of isolation are readily understood by one skilled in the art. The product is then filtered and dried to give pure compound (I). In reaction 4, the resultant reaction solution of Step 2 is heated to form compound (V). The heating range is from about 30° C. to the reflux temperature of the solvent. Preferred temperatures are from about 30° C. to about 120° C. Preferred solvents for the cyclization are acetic acid, trifluoroacetic acid, pyridine, chloroform, dichloromethane, dichlorobenzene, acetonitrile, and tetrahydrofuran. The most preferred solvent for the cyclization is acetic acid. The preferred time of reflux is solvent dependent due to the limitations of boiling points. By way of general example, the use of acetic acid as the solvent required a heating time of about 3 hours. The product can be isolated by the removal of the solvent via distillation followed by the drying of the solids. Preferably, compound (V) is carried forward without isolation. In reaction 4, compound (V) is hydrogenated under the identical conditions of Reaction 3 to give compound (I). The present invention may be further exemplified without limitation by reference to Scheme 2. The following examples are meant to be illustrative of the present invention. These examples are presented to exemplify the invention and are not to be construed as limiting the inventors scope. EXAMPLE 1 (R)-Methyl-3-[[[3[4[amino(hydroxyimino)methyl] phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N (butoxy-carbonyl)-L-alanine: Compound (III-i) A 100 gal stainless steel reactor was charged with methanol (87 Kg), compound (II-i) (11 Kg), hydroxylamine hydrochloride (3.6 Kg), and triethylamine (5.2 Kg). The reaction mixture was heated at 60° C. for 3 h and a large amount of solid precipitated during the reaction. After cooling to 0-5° C., the solid was filtered through a Nutsche filter and the cake was washed with a mixture of methanol and water (made from 20 Kg of methanol and 25 Kg of water). After dried the cake, the product (11.8 Kg) was obtained. EXAMPLE 2 (R)-Methyl-3-[[[3-[4-(aminoiminomethyl)phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N(butoxy carbonyl)-L-alanine monoacetate: Compound (I-i) A 50 gal stainless steel reactor was charged with acetic acid(63 Kg) and (R)-Methyl-3[[[3[4[amino(hydroxyimino) methyl]phenyl]-4, 5-dihydro-5-isoxazolyl]acetyl]amino]-N (butoxy-carbonyl)-L-alanine (Batch 1:10.0 Kg; Batch 2: 10.0 Kg.) A solution of acetic anhydride (Batch 1:2205 g; Batch 2:1983 g) in acetic acid (21 Kg) was charged into the reactor slowly over 30 min from a pressure cylinder using nitrogen pressure at rt (22° C.). Additional 5.3 Kg of acetic acid was then used to rinse the cylinder. After stirring at 22° C. for 30 min or until a clear solution was attained, a small sample was taken for HPLC analysis. After the reaction was complete as determined by HPLC. A slurry of Pd/C(Batch 1:3%Pd/C, 0.5 Kg; Batch 2: 5%Pd/C, 0.4 Kg) in acetic acid (5 L) was added and the resulting mixture was hydrogenated under 5 psi hydrogen pressure for 4-5 h. After the reaction was complete as determined by HPLC, the catalyst was filtered off and washed with acetic acid (21 Kg) to give a solution of the product. Anisole (80 Kg) was then added to the filtrate and the resulting mixture was concentrated at about 70° C. under vacuum (40 mm Hg or lower) in a 100 gal reactor. The distillation was stopped until that the distillate was about 148 L or the solid became visible in the batch. Cooled the reactor to 40° C., 72 Kg of acetone was added over 30-90 min. The slurry was stirred at ambient temperature for 1 h and the 0-5° C. for another 1 h. The solid was collected on a Rosenmund filter/dryer and the cake was washed with 10% methanol in acetone (made from 6 Kg of methanol and 57 Kg of acetone). The solid cake was dried until LOD<1%. A hot (80° C.) mixture of acetonitrile (27 Kg) and acetic acid (18 Kg) was charged into the filter to dissolve the cake and the hot solution was then transfer back to 100 gal reactor. The transfer line was washed with a mixture of acetic acid (0.9 Kg) and acetonitrile (1.4 Kg). After the solution was cooled to 40-45° C., acetone (65 Kg) was added within 10 min. The resulting slurry was stirred gently at 25° C. for 1 h and then 0-5° C. for another 1 h. The solid was filtered by the Rosenmund filter/dryer and the cake was washed with 10% methanol in acetone (prepared from 5.5 Kg methanol and 50 Kg of acetone). After drying the cake until LOD<0.1%, the product was obtained (Batch 1:6.3 Kg. Batch 2: 6.8 Kg). Heels from both batches in the Rosenmund filter/dryer were dissolved in acetonitrile and acetic acid and combined, which was crystallized in the Kilo lab to give additional 2.86 Kg of product. EXAMPLE 3 (R)-methyl-3-[[[3-[4-[(acetyloxyimino)aminomethyl] phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxycarbonyl)-L-alanine: Compound (IV-i) To a suspension of (R)-Methyl-3-[[[3-[4-[amino (hydroxyimino)methyl]phenyl]-4,5-dihydro-5-isoxazolyl] acetyl]amino]-N-(butoxycarbonyl)-L-alanine (11.76 g) in acetic acid (50 mL) was added acetic anhydride (3.6 g) dropwise. After the completion of addition, the reaction mixture was stirred at room temperature 15 min. The reaction mass became clear. Ether (200 mL) was added slowly and a thick slurry formed. The resulting mixture was then stirred for another 1.5 h at room temperature and the solid was filtered. The cake was washed with ether (50 mL) and dried to give (R)-methyl-3-[[[3-[4-[(acetyloxyimino) aminomethyl] phenyl]-4,5-dihydro-5-isoxazolyl] acetyl]amino]-N-(butoxycarbonyl)-L-alanine (12.3 g). EXAMPLE 4 (R)-methyl—N-(butoxycarbonyl)-3-[[[4,5-dihydro-3-[4-(5-methyl-1,2,4-oxadiazol-3-yl)phenyl]-5-isoxazolyl]acetyl] amino]-L-alanine: Compound (V-i) To a suspension of (R)-Methyl-3-[[[3-[4-[amino (hydroxyimino)methyl]phenyl]-4,5-dihydro-5-isoxazolyl] acetyl]amino]-N-(butoxycarbonyl)-L-alanine (1.05 g) in acetic acid (7 mL) was added acetic anhydride (0.35 g) dropwise. After the completion of addition, the reaction mixture was refluxed for 3 h. The solvent was distilled under vacuum and the solid was dried to give (R)-methyl-N-(butoxycarbonyl)-3-[[[4,5-dihydro-3-[4-(5-methyl-1,2,4-oxadiazol-3-yl)phenyl]-5-isoxazolyl]acetyl]amino]-L-alanine (1.05 g). EXAMPLE 5 (R)-Methyl-3-[[[3-[4-(aminoiminomethyl)phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxy-carbonyl)-L-alanine monoacetate: Compound (I-i) Method B: A mixture of (R)-methyl-N-(butoxycarbonyl)-3-[[[4,5-dihydro-3-[4-(5-methyl-1,2,4-oxadiazol-3-yl)phenyl]-5-isoxazolyl]acetyl]amino]-L-alanine (70 mg) and 3%Pd/C(30 mg) in methanol (3 mL) and acetic acid (0.5 mL) was stirred under hydrogen atmosphere for 3 h. The catalyst was filtered off and washed with methanol (4 mL). The combined filtrate and wash was concentrated to small volume. Acetone (2 mL) was added slowly and a slurry was formed. After stirred for 30 min, the solid was filtered and the cake was washed with 10% methanol in acetone (4 mL) and dried to give the product (25 mg). HPLC CONDITIONS Column: Eclipse XDB-C8 4.6×250 mm Mobile Phase: A: 0.1% trifluoroacetic acid/0.1% triethylamine in HPLC grade water B: tetrahydrofuran (unstabilized-suitable for liquid chromatography)/0.l% trifluoroacetic acid Gradient: t=0 min 85% A 15% B t=10 min 85% A 15% B t=32 min 50% A 50% B t=40 min 50% A 50% B Flow Rate: 1.5 mL/min Injection Volume: 10 microliters Stop Time: 40 minutes Post Time: 10 minutes Oven Temp.: 40° C. Detector: UV (280 nm, 230 nm, 260 nm) Sample Prep.: Dissolve approximately 0.5 mg of sample (dry solids weight) per mL in 50% tetrahydrofuran 49.9% H 2 O/0.1% acetic acid. Filter any undissolved solids through an Acrodisc 0.45 micron Nylon filter.
The present invention relates to processes for the conversion of nitrites to amidines in the preparation of compounds which are antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex. The compounds described herein are potent thrombolytics and useful for the inhibition of platelet aggregation in the treatment of thromboembolic disorders.
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CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is related to, and claims priority from U.S. patent application Ser. No. 10/938,868 “Method of Interactive System for Previewing and Selecting Eyeware” by Dr. Michael R. Neal filed Sep. 13, 2004. This application is also related to, and claims priority from U.S. Provisional Patent Application 60/659,605 “VIRTUAL MONITOR SYSTEM HAVING LAB-QUALITY COLOR ACCURACY” by Dr. Michael R. Neal filed Mar. 7, 2005. FIELD OF THE INVENTION [0002] The present invention relates to an interactive device which displays computer enhanced images, and more specifically to an interactive device which displays computer color-accurate enhanced images simulating a user wearing various products. BACKGROUND OF THE INVENTION [0003] There are several interactive computer systems generally known in the art to enable users to virtually view and select products. One such example exists in hair salons. A customer has their picture taken and displayed on a computer screen. The image is then computer enhanced to display different hair styles allowing the customer to select which hair style they prefer. This allows the consumer to view the hair design as it would look on them, without having to actually have their hair cut or styled. [0004] A problem with the device described above, and similar devices is that these devices are typically not intuitively obvious to use and are typically operated by an employee, taking up the employee's time. [0005] These images are also crude representations of the user and typically do not properly display the correct colors or overlay the computer enhancements. These do not give realistic representations, thereby distorting their color, thereby limiting their accuracy. [0006] Typically when customers are shopping they would like an indication of how various products such as cosmetics, hair coloring, apparel, hats, jewelry, glasses, colored contacts etc. would look on them. Typically the process of trying on clothes, putting on makeup or glasses becomes time consuming, or sometimes is not possible (as in coloring your hair). Therefore, a system which would take a picture of the customer, and add overlays of various products and coloring would be useful, both to the customer and to the employees. [0007] Currently there is a need for a device which may be easily operated by a customer, and provide an accurate image and colors of a customer wearing a product. SUMMARY OF THE INVENTION [0008] The present invention may be embodied as a method of providing a color accurate enhanced image of a user. [0009] The environment is darkened and the only lighting used is specially designed lighting having a spectrum that most closely resembles that of daylight. This minimizes the color distortion introduced. [0010] An input profile of an input device intended to be used is determined indicating the color distortion introduced by the input device and the lighting. [0011] An image is acquired using the input device in a controlled lighting environment. [0012] The color spectrum of at least one location of the acquired image is modified according to the input profile to create a workspace image. [0013] Features, such as lips, hair or skin of the image are interactively selected by the user to modify their colors. [0014] An output profile of an output device, such as a monitor, intended to display the workspace image, is calculated. [0015] The spectrum of the workspace image is adjusted according to the output profile to result in an adjusted image; and [0016] The adjusted image is displayed on the output device to the user to result in an image with substantially improved color accuracy relative to prior art devices. BRIEF DESCRIPTION OF THE DRAWINGS [0017] A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which: [0018] FIG. 1 is a perspective view illustrating a system compatible with the present invention. [0019] FIG. 2 is a graph showing the spectral output of daylight vs. the SoLux™ light. [0020] FIG. 3 is a graph showing the spectral output of daylight vs. incandescent light. [0021] FIG. 4 is a graph showing the spectral output of daylight vs. fluorescent light. [0022] FIGS. 5 a , 5 b and 5 c together are a flowchart illustrating the operation of a method according to the present invention. [0023] FIG. 6 is a screen shot of monitor 11 shown having two images 610 and 620 of user 2 displayed side by side. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0000] Color Basics [0024] The actual color of an object is a mixture of light rays of various visible light frequencies, with each frequency having a brightness or amplitude (a “spectrum”). Therefore, the color of an object at a specific point may accurately be described by its spectrum at that point. [0000] Input Devices [0025] Light is attenuated as it passes through various materials. Light waves at different frequencies are attenuated in different amounts as they pass through the same material. Therefore, light passing through lenses of a camera, or through the glass of a scanner attenuates some frequencies more than others. A measure of the attenuation over a visible range is defined as a light absorption profile. [0026] Also, solid state devices which convert light into electric currents have a sensitivity which varies by the frequency of the light. The light sensors of a digital camera and scanner may have greater sensitivity to some frequencies, providing a strong signal when receiving these frequencies; however, it may be less sensitive when receiving other frequencies, producing a weaker electric signal. The sensor response over a range of visible light frequencies may be described by a sensor profile. [0027] Light may also be reflected from mirrors which may distort the resulting amplitudes. These may also be described by a profile. [0028] Similarly, light may pass through or reflect off of other surfaces in its path which could alter its intensities across the visible frequency band. [0029] All of the elements which affect the resulting spectrum of the light should be taken into account to more accurately recover the original light spectrum. [0000] Lighting [0030] The ambient lighting present during the acquisition of an image affects the color spectra of the image. Lights illuminate with a spectral profile specific to each light. For example, if a light exhibits considerably amplified yellow frequencies relative to the remainder of the spectrum, it will cause an image acquired using this light to have amplified yellow frequencies as compared with the actual object. [0031] In order to correct for the lighting profile, the present invention uses light which mimics the spectrum of daylight such as the specially designed SoLux™ light bulbs by Tailored Lighting, Inc. However, it is not possible to exactly replicate the spectrum of daylight; the lights influence the spectrum of an acquired image. These effects should also be taken into account. [0032] A more complete description of the lighting spectra is provided at the website http://www.soluxtli.com/ hereby incorporated by reference as if set forth in its entirety herein. [0000] Monitors [0033] Synthetic devices which display images synthesize colors and hence images by trying to accurately reproduce these spectra at all locations of the image. CRT monitors create light with several different phosphors on their screen which illuminate when they are hit by a cathode ray. Each phosphor has a specific characteristic illumination spectrum. These phosphors are chosen to produce most of its illumination in a narrow range of the spectrum, for example a red spectrum range. Therefore, the object is to differentially illuminate each of the several phosphors to mix and provide a composite spectrum which most accurately represents the target color spectrum at a given point in the image. This is reproduced for all points (pixels) in the image. [0034] Similarly, a liquid crystal display unit employs several different types of liquid crystals each which have characteristic illumination spectra. These are differentially illuminated to approximate a color at each screen location. [0035] Since the monitors approximate the color using the tools (phosphors and liquid crystals) they have, they do not provide an exact reproduction of the original color. Therefore, it is possible to determine the characteristic output of each specific monitor to potentially correct for its imperfections. [0000] Calibration of the Monitor [0036] One way to calibrate a monitor is to provide the computer driving the monitor with an image having a known spectrum, display the spectrum and use a device to read the output of the monitor. The computer compares the readings to an intended spectrum to determine how much error is produced by the monitor. This results in a monitor profile. [0037] The computer driving the image to the monitor typically has no information as to the type of monitor or its characteristic monitor profile. The signal is generated which is not adjusted to take into account the color inaccuracies of the monitor. The signal sent to the monitor is an internal or workspace representation of the signal, and has no color corrections built into it. Therefore, even if the colors in the computer are accurately represented; the color output of the monitor will be inaccurate based due to the color inconsistencies introduced by the monitor, according to the monitor profile. [0000] Correction of Monitor Output [0038] Therefore, using the monitor profile, the spectral frequencies where the monitor decreases the amplitude by an attenuation factor in the monitor profile, theoretically will be increased by that attenuation factor. Similarly, the spectral band where the monitor increases the amplitude by an amplification factor as per the monitor profile, will be attenuated by that amplification factor. [0039] This corrected signal is then converted into an appropriate monitor signal (such as an RGB, composite video, etc) which is then displayed showing a more accurate representation of color. [0000] Printers Similarly, printers using several different colors of ink, the most common being cyan, magenta, yellow, and black each having a specific color spectrum, may be mixed to approximate the target color. [0040] Theoretically, many different colors of ink having their characteristic spectra may be combined to approximate a target color with each with varying degrees of accuracy. [0000] Implementation [0041] The present invention is such a device which is easy to operate and frees up the employees allowing them to take care of other tasks. It also allows the customer to view a larger number of products in a non-pressured environment. This device however must be very intuitive and provide accurate images, or its value will be significantly diminished. [0042] Referring now to the several drawing figures in which identical elements are numbered identically throughout, a description of the preferred embodiment of the present invention will be provided. The preferred embodiment of the invention is described for illustrative purposes, it being understood that the invention may be embodied in other forms not specifically shown in the drawings or described hereinafter. [0043] Referring now in detail to the drawings, FIG. 1 shows a virtual monitor system 1 having lab quality color accuracy according to one embodiment of the present invention. This includes a computer 10 with a digital camera 12 attached thereto. In the preferred embodiment, the computer 10 includes all the components of a typical computer system including a processor, memory storage devices and monitor 11 . The computer 10 also includes data input/output ports, such as a CD-ROM drive and serial and USB ports for connection to other devices. Additionally, monitor 11 of the computer 10 may be a touch screen display, through which the user can input data and/or make selections by touching the screen. Alternatively, a keyboard 31 and mouse 33 may be used for user input. [0044] In the preferred embodiment shown in FIG. 1 , the camera 12 includes a Velcro™ attachment on the underside of its housing and is secured to the computer 10 via a corresponding Velcro™ attachment located thereon. The camera 12 is connected to the computer 10 by data cable 16 , as is well known in the art. [0045] Typically, the computer 10 , will be set-up at a point of sale, such as an office of an eye care professional, a cosmetic counter, or apparel department, etc. where it would be useful to simulate products being used or worn by a user. [0046] It should also be understood that the exemplary embodiments shown here are for illustrative purposes only, and are not meant to limit the scope of the invention. In particular, the wording, labels, arrangement and visual effects displayed on the monitor 11 are exemplary embodiments and may be changed or modified without departing from the scope of the invention. [0047] Monitor 11 may display acquired images, overlays to images, text, buttons, icons etc. to interact with a user. [0048] The virtual monitor system 1 may initially display a greeting, and accompanying sounds or speech, inviting a user to try the program and asking whether they are interested in a product being sold. The system of the present invention may also include a motion detection feature so that when a user passes in view of the camera 12 , the system will invite the user to try the virtual monitor system 1 . [0049] Before the virtual monitor system 1 is used, the system must be calibrated for the specific input devices and output devices being used. [0050] FIGS. 5 a , 5 b and 5 c together show a flowchart of the operation of one embodiment of the virtual monitor system 1 according to the present invention. The functioning will be described here with reference to this flowchart and with reference to parts of the invention shown in FIG. 1 , [0000] Input Device Calibration [0051] As described above, camera 12 distorts the spectrum of light passing through it. Also, as mentioned above, the ambient lighting has an effect upon the spectrum of the acquired image. Therefore, the room is dark and lights 35 and 37 , specially designed to have the spectrum similar to that of daylight, are used as the sole source of light. [0052] Since we're trying to determine how the camera sees light, we must calibrate the camera with a test pattern and an electronic representation of the spectra of each of the colors/locations on the test pattern. In step 501 , a test pattern specially manufactured to have accurate colors at specific locations of the pattern is provided, along with a corresponding color-accurate electronic representation of the test pattern. [0053] In step 503 the test pattern is placed a fixed distance from camera 12 . [0054] Camera 12 then acquires an image in step 505 by taking a picture of the test pattern. This image is stored in computer 10 as an electronic representation in computer 10 of spectra of each of the colors of the test pattern. Each location of the test pattern has a corresponding location on the acquired picture. [0055] The electronic representation of the color at a location of the test pattern is compared to a corresponding location of the picture to determine the deviation in its color spectrum in step 507 . [0056] Step 507 is repeated for different locations/ colors of the test pattern and the acquired picture to result in a file describing the deviation in color due to the camera operating in the given light conditions. This is referred to as the ‘camera profile’. One such commonly available software product which may be used to determine the camera profile is MonacoDC Color™ by X-rite Photo Marketing. A more detailed description of this subject is provided in the “MonacoOPTIX XR , Color Management Systems” publication by X-rite Photo Marketing, at the website http://www.xritephoto.com/product/DCcolor.com hereby incorporated by reference as if set forth in its entirety herein. A similar operation may be performed for other input devices such as a document scanner to determine the profiles of these input devices. Collectively these may be referred to as input profiles. These input profiles are specific not only to the type and model of input device used, but are specific to the input device itself This is because manufacturing differences and changes over time may cause lenses to become discolored, scratched, tinted and photo sensors may alter their sensitivity spectrum. [0057] This input calibration must be performed whenever there is a change in performance, such as when a new camera is used, different lenses or filters are used, or the performance of the camera is otherwise changed. It is recommended that this calibration be performed when there is a noticeable difference in the color accuracy of the display. [0058] A more complete description of the determination of an input profile is provided at the website http://www.xritephoto.com/product/dccolor/ hereby incorporated by reference as if set forth in its entirety herein. [0000] Image Acquisition [0059] In step 509 , the user 2 , stands in front of the camera at a specific distance and interacts with touch screen monitor 11 or keyboard 31 and mouse 33 to select an icon displayed on monitor 11 causing an image to be acquired of user 2 . This may include various prompts either visual on monitor 11 , or audible music, or voice instructing the user. An image is then acquired by the camera 12 and transferred to computer 10 . One such piece of software which would function is the Breeze Camera Control application. [0000] Image Adjustment [0060] The input profile of step 507 defines the color deviation of the acquired image from the actual objects. The actual color representation of the image may be corrected in step 511 using the input profile of step 507 to correct the effects introduced by the input device and the ambient lighting. The adjusted image is now defined to have a ‘workspace profile’. One such software product which will perform such correction is Adobe Photoshop, however others may be employed. [0000] Overlay Selection [0061] In step 520 the user is asked to select a feature of their image which they would like to modify. In the Referenced Application, the user selected different colored contact lenses which essentially changed the color of their eyes. An overlay was constructed which covered the irises of the user's eyes in the image, and the color of the overlays were interactively chosen. [0062] The present application will perform this function in a more color-accurate manner. In addition, the present application allows for the user to select and change the color of other features of their image such as lip color, hair color, skin tone, blemishes, apparel, etc. and combinations of the above. [0063] One such method of selecting the overlay of step 520 would be to provide a message to the user indicating a menu of features to be changed, with choices being, for example, lip color, hair color, skin color, eye color, etc. in step 521 . [0064] Next, the user should choose a general area containing the feature in step 523 . [0065] The user is prompted to select a point inside of the feature in the chosen area in step 525 . [0066] In step 527 the computer determines a color characteristic which will be used to determine the extent of the feature, such as hue of the selected point, searches for, and selects connected pixels having the same hue, or connected pixels having a hue within a small range of the hue of the selected point. [0067] In step 529 , the collection of all selected pixels would be highlighted to the user allowing the user to select this feature, modify it or start over again. [0068] In step 531 a mask or overlay is constructed which has the same size and shape of the selected feature, which will be colored to overlay the selected feature. [0069] Alternatively, in step 520 , a pre-defined overlay may be selected, such as for the iris of user 2 's eyes. [0070] Processing continues on FIG. 5 b at the top marked “A”. After user 2 has selected the feature, user 2 then selects a color for the overlay in step 540 . [0071] In step 540 user 2 may simply use mouse 33 driving a cursor on monitor 11 to select an approximate color from a color palate displayed on the screen. User 2 may also select any point on the image being displayed. [0072] Alternately, in step 541 user 2 may select an icon on monitor 11 indicating that he/she would like to acquire another image from an input device. In this case, a picture may be scanned by a scanner 41 , or taken by camera 12 in step 543 . Each of these images is also corrected in step 545 by the appropriate corresponding input profile as described above. [0073] The resulting image is then displayed on a portion of the screen allowing user 2 in step 547 wherein user 2 selects an approximate color on the second image in step 549 . [0074] The overlays are merged into the workspace image in step 551 . Adobe Photoshop may be used to merge these. [0075] The output profile of output devices is determined in step 560 . For example, if the output device, monitor 11 is a cathode ray tube display, the process is as follows. [0000] Correction for Color Inaccuracy of the Monitor [0076] Computer 10 is loaded with an electronic file of known accurate colors which will be displayed on the output device in step 561 . A colorimeter device is placed on the screen of monitor 11 and accurately detects a color spectrum in step 563 . The calorimeter has been pre-calibrated and is designed to function on a general purpose computer, such as computer 10 . [0077] Computer 10 repeats steps 561 - 563 for various colors/frequencies across the visible spectrum in step 565 . The error introduced by the CRT monitor during display of the color is measured and stored in step 567 as an output profile. [0078] Profiles may also be performed for other output devices, such as with an LCD monitor, plasma displays and printers, which shall be collectively referred to as “output profiles”. [0079] MonacoOPTIXXR™ software from X-rite Photo Marketing is designed to profile monitor 11 's output. [0080] After step 567 of FIG. 5 b , processing continues at the top of FIG. 5 c where it is marked “B”. The output profile is used to adjust the image file prior to display in step 581 . [0081] The adjusted image is then displayed on monitor 11 in step 583 . [0082] In step 590 , it is determined if the user would like to create any other overlays. If “no”, then the process stops at step 591 . If the answer to step 590 is “yes”, then processing continues at step 521 at the location marked “C” in FIG. 5 a . This allows the user to colorize other features, such as hair color, complexion, etc. [0083] The present invention would also allow user 2 to select regions of skin, such as above the eyes and allow colors to gradually fade away in a given direction, to provide shading. [0084] A use of the present invention would be to select all regions which appear to be skin tones, and to make them several shades darker, simulating a tan. This would be useful in selling tanning services. [0085] Another use of the present invention would be to select regions of one's own skin which they prefer the color. The user may then virtually “brush on” the color to cover blemishes. [0086] The color-accurate representation may be sent to a cosmetic manufacturer to have custom shades of makeup made. If connected to the internet the order may be sent immediately. [0087] Once selected, these custom colors may be used to create custom makeup, or custom colored apparel. [0088] The present invention is also capable of saving the images created and displaying them side-by-side. FIG. 6 a screen shot of monitor 11 is shown having two images 610 and 620 of user 2 displayed side by side. The present invention is capable of saving and displaying numerous images, which may be the original image and/or those that have been enhanced with one or more colored overlays as described above. [0089] FIG. 6 also shows ‘before’ and ‘after’ images of a user with different color lipstick. It also shows software buttons 630 , 640 which, when clicked, cause the system to perform specified actions allowing the user to interact with the system. An instructional message 650 is shown on the left providing instructions to interact with user 2 . [0000] Contact Lenses/Eyeglasses [0090] The present invention has many uses, for example as stated above, it is useful in assisting customers select eyeglass frames, colorized contact lenses, and/or opaque novelty contact lenses, as set forth in U.S. patent application Ser. No. 10/938,868 “Method of Interactive System for Previewing and Selecting Eyeware” by Dr. Michael R. Neal filed Sep. 13, 2004 referred to in “Cross Reference to Related Applications” above, (the “Referenced Application”) and hereby incorporated by reference as if it were included at length in the body herein. [0091] The Referenced Application describes a system which is used to allow patients to interactively select colorized contact lenses and view a virtual image of themselves wearing these selected lenses. Since many times the contact lens or eyeglass the patient is currently wearing does not have the proper prescription, the patient is forced to evaluate these products while his vision is impaired. Thus, the customer is unable to view his or her own image accurately, and will often rely on an employee of the store in making their purchasing decision. [0092] Therefore, the systems described above, and other embodiments of the present invention depend upon accurate representation of the image including color accuracy. [0000] Cosmetics [0093] An example would be an embodiment intended to be used at a cosmetic counter. A customer would like to determine which shade of lipstick would best match her complexion. This typically would require trying on lipstick and viewing the result in the mirror. The lipstick would have to be removed, and the process repeated for the next color. This process either produces significant waste “test” products, or incurs the potential for transfer of diseases from one customer to another. It also requires significant input from the employees asking them which would look better since one must simply remember the previous colors. [0094] The present invention will quickly and accurately provide a virtual image of the user and allow her to select different colors of lipstick and interactively view the results. [0000] Apparel [0095] The present invention may be used to color-coordinate clothes, hats and other apparel. It would allow one to quickly and accurately change the colors of clothing, and display images simultaneously to do a side-by-side comparison. This allows a customer to try on many different color combinations in a short period of time. Once selected, the customer needs to only try on the clothes to select the proper size. [0096] Since the present invention will allow the colors of many features to be adjusted simultaneously, a user may color-coordinate colors of clothes with the proper colors of makeup, hair color, contact lens color, etc. to coordinate the entire look without actually changing anything on the user. [0097] Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
The present invention provides a simple interactive device intended to be used by the customer for acquiring an image of the customer, interactively allowing the customer to try on virtual shades of lipstick, makeup, color contacts, hair color, and/or apparel at the same time to change their appearance. The present invention takes into account the deviations due to the input devices and the output devices thereby resulting in laboratory quality color accuracy and very realistic images. Since it is so accurate, customers may rely on the present invention instead of “trying on” the products. This allows a customer to view many different colors and color schemes in a fraction of the time, while freeing up store employees. The present invention may also display several images simultaneously to allow a customer to efficiently determine the best color scheme or look requiring minimal employee input.
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